Damped Windage Tray Laminate for Engine NVH Reduction
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Solution Overview
Problem
Internal combustion engines experience efficiency loss and increased noise due to windage-induced drag and resonance from traditional metal or molded plastic windage trays, which fail to effectively mitigate noise, vibration, and harshness (NVH) issues.
Innovation Solution
A damped windage tray formed from a laminate structure comprising constraining layers and viscoelastic damping layers, bonded with a high tack polymer, designed to maximize composite loss factor at engine equilibrium oil temperature, reducing vibrations and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional metal or molded plastic windage trays are used, then windage losses are reduced, but noise and vibration increase due to resonance
Solution Approach 1:
The windage tray is constructed as a composite laminate consisting of multiple layers including viscoelastic damping layers (e.g., butyl rubber, natural rubber, or synthetic rubber) bonded between constraining layers (metal or plastic). This composite structure reduces noise and vibration by dampening resonant vibrations while maintaining the windage control function. The viscoelastic material dissipates vibrational energy as heat, effectively reducing NVH without sacrificing windage tray performance.
Solution Approach 2:
The invention changes the material parameters of the windage tray by incorporating viscoelastic damping materials with specific loss factors. The damping layers are selected to have optimal damping characteristics at engine operating temperatures, transforming the tray from a purely structural component to one that also provides active vibration and noise control through material property optimization.
2Object-generated harmful factors
If a laminate structure with viscoelastic damping layers is used, then noise and vibration are reduced, but manufacturing complexity increases
Solution Approach 1:
The laminate is constructed by segmenting the windage tray into multiple functional layers: constraining layers for structural integrity and windage control, and viscoelastic damping layers for vibration suppression. These layers are bonded together in a laminated structure, allowing each layer to perform its specific function while simplifying the overall manufacturing process through standardized layer assembly rather than attempting to create a monolithic damped structure.
Solution Approach 2:
The viscoelastic damping layers are applied as thin film or sheet materials between the constraining layers. This approach allows for easy handling, positioning, and bonding of the damping material during manufacturing. The thin film nature of the damping layers enables simple lamination processes while effectively providing vibration damping throughout the windage tray structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The damped windage tray effectively reduces engine noise and vibration, enhancing engine efficiency by optimizing damping at the engine's operating temperature, thereby improving overall performance and reducing NVH.
Implementation Method 1
a viscoelastic damping layer disposed between the first and second constraining layers and spanning substantially the entirety of the first and second constraining layers
Implementation Method 2
The viscoelastic damping layer may include a first viscoelastic layer and a second viscoelastic layer bonded by a high tack polymer layer
Data Source
AI summary
A damped windage tray for an engine including a windage tray formed from a laminate. The laminate operates to damp vibrations of the windage tray. The laminate includes a first constraining layer, a second constraining layer and a viscoelastic damping layer disposed between the first and second constraining layer. The viscoelastic damping layer spans substantially the entirety of the first and second constraining layers. Additionally, a method of forming the windage tray is provided.