Fiber-Reinforced Resin Composition for Engine Intake Noise Reduction
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Solution Overview
Problem
The existing techniques for reducing intake noise in internal combustion engines, which involve enhancing the flexural elasticity modulus and thickness of parts, result in weight increase, and fail to effectively shift the resonance frequency away from the low-frequency intake noise range.
Innovation Solution
A fiber-reinforced resin composition comprising block polypropylene type resin with a specific Melt Flow Rate, glass fibers, and mica, which enhances the flexural elasticity modulus and reduces the specific gravity of intake system parts, thereby shifting the resonance frequency to a higher range and reducing low-frequency intake noise without increasing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the thickness of the parts is increased to reduce intake noise, then the sound insulation performance is improved, but the weight of the parts increases
Solution Approach 1:
The patent uses a composite material consisting of polypropylene resin and hollow spherical filled material (such as hollow glass beads or hollow metal beads). This composite structure provides sound insulation performance comparable to thicker solid parts while significantly reducing weight, as the hollow spheres create acoustic impedance that blocks noise transmission without requiring increased thickness.
Solution Approach 2:
The hollow spherical filled material creates a porous-like structure within the resin matrix. These hollow spheres scatter and reflect sound waves, providing effective noise reduction particularly in low-frequency ranges, while the air-filled hollow spaces contribute to weight reduction compared to solid homogeneous materials.
2Object-affected harmful factors
If the flexural elasticity modulus is enhanced to reduce intake noise, then the resonance frequency is improved, but the weight of the parts increases
Solution Approach 1:
The combination of polypropylene resin with hollow spherical filled material creates a composite that achieves enhanced flexural elasticity modulus. The hollow spheres act as stiffening elements that raise the resonance frequency away from the low-frequency intake noise range (100-400 Hz), while the overall structure remains lightweight due to the air-filled hollow spaces replacing solid material.
3Object-affected harmful factors
If the thickness of the parts is increased to achieve equivalent inertance, then the sound insulation performance is improved, but the weight and complexity of the design increases
Solution Approach 1:
The patent changes the material parameters by incorporating hollow spherical filled material with specific size ranges (0.1-5.0 mm diameter) into the polypropylene resin. This parameter change allows achieving equivalent inertance and sound insulation performance with thinner parts, simplifying the design and reducing manufacturing complexity compared to traditional thick-walled structures.
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 composition achieves a higher flexural elasticity modulus and lower specific gravity, effectively reducing intake noise and allowing for a thinner, lighter design with equivalent inertance, resulting in a weight loss while maintaining sound insulation.
Implementation Method 1
glass fibers and mica the total of which are in the range of 20-40% by weight of the composition
Implementation Method 2
the composition comprises a block polypropylene type resin... and glass fibers and mica
Implementation Method 3
the resonance frequency of the intake system's parts can be shifted to a high frequency by enhancing the flexural elasticity modulus of the intake system's parts and reducing specific gravity of the parts
Implementation Method 4
reducing specific gravity of the parts
Data Source
AI summary
Main object is to provide a composition for parts of the intake system, which is capable of enhancing the flexural elasticity modulus of the parts of the intake system and reducing the specific gravity of the parts. Disclosed is a fiber reinforced resin composition for parts of intake system on the internal combustion engine comprising a block polypropylene type resin which has a MFR in the range of 40-70 g/10 minutes (at 230° C. and under a load of 2.16 kg) and which is in the range of 60-80% by weight of the composition, and glass fibers and mica the total of which are in the range of 20-40% by weight of the composition.