Intake Noise Damper With Friction-Welded Sealing Flange
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing acoustic attenuation devices for turbocharged engine intake lines face challenges in achieving consistent 20 dB attenuation across 1.5 kHz to 3.5 kHz frequency range, suffer from undesirable attenuation sags, and experience vibrations and acoustic leaks, leading to suboptimal performance.
Innovation Solution
An acoustic attenuation device with a radially outer tubular casing and an internal pipe structure forming at least two annular resonance chambers, where the pipe is axially wedged against internal shoulders to minimize vibrations and prevent leaks, using a duct with recesses for chamber communication and made from plastic or composite materials with friction welding to ensure secure assembly without internal welding, allowing for angular movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the internal pipe structure is welded to the casing to ensure acoustic sealing, then acoustic leakage is prevented, but the complexity of manufacturing increases and potential internal welding pollution occurs
Solution Approach 1:
A sealing flange acts as an intermediary element between the internal pipe structure and the casing. This flange provides a dedicated sealing interface that prevents acoustic leakage without requiring direct welding between the pipe structure and casing, thereby reducing manufacturing complexity and avoiding welding pollution inside the duct.
Solution Approach 2:
The device is divided into separate modular components: the casing, the internal pipe structure, and the sealing flange. This segmentation allows each component to be manufactured independently with optimized processes, and assembled through controlled interfaces, reducing overall manufacturing complexity while maintaining acoustic sealing integrity.
2Reliability
If the internal pipe structure is rigidly fixed to prevent vibrations, then acoustic leaks are minimized, but the ability to position the duct angularly is reduced
Solution Approach 1:
The mounting system transitions from a fully rigid fixed connection to a dynamic system that allows controlled angular movement. The duct can rotate angularly within the casing to achieve optimal positioning, while the sealing flange maintains acoustic sealing during this positioning process and prevents vibrations during operation.
Solution Approach 2:
The duct is first positioned angularly to the desired orientation using the free rotation capability, and then fixed in place before operation. This preliminary positioning action allows optimal angular adjustment while ensuring vibration control is achieved before the device begins operating.
3Strength
If welding is used to join the casing components, then structural strength is improved, but acoustic leakage may occur through weld imperfections and manufacturing complexity increases
Solution Approach 1:
The sealing flange serves as an intermediary sealing element that takes over the acoustic sealing function from the weld joints. This allows the casing to be joined by welding for structural strength while the flange provides a separate, dedicated sealing interface that is less susceptible to weld imperfections.
4Adaptability or versatility
If the duct is made movable in rotation for angular positioning, then adaptability is improved, but vibration control becomes more difficult
Solution Approach 1:
The system is designed to be dynamic during installation (allowing rotation for positioning) and static during operation (preventing vibrations). The mounting structure enables angular adjustment when needed, then provides rigid fixation once positioned, achieving both adaptability and vibration control at different stages.
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 solution achieves consistent acoustic attenuation of at least 20 dB across the desired frequency range while minimizing vibrations and leaks, ensuring optimal acoustic sealing and reducing the complexity of internal structures.
Implementation Method 1
forming at least two annular resonance chambers with the casing
Implementation Method 2
made from plastic or composite materials with friction welding to ensure secure assembly
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
The device (1) has a radially external tubular envelope (5) comprising two fluid inlet and outlet terminals. Two peripherals extensions (10, 12) are welded one onto another by forming a circumferential bulge. A control structure is located radially internal to the envelope. A conduit (2) is assembled inside the envelope while knocking against internal shoulders (13, 16) of one of the fluid inlet and outlet terminals. The shoulder extends from the peripherals extensions, and is axially fixed to one of ends (2a, 2b) of the conduit.