Composite muffler system thermosetable polymers

Abstract

A muffler assembly includes a housing defining at least one internal chamber. The housing is constructed from a composite material made from a thermoplastic resin and a reinforcing element. The reinforcing element is selected from a group of reinforcing materials consisting of glass fibers, aramid fibers, polyamide fibers, carbon fibers, graphite fibers, mineral fibers, ceramic fibers, carbon nanotubes, nano fillers, mineral fillers, ceramic fillers and combinations thereof. A pipe is received in the housing. The pipe includes at least one opening providing acoustic communication between an internal passage in the pipe and the chamber in the housing. An acoustic attenuating material is received in that chamber.

1 . A muffler assembly ( 10 ), comprising:
 a housing ( 12 ) defining at least one internal chamber ( 24 ), said housing being constructed from a composite material made from a thermoplastic resin and a reinforcing element selected from group of reinforcing materials consisting of glass fibers, aramid fibers, polyamide fibers, carbon fibers, graphite fibers, mineral fibers, ceramic fibers, carbon nanotubes, nano fillers, mineral fillers, ceramic fillers and combinations thereof;   a pipe ( 26 ) received in said housing, said pipe including at least one opening ( 30 ) providing acoustic communication between an internal passage in said pipe and said at least one chamber; and   acoustic attenuating material ( 32 ) received in said at least one chamber.   
     
     
         2 . The muffler assembly of  claim 1 , wherein said thermoplastic resin is selected from a group of resin materials consisting of polyamide, nylon 6, nylon 66, nylon 46, aromatic polyamide, polyetherimide, polyethersulfone, polysulfone, polyphthalamide, polyphenylene sulfide, syndiotactic polystyrene, polyetherimide/silicone blend, liquid crystal polymer, polybutylene terephthalate, polyethylene terephthalate, cyclic thermoplastic, macrocyclic butylenes terephthalate, macrocyclic ethylene terephthalate, macrocyclic polycarbonate, thermoplastic urethane, polytetrafluoroethylene, polyvinylidene fluoride, polyetheretherketone and combinations thereof. 
     
     
         3 . The muffler assembly of  claim 1 , wherein said composite material comprises a long fiber thermoplastic including a thermoplastic resin selected from a group of thermoplastic resins consisting of nylon 6, nylon 66, nylon 46, aromatic polyamide, polyetherimide, polyethersulfone, polysulfone, polyphthalamide, polyphenylene sulfide, syndiotactic polystyrene, polyetherimide/silicone blend, liquid crystal polymer, polybutylene terephthalate, polyethylene terephthalate, cyclic thermoplastic, macrocyclic butylenes terephthalate, macrocyclic ethylene terephthalate, macrocyclic polycarbonate, thermoplastic urethane, polytetrafluoroethylene, polyvinylidene fluoride, polyetheretherketone and combinations thereof and a glass reinforcing element with a glass fiber weight fraction ranging from about 5 to about 90 weight percent where greater than about 5 weight percent of said glass fiber fraction has an original length to diameter ratio of greater than or equal to 50. 
     
     
         4 . The muffler assembly of  claim 1 , wherein said composite material is a mixture of between about 0 and about 90 weight percent polypropylene, between about 0 and about 90 weight percent polyethylene terephthalate and between about 10 and about 85 weight percent glass fibers. 
     
     
         5 . The muffler assembly of  claim 1 , wherein said composite material also includes some thermoset resin. 
     
     
         6 . The muffler assembly of  claim 5 , wherein said thermoset resin is selected from a group of thermoset resins consisting of unsaturated polyester, dicyclopentadiene, phenolic, phenol formaldehyde, novalac, resol, epoxy, vinyl ester, urethane and combinations thereof. 
     
     
         7 . The muffler assembly of  claim 1 , wherein said housing includes an inlet ( 20 ) and an outlet ( 22 ), a first heat sink ( 34 ) provided in said inlet and a second heat sink provided in said outlet. 
     
     
         8 . The muffler assembly of  claim 1 , wherein said housing includes an overmolded reinforcement. 
     
     
         9 . The muffler assembly of  claim 8 , wherein said overmolded reinforcement is an inlay ( 50 ) constructed from a material selected from a group consisting of nonwoven fiber mat, woven fiber mat, unidirectional fiber fabric, metal sheeting and combinations thereof. 
     
     
         10 . The muffler assembly of  claim 9 , where said inlay is made from a material selected from a group consisting of glass fibers, natural fibers, carbon fibers, mineral fibers, metallic fibers, aramid fibers and combinations thereof. 
     
     
         11 . The muffler assembly of  claim 8 , wherein said overmolded reinforcement is an overlay ( 52 ) providing impact resistance. 
     
     
         12 . The muffler assembly of  claim 11 , wherein said overlay is constructed from a material including metal sheeting, steel, aluminum, stainless steel, woven fiber mat, unwoven fiber mat, unidirectional fiber fabric and combinations thereof. 
     
     
         13 . The muffler assembly of  claim 1 , further including a baffle ( 46 ) in said housing. 
     
     
         14 . The muffler assembly of  claim 1 , further including one or several mounting brackets ( 38 ) carried by said housing. 
     
     
         15 . The muffler assembly of  claim 1 , further including an active sound control device ( 48 ) carried by said housing. 
     
     
         16 . The muffler assembly of  claim 7 , wherein said housing includes a first section ( 14 ), a second section ( 16 ) and a part line. 
     
     
         17 . The muffler assembly of  claim 16 , wherein said part line runs through said inlet and said outlet. 
     
     
         18 . The muffler assembly of  claim 1 , wherein at least a portion of said outer housing forms a vehicle component selected from a group consisting of a spare wheel well, an underbody shield, a fender, a wheel arch, a bumper, a running board, a rocker panel, a side fairing and an air dam. 
     
     
         19 . The muffler assembly of  claim 1 , further including an inner housing received in said housing, said inner housing being constructed from a second composite material comprising a thermoset resin and a reinforcement element.