Abstract:
A compressor assembly for an intake system includes: a monolithic housing; a first resonator section formed in the monolithic housing, the first resonator section defining two or more volumes configured to attenuate noise associated with fluid flowing through the monolithic housing; a compressor section formed in the monolithic housing, the compressor section including a compressor configured to compress the fluid flowing through the monolithic housing; and a second resonator section formed in the monolithic housing, the second resonator section defining two or more volumes configured to attenuate noise associated with the fluid flowing through the monolithic housing.

Description:
This application is a Continuation application of PCT/US2013/057780 filed on 3 Sep. 2013, which claims benefit of U.S. Patent Application Ser. No. 61/706,248 filed on 27 Sep. 2012, and which application(s) are incorporated herein by reference. To the extent appropriate, a claim of priority is made to each of the above disclosed applications. 
    
    
     BACKGROUND 
     Supercharger compressors, such as roots-type blowers, can emit a distinctive noise, often referred to as a whine, during operation, especially at high differential pressure across the device. These high differential pressure conditions typically occur when the compressor is operating on an internal combustion engine at a compression ratio that is on the higher end of a compression ratio range. 
     The air running through the roots-type blowers can be amplified by the typical housing and bearing plate materials used to manufacture the blowers, as well as the induction systems employed for the end applications. The noise may attain an undesirable level if uncorrected. A resonator, such as that described in U.S. Pat. No. 7,934,581 to Kim, can be used to attenuate the noise associated with the air entering and/or leaving the roots-type blowers. 
     SUMMARY 
     In one aspect, a compressor assembly for an intake system includes: a monolithic housing; a first resonator section formed in the monolithic housing, the first resonator section defining two or more volumes configured to attenuate noise associated with fluid flowing through the monolithic housing; a compressor section formed in the monolithic housing, the compressor section including a compressor configured to compress the fluid flowing through the monolithic housing; and a second resonator section formed in the monolithic housing, the second resonator section defining two or more volumes configured to attenuate noise associated with the fluid flowing through the monolithic housing. 
     In another aspect, an intake system includes: a monolithic housing extending from a first end to a second end; a first resonator section formed in the monolithic housing at the first end, the first resonator section defining a plurality of volumes configured to attenuate noise associated with fluid flowing through the monolithic housing; a compressor section formed in the monolithic housing and in fluid communication with the first resonator section, the compressor section including a roots-type blower configured to compress the fluid flowing through the monolithic housing; and a second resonator section formed in the monolithic housing at the second end, the second resonator section defining two or more volumes configured to attenuate noise associated with the fluid flowing through the monolithic housing. 
     In yet another aspect, an intake system includes: a cast monolithic housing extending from a first end to a second end; a first resonator section formed in the monolithic housing at the first end, the first resonator section defining a plurality of volumes configured to attenuate noise associated with fluid flowing through the monolithic housing; a compressor section formed in the monolithic housing and in fluid communication with the first resonator section, the compressor section including a roots-type blower configured to compress the fluid flowing through the monolithic housing; and a second resonator section formed in the monolithic housing at the second end, the second resonator section defining two or more volumes configured to attenuate noise associated with the fluid flowing through the monolithic housing; wherein each of the first resonator section and the second resonator section includes: a conduit portion defining an inlet, an outlet, and a plurality of apertures; and a plurality of chambers in communication with the conduit portion through the plurality of apertures. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic view of an engine and intake system. 
         FIG. 2  is a schematic cross-section view of the compressor assembly of  FIG. 1 . 
         FIG. 3  is a side view of the compressor of the compressor assembly of  FIG. 2 . 
         FIG. 4  is a cross-sectional view of an outlet of the compressor of  FIG. 3 . 
         FIG. 5  is a cross-sectional view of one resonator of the compressor assembly of  FIG. 2 . 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure is directed towards compressors such as roots-type blowers. In examples described herein, one or more resonators are integrated into the roots-type blowers to attenuate noise. It will be appreciated that side designations are used herein for convenience only and are not intended to limit how the device may be used. In this regard, it will be appreciated that embodiments in accordance with the principles of the present disclosure can be used in any orientation. 
       FIG. 1  is a schematic representation of an engine and intake system  10 , including an engine E, a compressor assembly  12 , and a source of fluid, such as an air intake or exhaust gas recirculation (“EGR”) system. In the embodiment illustrated, the engine E is an internal combustion engine, and the compressor assembly  12  is a portion of a supercharger. 
     The compressor assembly  12  is an integrated unit including both a compressor section  128  and one or more resonator sections  126 ,  130 . In other words, the compressor assembly  12  includes a single housing (i.e., an integral and/or unitary and/or monolithic structure) including both a compressor and one or more resonators. 
     Referring now to  FIGS. 2-5 , the compressor assembly  12  is described in more detail. 
     The compressor assembly  12  includes a housing  18  extending from a first end  120  to a second end  122 . The first end  120  forms a fluid inlet, and the second end  122  forms a fluid outlet. As noted, the housing  18  is formed as a single piece, as described further below. 
     The housing  18  forms three sections, the first resonator section  126 , the compressor section  128 , and the second resonator section  130 . In this example, the first and second resonator sections  126 ,  130  are configured to attenuate noise associated with fluid flowing through the compressor assembly  12 . The compressor section  128  includes a roots-type blower  124  configured to compressor fluid that is delivered to the engine E. 
     Referring now to  FIGS. 3 and 4 , the compressor section  128  including the roots-type blower  124  is shown in isolation within the housing  18 . 
     The roots-type blower  124  may comprise any air pump with parallel lobed rotors. A plurality of rotors  23  may be disposed within the overlapping cylindrical chambers  22 . Each of the rotors  23  may have four lobes. Although four lobes are mentioned in detail, each of the rotors  23  may have fewer or more lobes in other embodiments. 
     Each of the rotors  23  may be mounted on a rotor shaft for rotation therewith. Each end of each rotor shaft may be rotatingly supported within a bearing plate  14  or a single component housing. At least one of the rotors  23  may utilize any of various input drive configurations (an input shaft portion and/or step up gear set, for example and without limitation) by means of which the roots-type blower  124  may receive input drive torque. 
     The roots-type blower  124  may include a backplate portion  24 . Backplate portion  24  may define an inlet port  26 . The inlet port  26  may be in fluid communication with at least one of the chambers  22  in which the rotors  23  are disposed. 
     The roots-type blower  124  may also define an outlet port  28 . The outlet port  28  may also be in fluid communication with at least one of the chambers  22  in which the rotors  23  are disposed. The outlet port  28  may be angled (e.g., not substantially perpendicular to the longitudinal axis  13  of roots-type blower  124 ). For example, as shown in  FIG. 4 , the port end surface may be angled outwardly by an angle α. Angle α may be less than 45 degrees in an embodiment. Although angle α specifically mentioned as being less than 45 degrees, angle α may be larger or smaller in other embodiments. For example, the angle α may be 30 degrees in some embodiments. 
     Additional details about the roots-type blower  124  are described in U.S. Patent Application Publication No. 2009/0148330 to Swartzlander, entitled “Optimized Helix Angle Rotors for Roots-Style Supercharger,” and/or U.S. Patent Application Publication No. 2010/0086402 to Ouwenga et al., entitled “High Efficiency Supercharger Outlet,” the entireties of which are hereby incorporated by reference. Other types of compressors can also be used. 
     Referring now to  FIG. 5 , the first resonator section  126  is shown in isolation within the housing  18 . The first resonator section  126  generally operates to reduce the noise transmitted by fluid flowing through and being compressed by the roots-type blower  124 . 
     The first resonator section  126  includes an inner member  30  having a conduit portion  32 , a first annular wall  34 , and a second annular wall  36 . 
     In the embodiment illustrated, the conduit portion  32  includes a first conduit portion  50 , a second conduit portion  52 , an outside conduit surface  54 , an inside conduit surface  56 , a plurality of first conduit apertures  58 , and a plurality of second conduit apertures  60 . All of the apertures shown in the sectioned portion of the first conduit portion  50  are first conduit apertures  58 , while all of the apertures shown in the sectioned portion of the second conduit portion  52  are second conduit apertures  60 . 
     The annular walls  34 ,  36 , the housing  18 , and the conduit portion  32  define first and second chambers  64 ,  66 . In the embodiment illustrated, the first chamber  64  and the second chamber  66  have generally the same volume, although other configurations are possible. 
     In the embodiment illustrated, each first conduit aperture  58  is generally cylindrical, and each second conduit aperture  60  is generally cylindrical, although the first conduit apertures  58  and the second conduit apertures  60  need not be cylindrical. Each first conduit aperture  58  is generally the same diameter as each second conduit aperture  60 . 
     Additionally, the number of second conduit apertures  60  is greater than the number of the first conduit apertures  58 . In one embodiment, the resonator  20  has twenty-four (24) first conduit apertures  58  and thirty-four (34) second conduit apertures  60 , where the first conduit apertures  58  are generally the same diameter as the second conduit apertures  60 . The first conduit apertures  58  are generally evenly distributed within the first conduit portion  50 , and the second conduit apertures  60  are generally evenly distributed within the second conduit portion  52 . 
     Additional details regarding the first resonator section  126  and other similar resonators are described in U.S. Pat. No. 7,934,581 to Kim entitled “Broadband noise resonator,” the entirety of which is hereby incorporated by reference. Although the example first resonator section  126  is shown herein, other configurations for a resonator can also be used. The second resonator section  130  is configured in a manner similar to that of the first resonator section  126 . 
     Referring again to  FIG. 2 , the first and second resonator sections  126 ,  130  and the compressor section  128  (including the roots-type blower  124 ) are formed within a single integrated housing  18 . In this example, the housing  18  is cast of a metal such as iron or aluminum. 
     In some examples, the first and second chambers  64 ,  66  of the resonator sections  126 ,  130  are formed using various techniques. In one example, the chambers are formed using sand cores or lost foam techniques during casting of the housing  18 . In other examples, the annular wall  34  and the conduit portion  32  are formed of a molded polymeric material or a separate cast material that is incorporated into the housing  18  after the housing is cast. For example, the annular wall  34  and the conduit portion  32  can be injection molded or die-cast in place or otherwise formed and fixed within the housing  18 . 
     As depicted, the housing  18  is formed linearly, so that fluid flows axially through the first resonator section  126 , into the roots-type blower  124  within the compressor section  128 , and finally through the second resonator section  130  before being delivered to the engine E. In other words, the first resonator section  126  is in fluid communication with the compressor section  128 , and the compressor section  128  is in fluid communication with the second resonator section  130 . 
     In one example, the roots-type blower  124  includes the high efficiency outlet described in U.S. Patent Application Publication No. 2010/0086402. In such a configuration, fluid leaving the roots-type blower  124  is directed at approximately a 30 degree angle relative to the longitudinal axis of the blower, so that the second resonator section  130  is positioned approximately 30 degrees off of the longitudinal axis of the roots-type blower  124 . In this configuration, the housing  18  is formed so that the second resonator section  130  accommodates this angle. 
     There can be various advantages associated with incorporating the resonators into the same housing as that of the compressor. For example, placing the resonators in the same housing as the compressor allows the resonators to be positioned close to the compressor, thereby minimizing the untreated volume through which the fluid must travel before being attenuated. In addition, the single housing minimizes assembly time and the number of components for the compressor assembly, thereby resulting in lower assembly cost and complexities. 
     Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims.