Vehicle Bulkhead Noise Insulation with Integrally Molded Fixing Projections
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Solution Overview
Problem
Existing noise insulation elements for vehicle bulkheads require additional fastening elements like bolts and screws, increasing production costs and assembly effort.
Innovation Solution
A noise insulation element with a mass-spring structure featuring a plastic support layer and a noise damping layer, incorporating integrally designed hollow fixing projections that compress to fit into vehicle body openings, eliminating the need for additional fastening elements by engaging with the vehicle body's receiving openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional fastening elements like bolts and screws are used to mount the noise insulation element, then the fixation reliability is improved, but the production cost and assembly effort increase
Solution Approach 1:
The fixing projection is integrally formed with the support layer, merging the fastening function into the noise insulation element itself. This eliminates the need for separate fastening elements while maintaining reliable fixation through the receiving groove engagement with the vehicle body opening
Solution Approach 2:
The fixing projection automatically engages with the vehicle body through its receiving groove without requiring additional fastening operations. The elastic deformation capability allows self-adjustment during insertion, and the flange provides automatic positioning and retention
2Stability of the object's composition
If the fixing projection is made rigid to ensure stable engagement, then the fixation stability is improved, but the insertability into the receiving opening deteriorates
Solution Approach 1:
The fixing projection incorporates elastic deformation capability through its side wall and bottom wall design, allowing it to dynamically adjust during insertion. The projection can elastically deform to fit into the receiving opening and then return to its original shape to provide stable engagement
Solution Approach 2:
The physical state of the fixing projection changes from a rigid structure to one with controlled flexibility. The side wall and bottom wall are designed to be elastically deformable, changing the mechanical properties from purely rigid to semi-flexible, enabling both easy insertion and stable fixation
3Strength
If the fixing projection is made larger to increase engagement area, then the fixation strength is improved, but the complexity of the structure increases
Solution Approach 1:
The fixing projection is segmented into functional zones: a side wall for engagement, a bottom wall for support, and a flange for positioning. The receiving groove is segmented to engage with the opening edge at multiple points, distributing the fixation strength across these segments rather than requiring a single large structure
Solution Approach 2:
The fixing projection utilizes the flange dimension extending beyond the support layer to provide additional engagement area. This dimensional extension in the lateral direction increases fixation strength without increasing the projection's depth or requiring complex internal 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
Facilitates easier assembly by eliminating the need for additional fastening elements, reducing production costs and assembly effort while providing effective noise insulation.
Implementation Method 1
the side wall of the fixing projection are designed to be compressible in at least two opposite sections, whereby the side wall is designed to be compressible in at least two opposite sections which allows for a movement of the opposite side wall sections towards each other
Implementation Method 2
the outer receiving groove of the side wall of the fixing projection engages around the opening edge of the receiving opening of the vehicle body
Implementation Method 3
a noise damping layer made from a noise absorption material or a noise damping material connected to the rear wall as the so-called spring layer
Data Source
AI summary
A noise insulation element (14) for the bulkhead (12) of a vehicle body (10) is provided with a mass-spring element (20) which has a plastic support layer (22) as the heavy layer with a front side facing away from the bulkhead (12) when the mass-spring element (20) is installed and with a rear side facing towards the bulkhead (12), and a noise damping layer (24) made from a noise insulating material connected to the rear wall as the spring layer. The support layer (22) is provided on its rear side with an integrally designed hollow fixing projection (16) which is formed on an edge recess with a recess edge which recess is open towards an outer limiting edge section (28) of the support layer (22) and a side wall (30) projecting from the rear side of the support layer (22) and extending along the recess edge.