Filled Polyurethane Foam Insulation for Engine Flame Protection

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Solution Overview

Problem

Current thermal and acoustic insulation for internal combustion engines lacks effective flame retardant properties, particularly in meeting FMVSS302 standards, and does not utilize polyurethanes based on filled polyether polyols for enhanced insulation.

Innovation Solution

A process for producing thermal and acoustic insulation using polyurethane foams obtained by reacting di- and/or polyisocyanates with filler-containing polyols, where the filler is a reaction product of di- and/or polyisocyanates with isocyanate-reactive compounds, in the presence of water and/or physical blowing agents, along with auxiliaries and additives, to achieve a filler content of 2 to 30% by weight, ensuring good flame retardancy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional flame retardants are used in polyurethane foam insulation, then flame retardant effect is improved, but the insulation material lacks sufficient flame protection according to FMVSS302 standards

Engineering Contradiction:

Improveflame protectionVSAvoidflame retardancy insufficiency

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent uses filled polyether polyols as a composite material system, where the filler (reaction product of di- and/or polyisocyanates with compounds containing isocyanate-reactive hydrogen atoms) is integrated into the polyol structure. This composite approach provides inherent flame retardant properties without relying solely on conventional flame retardant additives, achieving FMVSS302 compliance while maintaining insulation performance.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the chemical composition parameters of the polyurethane foam by incorporating filled polyether polyols with specific filler content (2-30% by weight based on total polyol). This parameter change in the base material composition provides enhanced flame retardancy, allowing the insulation to meet FMVSS302 standards without compromising thermal and acoustic insulation properties.

Inventive Principle:

Principle #35Parameter changes

2Ease of operation

If complete encapsulation of motor housing is proposed for best sound insulation, then acoustic insulation is improved, but the complexity of the insulation system increases

Engineering Contradiction:

Improveacoustic insulationVSAvoidencapsulation complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent employs a multi-functional polyurethane foam material that simultaneously provides thermal insulation, acoustic insulation, and flame protection. This universal material eliminates the need for separate encapsulation systems for each function, reducing overall system complexity while maintaining complete motor housing encapsulation for optimal acoustic insulation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If filled polyether polyols with filler content of 2 to 30% by weight are used, then flame retardant properties are enhanced, but the manufacturing process complexity increases

Engineering Contradiction:

Improveflame retardant propertiesVSAvoidproduction process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The filler is pre-integrated into the polyol structure during polyol synthesis, creating filled polyether polyols before the polyurethane foam production step. This preliminary action incorporates the flame retardant filler at the material synthesis stage, simplifying the subsequent foam manufacturing process as the filler is already uniformly distributed in the polyol, eliminating the need for separate filler addition steps.

Inventive Principle:

Principle #10Preliminary action

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 provides polyurethane foams with enhanced flame retardant properties, effectively meeting FMVSS302 standards and offering improved thermal and acoustic insulation for internal combustion engines.

Implementation Method 1

the filler being a reaction product of di- and/or polyisocyanates with compounds containing isocyanate-reactive hydrogen atoms

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Implementation Method 2

in the presence of water and/or physical blowing agents

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 3

Thermal insulation reduces the warm-up phase of the still cold engine after starting

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 4

acoustic insulation for internal combustion engines

Methodology Applied

Scientific EffectAcoustic absorption: Acoustic Absorption

Data Source

PatentEP3425187A1Flame retardant insulation for internal combustion engines

Publication Date: 2019.01.09 COVESTRO DEUTSCHLAND AG

AI summary

The invention relates to a method for producing thermal and acoustic insulation for internal combustion engines using polyurethane foams obtainable by reacting di- and/or polyisocyanates with filler-containing polyols, wherein the filler is a reaction product of di- and/or polyisocyanates with compounds having hydrogen atoms reactive towards isocyanates, in the presence of water and/or physical blowing agents, as well as the thermal and acoustic insulation for internal combustion engines itself.