Flexible Foil Insulating Device for Complex Geometries

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Solution Overview

Problem

Existing insulating devices lack adaptability and ease of application to components, particularly at high temperatures, and require complex structural efforts and special connection points, limiting their use in diverse applications.

Innovation Solution

An insulating device featuring a metallic fine wire fabric inner jacket and a flexible, plastically deformable outer casing with a barrier layer, such as stainless steel or aluminum foil, allowing for easy adaptation to components without specialized tools, and incorporating insulating materials like stainless steel wool or glass fiber needle mats, which can withstand high temperatures up to 1000°C.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a rigid double-walled structure with metal shells and fibrous insulation is used, then thermal insulation performance is improved, but adaptability to complex geometries and ease of installation deteriorate

Engineering Contradiction:

Improvethermal insulation performanceVSAvoidadaptability to complex geometries

Core Design Contradiction:

TemperatureVSAdaptability or versatility

Solution Approach 1:

The patent replaces rigid metal shells with flexible foil casings (aluminum foil, stainless steel foil, or glass fabric with coating) that can be easily deformed and adapted to complex geometries of exhaust pipes and other components. The foil casing maintains thermal insulation functionality while providing the necessary flexibility for installation on various component shapes without requiring rigid structural support.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent uses composite material structures combining foil casings with insulating materials (stainless steel wool, glass fiber needle mats) and barrier layers (PTFE, silicone, PE coatings). This composite approach provides both thermal insulation performance and flexibility, resolving the contradiction between maintaining insulation effectiveness and achieving adaptability to complex geometries.

Inventive Principle:

Principle #40Composite materials

2Strength

If conventional fabric coverings are used for insulating material, then structural strength is improved, but protection against liquid ingress and high-temperature resistance deteriorate

Engineering Contradiction:

Improvestructural strengthVSAvoidliquid ingress and high-temperature damage

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent employs composite material structures where conventional fabric coverings are combined with barrier layers (PTFE, silicone, or PE coatings) and foil casings. This composite approach maintains the structural strength provided by fabric while adding liquid ingress protection through the barrier layer and high-temperature resistance through the foil casing and heat-resistant insulating materials.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent introduces barrier layers as intermediary protective elements between the insulating material and the external environment. These barrier layers (PTFE, silicone, PE coatings) specifically address liquid ingress protection, while the foil casing serves as an intermediary for high-temperature protection, allowing the conventional fabric covering to maintain its structural function without direct exposure to harmful factors.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If insulating devices are designed with specialized connection points and complex structures, then fixation reliability is improved, but ease of installation and production simplicity deteriorate

Engineering Contradiction:

Improvefixation reliabilityVSAvoidproduction simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent uses flexible foil casings that can be easily deformed and adapted to component geometries during installation. This flexibility eliminates the need for complex pre-formed structures and specialized connection points, allowing simple installation through wrapping and securing the foil casing around components while maintaining reliable fixation through the flexibility and conformability of the material.

Inventive Principle:

Principle #30Flexible shells and thin films

4Stability of the object's composition

If rigid metal shells are used for outer casing, then structural stability is improved, but flexibility for deformation and adaptation to components deteriorates

Engineering Contradiction:

Improvestructural stabilityVSAvoidflexibility for deformation

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The patent replaces rigid metal shells with flexible foil casings made from aluminum foil, stainless steel foil, or glass fabric with coating. These foil casings provide sufficient structural stability to maintain the insulating device's integrity while offering the flexibility needed for deformation and adaptation to various component geometries during installation.

Inventive Principle:

Principle #30Flexible shells and thin films

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 enables flexible and reliable heat insulation and soundproofing with reduced structural effort, simplified production, and adaptability to complex geometries, while maintaining durability and resistance to liquids and fuels, suitable for high-temperature applications in motors and motor vehicles.

Implementation Method 1

an insulating device (100) for heat insulation and/or soundproofing... The insulating material (3) is arranged between the inner jacket (1) and the outer jacket (2)... stainless steel wool or insulating fiber material or glass fiber needle mat

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

The outer jacket (2) is designed as a barrier layer, in particular as a stainless steel foil, aluminum foil or as a glass fabric with a lamination or coating, in particular on one side, made of PTFE, silicone or PE, for which the formation as a film preferably serves as a barrier layer in order to advantageously prevent the ingress of liquid, in particular water or fuel

Methodology Applied

Scientific EffectBarrier layer:

Implementation Method 3

an insulating device (100) for heat insulation and/or soundproofing... The insulating material (3) is arranged between the inner jacket (1) and the outer jacket (2)... designed as stainless steel wool or insulating fiber material or glass fiber needle mat

Methodology Applied

Scientific EffectSound absorption: Acoustic Absorption

Data Source

PatentEP2241435B1Insulating device

Publication Date: 2012.06.27 BDD BETEILIGUNGS

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AI summary

The invention relates to an insulating device for a component, particularly one through which a hot medium flows, comprising an inner sheath (1) and an outer sheath (2), between which insulating material (3) is arranged. The insulating device is to be further developed in such a way that it allows for simple yet reliable adaptation to and/or attachment to the component to be insulated. For this purpose, it is proposed that the inner sheath (1) be designed as a metallic wire mesh and the outer sheath (2) as a foil or sheet, and that the insulating device be deformable and/or adaptable to the component.