Multilayered Heat Shield Flanging via Integrated Pressing
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Solution Overview
Problem
Existing methods for producing multilayered heat shields require multiple complex process steps and tools, making them economically inefficient and time-consuming.
Innovation Solution
A method involving a two-stage pressing process using two tools to connect metal layers with an insulating layer in between, where the edge portions of the metal layers are formed into a standing seam and then flanged to create a hem, reducing the number of manufacturing steps and tools needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple process steps and tools are used to connect metal layers by flanging, then the connection reliability is improved, but the manufacturing complexity and time increase
Solution Approach 1:
The patent combines multiple separate manufacturing steps (deep drawing, positioning, repositioning, pushing closed) into a single integrated pressing operation. The pressing tool simultaneously forms the folded edge and connects the metal layers in one stroke, eliminating the need for multiple sequential steps and separate tools, thus reducing manufacturing complexity while maintaining connection reliability
Solution Approach 2:
The pressing tool is designed to perform multiple functions in one operation: it forms the folded edge of the first metal layer, positions the insulating layer and second metal layer, and executes the flanging connection all in a single pressing stroke. This multi-functional approach reduces the number of required tools and process steps while ensuring reliable connection
2Manufacturing precision
If multiple process steps are used to connect metal layers, then the manufacturing precision is improved, but the productivity decreases
Solution Approach 1:
The pressing tool is pre-configured with positioning elements and forming surfaces that automatically guide the metal layers and insulating layer into correct positions before the pressing action occurs. The tool geometry itself ensures proper alignment and positioning, eliminating the need for separate positioning steps while maintaining manufacturing precision and increasing productivity
3Strength
If traditional multi-step flanging process is used, then the connection strength is improved, but the loss of time increases
Solution Approach 1:
The pressing operation continues in one uninterrupted motion throughout the entire connection process. The pressing tool applies continuous force from the initial contact through the forming of the folded edge and completion of the flanging connection, eliminating idle time between steps while ensuring adequate connection strength through sustained pressing force
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
This approach simplifies the production process to two steps, eliminating the need for additional tools and reducing the complexity of connecting metal layers, thereby enhancing manufacturing efficiency and cost-effectiveness.
Implementation Method 1
a forming of the edge portion of the first metal layer and the edge portion of the second metal layer relative to the horizontal plane of the insulating layer is effected, wherein the edge portion of the first metal layer and the edge portion of the second metal layer are bent over together in one direction
Implementation Method 2
the upper tool and the lower tool are moved toward one another and, during the closing movement, the upper tool comes into contact with the folded end of the standing seam before the free end of the standing seam comes into contact with the lower tool, and the standing seam of the edge portion of the first metal layer is flanged to form a hem around the edge portion of the second metal layer
Data Source
AI summary
In a method for producing a multilayered heat shield, which has a first metal layer and a second metal layer that has an insulating layer arranged between the metal layers, the metal layers are connected at the edge by a flanging. To produce the heat shield, the first metal layer, the insulating layer and the second metal layer are placed into a first pressing tool. This is effected in such a way that an edge portion of the first metal layer protrudes beyond an edge portion of the second metal layer. The insulating layer is set back from the edge portions of the first metal layer and of the second metal layer.