Hybrid Engine Cover Skeleton Panel Noise Reduction

Solution Overview

Problem

Internal combustion engine oil pans and valve covers face challenges in achieving both design flexibility and effective sound insulation, with existing solutions either limiting shapeability or increasing weight and cost.

Innovation Solution

A hybrid engine cover design combining a skeleton structure with ribs and panels, using a composite material that includes a viscoelastic polymer core, allowing for flexible design and superior sound dampening capabilities, with a sealant material to secure panels to the frame, reducing noise transmission.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If metal-polymer-metal sheets are used for noise reduction, then sound insulation is improved, but shapeability and design flexibility deteriorate

Engineering Contradiction:

Improvenoise reductionVSAvoidshapeability

Core Design Contradiction:

Object-affected harmful factorsVSAdaptability or versatility

Solution Approach 1:

The oil pan is divided into a skeleton structure (frame) and separate panel components that can be independently formed and then assembled together. This segmentation allows the panels to be manufactured using drawing processes for noise reduction while the skeleton provides the necessary structural flexibility and fitment for different engine configurations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The oil pan combines different materials strategically: metal panels (for sound insulation and rigidity) are integrated with a metal skeleton structure (for strength and adaptability). This composite construction allows each component to contribute its superior properties while overcoming the limitations of individual materials.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If cast metal components are used for design flexibility, then shape adaptability is improved, but weight and manufacturing cost increase

Engineering Contradiction:

Improvedesign flexibilityVSAvoidweight

Core Design Contradiction:

Adaptability or versatilityVSWeight of moving object

Solution Approach 1:

The oil pan is divided into a skeleton structure (frame) and separate panel components that can be independently formed and then assembled together. This segmentation allows the panels to be manufactured using drawing processes for noise reduction while the skeleton provides the necessary structural flexibility and fitment for different engine configurations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the oil pan are made from different materials suited to their specific functions: rigid metal panels for noise-critical areas and a more flexible skeleton structure for areas requiring adaptability and fitment. This local differentiation optimizes both weight and performance.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If cast metal components are used for design flexibility, then shape adaptability is improved, but sound insulation capability deteriorates

Engineering Contradiction:

Improvedesign flexibilityVSAvoidsound insulation

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The oil pan is divided into a skeleton structure (frame) and separate panel components that can be independently formed and then assembled together. This segmentation allows the panels to be manufactured using drawing processes for noise reduction while the skeleton provides the necessary structural flexibility and fitment for different engine configurations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The oil pan combines different materials strategically: metal panels (for sound insulation and rigidity) are integrated with a metal skeleton structure (for strength and adaptability). This composite construction allows each component to contribute its superior properties while overcoming the limitations of individual materials.

Inventive Principle:

Principle #40Composite materials

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 hybrid design offers the flexibility of cast components with the sound insulation attributes of composite materials, reducing noise generation and transmission while maintaining low weight and cost, suitable for various engine configurations.

Implementation Method 1

A pool of oil is usually collected in a reservoir that is near a low point of the engine

Methodology Applied

Scientific EffectViscoelasticity: Viscoelasticity

Implementation Method 2

These large flat surfaces often tend to resonate during operation of the engine, and either generate or relay noise during operation of the engine

Methodology Applied

Scientific EffectVibration damping: Damping

Implementation Method 3

A seal is located between the at least one panel and the skeleton structure

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS7509935B2Engine cover and method

Publication Date: 2009.03.31 INT ENGINE INTPROP CO LLC

AI summary

An engine cover (400), such as a valve cover (700) or an oil pan (400), includes a skeleton structure (402) that may have a plurality of ribs (406) and at least one opening. At least one panel (404) is configured to fit in the at least one opening, and is operably connected to the skeleton structure (402). A seal (424) is located between the at least one panel (404) and the skeleton structure (402). The plurality of ribs (406) defines a plurality of channels (802) located around the at least one or more openings. Each panel (404) is held to the skeleton structure (402) by the plurality of channels (802).