Insulated Structural Element for Electric Vehicle Acoustic Sealing
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Solution Overview
Problem
Existing sealing solutions for motor vehicles with cavities are not suitable for electrically powered vehicles, as they are designed for internal combustion engines, leading to inadequate acoustic insulation and increased noise transmission.
Innovation Solution
A system comprising two insulating elements with carriers completely covered in expanded material, arranged one behind the other, providing improved acoustic insulation by creating a closed air chamber and effectively sealing irregularly shaped cavities, which can be easily applied before body dip-coating and baked to expand, offering better soundproofing in the 500-3000 Hz frequency range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a single insulating element is used to seal cavity 17, then the sealing function is provided, but the acoustic insulation performance is insufficient for electric vehicles
Solution Approach 1:
The insulating element is divided into two separate components (first insulating element 16 and second insulating element 16) that are arranged one behind the other in the cavity. This segmentation allows each element to contribute to acoustic insulation in different frequency ranges, with the combined system achieving superior noise reduction performance compared to a single element, particularly for the high-frequency sounds characteristic of electric vehicles.
2Object-affected harmful factors
If two-component polyurethane foam is used for insulation, then good acoustic insulation is achieved, but handling and application become more complex
Solution Approach 1:
The insulating elements are pre-formed as complete units with the expanded material already integrated into the support structure. This preliminary preparation eliminates the need for complex on-site mixing and application procedures required by two-component polyurethane foams. The pre-formed elements can be directly installed in the cavity before dip-coating, significantly simplifying the application process while maintaining effective acoustic insulation performance.
3Ease of operation
If insulation elements are applied before dip-coating, then easier handling is achieved, but the body must be dip-coated first adding process steps
Solution Approach 1:
The insulating elements are installed in the structural element's cavity before the dip-coating process. This preliminary installation takes advantage of the fact that the cavity is accessible before painting, allowing for straightforward placement and fixation of the insulation elements. The dip-coating process then proceeds to seal and protect the entire assembly, creating an integrated final product without requiring additional post-coating insulation steps.
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 solution achieves significantly better acoustic insulation for electric vehicles, comparable to two-component polyurethane foams, with easier handling and reduced labor costs, while maintaining structural integrity and noise reduction.
Implementation Method 1
these proposed insulation elements can be installed in the structural components before the body is dip-coated, and then expanded in a curing oven after painting
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
A system of insulated structural elements in a motor vehicle comprises a structural element and two insulation elements. Each of the two insulation elements comprises a wall and an expanded material that completely covers at least one side of that wall.