Vehicle Insulation Plate Clamped in Weldable Carrier
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Solution Overview
Problem
Existing vehicle component insulation, typically thin metal sheets with structured surfaces, is difficult and expensive to attach due to the need for screwing, as they cannot be welded easily, requiring multiple holes and screws.
Innovation Solution
A separate carrier with a clamping profile, such as a U-shaped design, is used to mechanically fasten and then weld the plate-like insulation component to the vehicle component, allowing for quick and cost-effective attachment via a single weld seam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If thin metal sheet insulation is used, then heat radiation efficiency is improved, but fastening complexity increases
Solution Approach 1:
The insulation system is divided into two functional parts: a thin plate-like component for heat radiation and a separate carrier for fastening. This segmentation allows each part to be optimized independently - the plate remains thin for thermal performance while the carrier provides robust mechanical attachment capabilities
Solution Approach 2:
The separate carrier acts as an intermediary between the thin plate-like insulation and the vehicle component. The carrier provides welding surfaces and structural support, enabling the thin plate to be attached without compromising either thermal performance or mechanical fastening
2Quantity of substance
If thin metal sheet insulation is used, then material cost is reduced, but manufacturing complexity increases
Solution Approach 1:
By separating the insulation function (thin plate) from the fastening function (carrier), the system uses minimal material for the plate while the carrier is designed specifically for easy manufacturing and attachment processes
Solution Approach 2:
The invention replaces complex mechanical fastening (screws, holes, clamps) with welding, which is generally simpler and more cost-effective for metal components. The carrier is designed with welding surfaces that enable direct welding to the vehicle component
3Reliability
If screw fastening is used, then attachment reliability is improved, but installation time increases
Solution Approach 1:
The invention replaces the multi-step screw fastening process with welding, which achieves reliable attachment in a single operation. The carrier is designed with welding surfaces that allow direct welding to the vehicle component, eliminating the need for drilling, countersinking, and screw insertion
4Weight of moving object
If thin metal sheet insulation is used, then weight is reduced, but weldability decreases
Solution Approach 1:
The system separates the thin plate (for weight savings and thermal function) from the carrier (for welding and structural support). The carrier is made of weldable material with sufficient thickness to accommodate welding processes, while the plate remains thin for weight reduction
Solution Approach 2:
The carrier serves as an intermediary that provides welding surfaces between the thin plate and the vehicle component. This allows the thin plate to be attached via welding through the carrier, which has adequate material thickness for proper weld formation
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
Enables easy, quick, and cost-effective attachment of insulation to vehicle components by allowing the plate-like component to be clamped and welded, reducing the complexity and expense of the fastening process compared to traditional screwing methods.
Implementation Method 1
a type of air gap is created between the area of the respective component to be insulated, in particular the respective exhaust system component, which causes air gap insulation and greatly reduces the heat transfer from the insulated area to the plate-shaped, thin-walled insulation
Implementation Method 2
this creates a large surface that is characterized by efficient heat radiation
Implementation Method 3
EP 1 772 603 A1 shows a tubular body to which a jacket is attached by means of a weld seam
Data Source
Figure 1~4
AI summary
The isolation (10) has a plate-like component (12) and a separate carrier (14). The carrier comprises a recess (16). An outer rim (18) of the plate-like component is arranged in the recess in installation position. A portion of the outer rim of the plate-like component rests against an inner edge (24) of the recess of the carrier in the installation position. The carrier comprises an attaching unit (20) i.e. mounting rail. The carrier is configured as a clamping profile, and comprises a weldable portion. The profile comprises two legs (22), and is designed as U-shaped clamping profile. An independent claim is also included for an automotive industry part.