Lightweight Thermal Shield Structure for Heat and Vibration Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional heat shields for vehicles are heavy due to their robust construction, which is necessary for thermal protection and vibration resistance, resulting in a significant weight penalty.
Innovation Solution
A lightweight thermal shield design using a support screen made from mesh material with an infused insulation layer that provides structural stiffness and thermal insulation, reducing weight while maintaining structural integrity and thermal protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If robust thick metallic sheets and stiffening structures are used, then structural integrity and vibration resistance are improved, but weight increases significantly
Solution Approach 1:
The patent applies composite materials by combining a metallic support screen (providing structural integrity and vibration resistance) with a ceramic fiber insulation layer (providing thermal protection). This composite structure achieves the required strength and thermal protection without the weight penalty of thick solid metal sheets, as each material performs its specialized function in the composite system.
Solution Approach 2:
The patent utilizes a mesh or screen structure for the support layer, which is inherently porous. This porous metallic support provides sufficient structural integrity and vibration resistance while maintaining low weight, as the open structure reduces material usage compared to solid sheets while still providing the necessary mechanical properties.
2Temperature
If thick metallic sheets are used, then thermal protection is improved, but weight increases
Solution Approach 1:
The patent uses a composite structure where the ceramic fiber insulation layer provides the primary thermal protection function. This allows the use of thin metallic support screens instead of thick metal sheets, achieving superior thermal insulation without the weight penalty, as ceramic fibers have much lower thermal conductivity and lower density than metal.
Solution Approach 2:
The ceramic fiber insulation layer acts as an intermediary thermal barrier between the hot exhaust components and the protected engine bay components. This intermediate insulating layer provides effective thermal protection while being lightweight, eliminating the need for heavy metallic thermal barriers.
3Reliability
If stiffening structures and embossments are added, then vibration resistance is improved, but device complexity increases
Solution Approach 1:
The patent achieves vibration resistance through the inherent mechanical properties of the metallic support screen material and its structural design, rather than adding complex embossments or stiffening structures. The composite nature allows the support screen to be optimized for vibration resistance while keeping the overall structure simple and free of complex features.
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 lightweight thermal shield effectively protects heat-sensitive systems from high temperatures and vibrations while significantly reducing the overall weight, offering improved insulating capability and resistance to high-cycle fatigue.
Implementation Method 1
a core layer of insulating fabric that serves to prevent the interior surfaces of the sheet metal layers from contacting or rubbing against each other
Implementation Method 2
The outer surface of the metallic sheet layer closest to the heat source is often configured to reflect radiated heat away from the heat shield
Data Source
Figure 1~3
Figure 4~5
Figure 6
AI summary
A method of making a lightweight thermal shield (902) that includes obtaining a mold (950) having a shaped support screen (960) with a molding surface configured to allow the passage of air and moisture therethrough, and with the mold (950) being adapted for drawing a vacuum (972) from behind the support screen (960). The method also includes applying a wet insulation material onto the molding surface of the support screen (960) and drawing a vacuum (972) to withdraw moisture through the support screen (960) and consolidate a layer of insulation material (93) on top the molding surface. The method further includes removing the consolidated layer of insulation material (933) from off the molding surface, installing the consolidated layer of insulation material (933) into an outer shell layer (920), and drying the consolidated layer of insulation material (933) within the outer shell layer (920) to form a lightweight core insulation layer (930).