Multilayer Composite Panel Waveform Design for Heat Protection
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Solution Overview
Problem
Conventional heat protectors, such as those using aluminum thin plates, face challenges in durability, noise reduction, and simultaneous heat-blocking and heat-dissipation characteristics, especially at elevated temperatures, due to complex manifold shapes and insufficient air layers, which limit their effectiveness in early engine operation stages and soundproofing.
Innovation Solution
A multi-layered composite panel is formed by overlapping thin plates with continuous waveform patterns of different heights, creating closed air layers in triangle-patterned cells, and orthogonal pressing portions are introduced to enhance formability and prevent plate separation, ensuring continuous closed air layers and improved heat-blocking and heat-dissipation capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If aluminum thin plates are used for heat protectors, then heat dissipation ability is improved, but durability deteriorates due to tearing and cracks
Solution Approach 1:
The patent uses composite materials by combining multiple aluminum thin plates with different waveform patterns (first waveform pattern on one plate, second waveform pattern on another plate) to create a heat protector that maintains the heat dissipation benefits of aluminum while improving durability through the composite structure. The layered composite design prevents tearing and cracks that would occur in single-plate configurations.
Solution Approach 2:
The patent applies the nesting principle by placing one aluminum thin plate with a first waveform pattern inside or alongside another aluminum thin plate with a second waveform pattern. This nested multi-plate structure allows each plate to contribute to heat dissipation while the combined structure provides enhanced mechanical strength and resistance to tearing and cracking.
2Loss of energy
If two aluminum thin plates are overlapped to form air layers, then heat-blocking ability is improved, but manufacturing difficulty increases due to plate separation
Solution Approach 1:
The patent applies dimensionality change by introducing waveform patterns in the thickness direction (z-axis) of the aluminum thin plates. The first and second waveform patterns create air layers between plates while the waveforms interlock to prevent plate separation during manufacturing. This dimensional approach allows heat-blocking air layers to form without compromising manufacturing ease.
Solution Approach 2:
The patent uses curvature through waveform patterns (sinusoidal, triangular, or trapezoidal waves) on the aluminum thin plates. These curved surface patterns create the necessary air gaps for heat blocking while the interlocking nature of the waveforms prevents plate separation during assembly and manufacturing processes.
3Ease of manufacture
If simple waveform patterns are used, then manufacturing ease is improved, but heat-blocking and heat-dissipation characteristics cannot be simultaneously obtained
Solution Approach 1:
The patent combines multiple aluminum thin plates with different waveform patterns to achieve both heat-blocking and heat-dissipation characteristics. The composite structure allows one plate's waveform to create air layers for heat blocking while the other plate's waveform maintains heat dissipation pathways, all while remaining manufacturable through standard forming processes.
Solution Approach 2:
The patent applies local quality by assigning different waveform patterns to different plates or different regions. The first aluminum thin plate has a first waveform pattern optimized for one function (e.g., heat blocking), while the second plate has a second waveform pattern optimized for another function (e.g., heat dissipation), allowing each local region to perform its specific thermal function effectively.
4Object-generated harmful factors
If air layers are formed between thin plates, then soundproofing is improved, but heat-blocking ability at low temperatures deteriorates
Solution Approach 1:
The patent uses composite materials with multiple plates having different waveform patterns to simultaneously achieve soundproofing and maintain heat-blocking ability at low temperatures. The multi-layered structure with varied waveforms creates acoustic impedance for soundproofing while maintaining thermal pathways when needed, resolving the contradiction between sound isolation and thermal management.
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 solution provides enhanced heat-blocking and heat-dissipation characteristics, improved soundproofing, and increased formability, reducing manufacturing costs by maintaining uniform air layers and preventing thermal damage, while effectively managing engine heat at both low and high temperature ranges.
Implementation Method 1
heat protectors are manufactured by overlapping two or more sheets of aluminum thin plates and adding various shapes, such as embossing, prominences and depressions, waveforms and the like... heat-blocking ability may be reduced at an activation temperature or less of a catalyst where thermal efficiency is required to increase
Implementation Method 2
Aluminum thin plates have the advantages of high thermal conductivity and excellent heat dissipation
Implementation Method 3
soundproofing effect for blocking noise caused by vibration may be limited... improved soundproofing
Data Source
AI summary
Disclosed is a multi-layered composite panel. The multi-layered composite panel comprises at least two sheets of thin plates with continuous waveform patterns having the same pitch and different heights in one direction are overlapped. In the multi-layered composite panel, an air layer is formed between the overlapping thin plates, orthogonal pressing portions, which divide the waveform patterns on the top and the bottom of the thin plates into the unit of triangle-patterned cell by being pressed orthogonally to cross each other on the top and the bottom of the thin plates overlapping in the orthogonal direction crossing the direction of the waveform patterns, are formed and an undercut portion is formed by pressing the centers of both sides connecting a groove and a ridge of each cell on the top and the bottom of the thin plates with opposite orthogonal pressing portions.