Oleophobic Insulating Shield With Low-Penetration PTFE Coating

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Solution Overview

Problem

Current thermal and acoustical shielding methods fail to meet new flammability requirements without compromising acoustic or thermal shielding properties or increasing manufacturing costs, especially in high-temperature environments like automobile exhaust systems.

Innovation Solution

A moldable, self-supporting insulating shield made from a nonwoven material with an oleophobic coating, such as polyethylene terephthalate (PET) or polytetrafluoroethylene (PTFE), which prevents oil absorption and provides improved flame resistance without penetrating deeply into the material, maintaining air flow and insulation properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a coating is applied to provide flame resistance, then flammability requirements are met, but coating weight and penetration increase which may compromise thermal and acoustical insulation properties

Engineering Contradiction:

Improveflame resistanceVSAvoidthermal and acoustical insulation properties

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent applies a light-weight PTFE-based oleophobic coating that minimizes penetration into the nonwoven material while providing flame resistance. By controlling coating parameters (weight, penetration depth) and selecting appropriate PTFE formulations, the shield meets flammability standards while preserving thermal and acoustical insulation properties.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a composite structure combining nonwoven material (for insulation) with a PTFE-based oleophobic coating (for flame resistance and oil repellency). This composite approach allows each layer to perform its specific function while maintaining overall shield performance.

Inventive Principle:

Principle #40Composite materials

2Reliability

If oleophobic coating is applied to prevent oil absorption, then flammability standards are met, but manufacturing cost increases

Engineering Contradiction:

Improveflammability standardsVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent optimizes coating parameters to achieve flame resistance at minimal coating weights (e.g., 0.5-2.0 oz per 100 sq ft). By controlling application methods and PTFE formulation, the coating provides necessary protection while minimizing material consumption and manufacturing cost.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a thin, cost-effective PTFE coating that provides the necessary flame-resistant layer without requiring thick, expensive applications. The coating is applied sparingly to achieve standards compliance at lower material and processing costs.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If coating penetration is increased to ensure flame resistance, then flammability requirements are met, but air flow and insulation properties are compromised

Engineering Contradiction:

Improveflame resistanceVSAvoidair flow and insulation properties

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent carefully controls coating penetration depth to ensure flame resistance while minimizing impact on air flow and insulation. By optimizing application parameters and selecting appropriate PTFE formulations, the coating remains sufficiently superficial to preserve the nonwoven material's functional properties.

Inventive Principle:

Principle #35Parameter changes

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 effectively meets self-extinguishing flammability standards when exposed to engine oil, maintains acoustical insulation, and reduces manufacturing costs by minimizing coating weight and penetration, ensuring the shield does not compromise thermal or acoustical performance.

Implementation Method 1

an oleophobic coating applied thereon... which prevents oil absorption

Methodology Applied

Scientific EffectOleophobic effect: Hydrophobe

Implementation Method 2

thermal and acoustical insulating shields... providing thermal and acoustical shielding

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 3

providing thermal and acoustical shielding... acoustical insulating value

Methodology Applied

Scientific EffectAcoustical insulation: Acoustic Absorption

Data Source

PatentUS10344426B2Oleophobic insulating shield and method of making

Publication Date: 2019.07.09 L INT IP HLDG LLC

AI summary

According to some embodiments, a material and a method of providing thermal and acoustical insulation with an insulating shield that is moldable and self-supporting insulating shield, is presented. The shield includes a nonwoven material and an oleophobic coating applied to the outer surface of the nonwoven material. The oleophobic coating includes a percent add-on (% AO) of less than approximately 3% AO and a penetration into the surface of the nonwoven material of less than approximately 10%.