3D Printed Insulating Element for Vehicle Cavities
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Solution Overview
Problem
Existing methods for producing insulating elements for vehicle cavities are costly due to high investment requirements for tools, especially for small series production, and struggle with creating complex three-dimensional shapes.
Innovation Solution
An insulating element comprising a carrier element made of a high-temperature solid material and an expandable element, printed in a limited number of layers using three-dimensional printing, allowing for efficient production of complex shapes without high tooling costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional injection molding process is used to produce insulating elements, then manufacturing precision and reliability are improved, but investment costs and device complexity increase significantly
Solution Approach 1:
The patent changes the production method from conventional injection molding to 3D printing, fundamentally altering the manufacturing parameters. This allows complex geometries to be produced without expensive molds, reducing tooling investment while maintaining geometric precision through digital modeling and additive manufacturing processes
Solution Approach 2:
The patent replaces the mechanical injection molding system with a 3D printing system that uses digital files and layered material deposition. This substitution eliminates the need for physical molds and tooling, significantly reducing investment costs while maintaining the ability to produce complex insulating element geometries
2Productivity
If injection molding process is used for large series production, then production costs per unit decrease, but investment costs and production time increase for small series
Solution Approach 1:
The patent uses 3D printing technology that allows digital models to be prepared in advance without requiring physical mold setup. This preliminary digital preparation enables rapid production switching between different insulating element designs, eliminating mold changeover time and making small series production as efficient as large series production
Solution Approach 2:
The patent implements a dynamic production system where the manufacturing process can be easily adjusted by changing digital parameters rather than physical tooling. This dynamic approach allows the production system to adapt quickly to different production volumes and designs, optimizing efficiency for both small and large series without fixed mold constraints
3Ease of manufacture
If alternative production methods like profile extrusion or multi-layer stamping are used, then investment costs decrease, but manufacturing precision and geometric complexity capability are reduced
Solution Approach 1:
The patent changes from traditional subtractive or formative methods (extrusion, stamping) to additive manufacturing. This parameter change enables the production of complex three-dimensional geometries that cannot be achieved with extrusion or stamping, while maintaining low investment costs through the elimination of expensive molds and tooling
4Reliability
If complex three-dimensional shapes are produced using conventional methods, then sealing and reinforcement effectiveness are improved, but production costs and tooling complexity increase
Solution Approach 1:
The patent changes the manufacturing approach to 3D printing, which directly deposits material in the final complex geometry without requiring multi-step tooling processes. This enables effective sealing and reinforcement shapes to be produced in a single additive process, maintaining reliability while significantly reducing production costs and eliminating complex tooling requirements
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 approach reduces production time and costs by using fewer layers and coarser material strands, enabling cost-effective production of insulating elements for both small and large series, while accommodating complex geometries and enhancing structural reinforcement and sealing.
Implementation Method 1
the second material being expandable at a temperature between 120° C. and 200° C.
Data Source
Figure 1~2b
Figure 3a~4b
Figure 5a~7b
AI summary
The invention relates to a damping element (16) for damping a structured element (12, 14) in a vehicle, comprising a support element (11) and an expandable element (13). The support element consists of at least one printed material strand (1) of a first material, which is in a solid aggregate state at least up to a temperature between 120 °C and 200 °C, and the expandable element consists of at least one printed material strand (3) of a second material, which is expandable at a temperature between 120 °C and 200 °C. The damping element has at least two and maximally ten layers which lie one over the other at the thickest point (5) measured perpendicularly to a plane (22) of the damping element.