Pyramidal Cell Metal Sheet for Heat Protector Strength
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Solution Overview
Problem
Existing heat protectors made from aluminum thin films face issues with tearing, cracking, and limited noise reduction, and struggle to maintain both heat-blocking and heat-dissipating characteristics, especially in complex manifold shapes and high-temperature environments.
Innovation Solution
A strength-reinforcing aluminum metal sheet with repetitive concave and convex features, including pyramidal cells with eccentric uppermost points, which enhances both strength and formability, allowing for improved heat protection and noise reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If Al thin films are used for heat protectors, then lightness and thermal conductivity are improved, but formability and resistance to tearing/cracking deteriorate
Solution Approach 1:
The patent uses a composite structure consisting of multiple Al thin films laminated together with an insulating layer in between. This composite structure maintains the lightness and thermal conductivity advantages of Al thin films while the multi-layer construction with insulating layers provides improved strength and resistance to tearing and cracking compared to single-layer Al thin films.
Solution Approach 2:
The heat protector is divided into multiple separate Al thin film layers rather than using a single thick layer. Each thin film layer is separated by an insulating layer, creating a segmented structure that improves formability and reduces the likelihood of tearing and cracking while maintaining the inherent advantages of thin Al films.
2Strength
If Al thin films are laminated to improve endurance, then resistance to tearing and cracking is improved, but device complexity increases
Solution Approach 1:
The heat protector structure is segmented into multiple Al thin film layers separated by insulating layers. This segmentation approach improves endurance by distributing mechanical stresses across multiple layers, reducing the likelihood of tearing and cracking, while the regular repeating pattern keeps the manufacturing process relatively simple.
Solution Approach 2:
The patent creates a composite material structure by laminating multiple Al thin films with insulating layers between them. This composite structure enhances endurance and thermal management capabilities while maintaining a systematic manufacturing approach that doesn't excessively increase device complexity.
3Productivity
If heat protectors are formed by pressing Al thin films, then manufacturing efficiency is improved, but film separation and vulnerability to vibrations occur
Solution Approach 1:
The pressing process creates a segmented structure where Al thin films are separated by insulating layers. This segmentation allows each layer to be formed independently during pressing, improving manufacturing efficiency, while the insulating layers act as spacers that prevent film separation and enhance vibration resistance.
Solution Approach 2:
The insulating layers serve as intermediary elements between the Al thin films. These intermediaries prevent direct contact between Al film layers, eliminating film separation issues during pressing, and provide mechanical coupling that enhances vibration resistance while allowing efficient manufacturing.
4Ease of manufacture
If simple wave-shaped patterns are used, then manufacturing simplicity is maintained, but heat-insulating and heat-dissipating characteristics are limited
Solution Approach 1:
The patent combines multiple Al thin films with insulating layers in a laminated composite structure. This composite approach enables both heat-blocking (through the Al layers) and heat-dissipating (through the insulating layers and air gaps) characteristics to function simultaneously, improving overall thermal management performance while maintaining manufacturability.
Solution Approach 2:
The heat protector structure is segmented into alternating layers of Al films and insulating materials. This segmentation creates a multi-functional structure where different layers perform different thermal functions, enabling both heat blocking and heat dissipation to occur simultaneously, thereby improving reliability without complicating manufacturing.
Data Source
AI summary
A strength-reinforcing metal sheet having repetitive concave and convex features is provided. Concave beads extend in repetitive quadrangular lattice features. A plurality of convex cells are defined between the beads, protrude above the beads, and have repetitive convex features. The upper portion of each of the cells has a pyramidal shape similar to a dome. The uppermost point thereof is formed at an eccentric point offset from the central point of the cell.