Insulated Structural Element with 3500% Expansion Material
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Solution Overview
Problem
Existing sealing and reinforcing elements for vehicle cavities are not suitable for electrically powered vehicles, and conventional insulation methods like two-component polyurethane foams are complex, costly, and require additional sealing steps.
Innovation Solution
A system comprising a structural element with a support covered by expanded material, achieving a minimum thickness of 40 mm and an expansion rate of at least 3500%, which provides effective acoustic insulation for electric vehicles, especially for higher-frequency sound waves, and can be easily installed before dip-coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional insulation methods like two-component polyurethane foams are used, then acoustic insulation is achieved, but device complexity and installation cost increase
Solution Approach 1:
The patent changes the expansion rate parameter from conventional values (typically <100%) to a very high expansion rate of at least 3500%, enabling the insulation material to achieve effective acoustic insulation thickness without complex application equipment or multi-step processes. This single-parameter change transforms the insulation application into a simple one-step expansion process that eliminates the need for complex sealing and blocking procedures required by two-component foams.
2Reliability
If thick insulation layers are used to improve acoustic insulation, then acoustic performance improves, but weight increases
Solution Approach 1:
The patent applies parameter changes by using material with extremely high expansion capability (≥3500%) to achieve the required acoustic insulation thickness with minimal initial material volume. The expanded material creates a thick insulation layer (minimum 40 mm) from a compact unexpanded state, providing effective acoustic insulation for high-frequency sound waves in electric vehicles without adding significant weight.
3Reliability
If conventional sealing elements are used, then sealing is achieved for combustion engine vehicles, but adaptability to electric vehicles is insufficient
Solution Approach 1:
The patent creates a universal insulation solution that adapts to different vehicle types (combustion engine and electric vehicles) by focusing on the acoustic insulation requirements specific to electric vehicles. The high-expansion material (≥3500%) provides effective insulation for high-frequency sound waves characteristic of electric vehicle operation, making the system universally applicable across different drive types while optimizing for electric vehicle performance 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
The system offers superior acoustic insulation for electric vehicles, simplifies installation, and reduces complexity and cost compared to conventional methods, while maintaining open mounting spaces for cables and other components.
Implementation Method 1
the expandable material is expanded with an expansion rate of at least 3500%
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
A system of insulated structural elements in a motor vehicle comprises a structural element and an insulating element arranged therein. The insulating element has a support and an expanded material that completely covers at least one wall of the support on one side. The expanded material has a minimum thickness of 40 mm and is expanded at a rate of at least 3500%.