Thermal Bushing Structure for Heat-Isolated Vehicle Trim Mounting
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Solution Overview
Problem
Existing thermal protection components, such as ceramic washers, fail to adequately protect against thermal conductivity and compressive loads, leading to warping, distortion, and degradation of plastic parts when exposed to elevated temperatures.
Innovation Solution
A thermal protection bushing made from non-ceramic materials like DURAFIDE PPS, featuring a one-piece design with an air gap, is molded into the trim component to insulate against heat sources and accommodate compressive loads, using a cylindrical body with disk portions to create a thermal barrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If ceramic washers are used for thermal protection, then thermal protection is provided, but the component cannot accommodate compressive loads and the ceramic washers fail and crumble into pieces
Solution Approach 1:
The patent uses a composite structure combining a ceramic coating layer applied to a metal substrate. The metal substrate (e.g., steel or stainless steel) provides compressive strength and load-bearing capability, while the ceramic coating layer provides thermal protection. This composite approach resolves the contradiction by integrating materials with complementary properties.
Solution Approach 2:
The ceramic coating is applied only to the specific regions requiring thermal protection (such as the bearing surface and edges), while the metal substrate provides structural integrity throughout. This localized application of different material properties allows the component to withstand compressive loads while providing thermal protection where needed.
2Object-affected harmful factors
If ceramic washers are used, then thermal protection is provided, but the ceramic washers only protect the face of the component and do not protect the thermal conductivity from the sides of a screw
Solution Approach 1:
The invention transitions from two-dimensional face protection to three-dimensional comprehensive protection by extending the ceramic coating to the peripheral edges and sides of the component. This ensures that thermal protection is provided not only on the bearing surface but also on the vertical faces where screw contact occurs, addressing the limitation of prior art.
Solution Approach 2:
The thermal protection is segmented into multiple zones: a primary ceramic coating layer on the bearing surface and extended ceramic coating on the peripheral edges. This segmentation allows each zone to address specific thermal exposure areas, providing comprehensive protection against heat conduction from multiple directions.
3Object-affected harmful factors
If a thermal protection barrier is provided, then thermal protection is improved, but the device complexity increases
Solution Approach 1:
The invention merges the thermal protection function with the existing component structure by integrating the ceramic coating directly onto the metal substrate in a single manufacturing step. This eliminates the need for separate thermal protection components and reduces assembly complexity while maintaining comprehensive thermal protection.
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 thermal protection bushing effectively mitigates thermal radiation and maintains component integrity by preventing warping and degradation while allowing for secure attachment.
Implementation Method 1
The present disclosure provides a thermal protection bushing that provides an air gap between components to mitigate thermal radiation from the heat source to the surrounding parts
Implementation Method 2
A thermal bushing is coupled with the attachment bracket to provide thermal insulation for the trim part. The thermal bushing is made from non-ceramic material that provides high heat resistance
Data Source
AI summary
A trim part for a vehicle has a body with an attachment bracket to secure the trim part to the vehicle. A thermal bushing is coupled with the attachment bracket to provide thermal insulation for the trim part and the trim attachment bracket. The bushing has a first disk portion, a second disk portion and a cylindrical body, with two ends. The first and second disks are each positioned at one end of the cylinder. A bore passes through the first disk portion, cylindrical body and second disk portion to receive a fastener. A wall defining the bore is sized to define an air gap between the fastener and the bushing.