Vehicle Insulation Element with Partial Expandable Material Coverage
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Solution Overview
Problem
Conventional insulating elements for structural elements in vehicles fail to provide optimal acoustic insulation due to the partial propagation of sound waves through the carrier material, and they require extensive use of expandable material for complete coverage.
Innovation Solution
An insulating element with a carrier element having a first surface divided into partial areas with and without expandable material, where the expandable material covers the entire surface after expansion, optimizing the use of material and improving acoustic insulation by minimizing sound wave propagation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If expandable material is applied to the entire surface of the carrier element, then complete coverage is achieved, but material usage and cost increase significantly
Solution Approach 1:
The first surface of the carrier element is divided into multiple partial areas, with expandable material applied only to selected partial areas rather than the entire surface. This segmentation allows complete coverage after expansion while reducing the total quantity of expandable material needed.
Solution Approach 2:
The solution transitions from a two-dimensional surface coverage problem to a three-dimensional volume expansion problem. By applying expandable material to only certain areas and utilizing its expansion capability in the third dimension, complete coverage is achieved with reduced material usage.
2Strength
If expandable material is used to seal and reinforce cavities, then structural integrity improves, but acoustic insulation performance remains insufficient
Solution Approach 1:
Different regions of the carrier element's first surface are assigned different functions: some partial areas are covered with expandable material for sealing and reinforcement, while other partial areas remain free of expandable material to optimize acoustic insulation properties.
Solution Approach 2:
The insulating element combines the carrier element (providing structural reinforcement) with expandable material (providing sealing and acoustic insulation) in a composite structure, where the strategic placement of expandable material on selected partial areas creates synergistic effects for both structural integrity and acoustic performance.
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 solution achieves significantly better acoustic insulation with reduced material usage, allowing for cost-effective and efficient production and ensuring complete coverage of the carrier surface with expanded material, effectively sealing and reinforcing structural elements.
Implementation Method 1
the expandable material is essentially arranged on this edge region 21 of the support element 11. After this coating, the expandable material 13 is typically expanded by the application of heat
Implementation Method 2
the expanded material 13' and the support 11 are able to absorb some of the sound waves
Data Source
Figure 1~2b
Figure 3a~3h
Figure 4a~5b
AI summary
An insulating material for insulating a structural element in a vehicle comprises a support element with a first surface and a second surface, and an expandable material which is arranged on the support element. The expandable material is arranged here on a first sub-region of the first surface of the support element, and a second sub-region of the first surface is free from expandable material. The first sub-region is configured here in such a manner that the first surface of the support element is completely covered with expanded material after expansion of the expandable material.