Insulating Molded Part with Evacuated Cavities
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing insulating molded parts face challenges such as high production complexity and cost, limited dimensional stability, and thermal bridges due to metallic materials, while seeking a balance between insulation and stability.
Innovation Solution
The development of insulating molded parts with a one-piece design using injection or die-casting processes, featuring airtightly separated cavities that can be evacuated, made from composite materials with natural or recycled materials, allowing for easy production and enhanced insulating properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If metallic honeycomb structures are used for insulating molded parts, then thermal insulation properties are improved, but weight increases and production cost increases
Solution Approach 1:
The patent uses evacuated cavities within a plastic matrix to create an insulating structure. The cavities are filled with gas at reduced pressure, providing thermal insulation through the vacuum/low-pressure environment rather than through solid material density. This achieves high insulation without the weight penalty of metallic honeycomb structures.
2Temperature
If metallic materials are used for insulating molded parts, then thermal insulation properties are improved, but thermal bridges are created
Solution Approach 1:
The plastic material with evacuated cavities eliminates thermal bridges by using a non-conductive plastic matrix instead of metallic structures. The gas-filled cavities provide insulation without creating continuous conductive paths, thus preventing thermal bridge formation while maintaining insulation performance.
3Temperature
If porous materials or granules are welded in an air-impermeable film, then insulating properties are improved, but dimensional stability is limited
Solution Approach 1:
The patent changes the pressure parameter within the cavities by evacuating them to create a vacuum or low-pressure environment. This parameter change provides superior insulation compared to atmospheric pressure while the plastic matrix maintains dimensional stability. The structured cavity design prevents the dimensional instability issues associated with random porous materials.
4Temperature
If two-part or multi-part moldings are used to balance insulation and stability, then a compromise is achieved, but production complexity increases
Solution Approach 1:
The patent merges the structural matrix and the insulating cavities into a single integrated plastic component. The cavities are formed directly within the plastic material during molding, eliminating the need for separate assembly of multiple parts. This single-integration approach reduces production complexity while achieving both insulation and stability through the evacuated cavity structure.
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 results in molded parts that are cost-effective, offer superior insulation, and maintain high stability, with the ability to be cut to size without compromising insulating ability and facilitated assembly due to airtight separation of chambers.
Implementation Method 1
Molded insulating parts are known in which honeycomb structures are made of metal, for example, which are subsequently evacuated, that is to say under negative pressure, preferably under vacuum.
Implementation Method 2
Temperature ranges are proposed according to the invention, in which the composite material should cure.
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
The invention relates to an insulating molded part, comprising an upper part (7) and a lower part (8), wherein according to the invention, the upper part (7) and the lower part (8) are designed as a one-piece injection-molded or die-cast part, which has cavities in the interior thereof, the cavities being designed as chambers (3) that are separated in an airtight manner from each other. In a corresponding method for producing such an insulating molded part, in a first method step within the context of an injection-molding or die-casting process, the composite material of the upper part (7) is introduced into a first mold together with additives made of natural materials or recycled material, and in a second method step within the context of a fusible-core process, the composite material of the lower part (7) is introduced into a second mold together with additives made of natural materials or recycled material, wherein the second mold contains a fusible core having individual fusible bodies, which are connected to the outside by means of openings (1) in the second mold, and after the second method step, the fusible bodies are melted out to form individual chambers (3).