Multi-layer insulation product simultaneous thermoforming
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Solution Overview
Problem
Current methods for manufacturing multilayer products with sound and thermal insulation capabilities require multiple steps and lengthy processes, leading to increased costs and inefficiencies due to the need for high-temperature forming and adhesion challenges between layers of different chemical and physical natures.
Innovation Solution
A method involving simultaneous thermoforming and molding of a dense polymer layer with a flexible layer in a single step using a thermal crosslinking agent, allowing for immediate removal of the multilayer product without decohesion or delamination, and utilizing conventional tooling without extreme thermal constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple manufacturing steps are used to assemble multilayer products with felt and heavy mass, then adhesion between layers can be achieved, but production time and manufacturing complexity increase significantly
Solution Approach 1:
The patent combines multiple manufacturing steps (felt forming at high temperature, heavy mass molding, and adhesion) into a single simultaneous operation. The heavy mass is molded directly onto the felt in one step, eliminating sequential assembly operations and reducing production time while maintaining layer adhesion through direct contact during the molding process.
Solution Approach 2:
The felt is pre-formed and positioned in the mold before the heavy mass is molded onto it. This preliminary preparation of the felt layer allows the subsequent heavy mass molding to proceed directly onto the prepared surface, ensuring proper adhesion without requiring separate assembly steps afterward.
2Reliability
If high temperatures are used for felt forming and adhesion, then proper bonding between layers is achieved, but energy consumption increases
Solution Approach 1:
The patent merges the heating functions into a single simultaneous process where both the felt forming and heavy mass molding occur at elevated temperatures in one operation. This eliminates the need for separate heating cycles for each step, reducing total energy consumption while achieving proper bonding between layers through the sustained thermal environment during the combined process.
3Manufacturing precision
If conventional sequential manufacturing methods are used, then product quality can be maintained, but manufacturing cost and process complexity increase
Solution Approach 1:
The patent consolidates multiple manufacturing operations (felt forming, heavy mass molding, and layer assembly) into a single integrated process step. This reduces process complexity by eliminating intermediate handling and assembly operations while maintaining product quality through direct molding of the heavy mass onto the pre-positioned felt in a controlled mold environment.
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 significantly reduces production time and energy consumption, enhances mechanical adhesion between layers, and improves the profitability of multilayer product manufacturing while maintaining effective insulation properties.
Implementation Method 1
the removal of a multilayer product is possible without prior cooling by virtue of the crosslinking of the at least one dense layer initiated by the thermal crosslinking agent
Implementation Method 2
pressing-thermoforming the at least one flexible layer, molding the at least one dense layer on the at least one flexible layer
Implementation Method 3
The present invention relates to multilayer products and their use for sound and / or thermal insulation
Implementation Method 4
The present invention relates to multilayer products and their use for sound and / or thermal insulation
Data Source
AI summary
A method for manufacturing a multi-layer product comprising at least one polymer-based dense layer and at least one fibre-based low density flexible layer, the method comprising placement steps of said at least one dense layer and of said at least one flexible layer in a tool for thermoforming, pressing-thermoforming of said at least one flexible layer, moulding of said at least one dense layer on said at least one flexible layer, and removal of the multi-layer product of the thermoforming tool without decohesion of the dense layer(s) and without delamination between the flexible and dense layer(s), the pressing-thermoforming of said at least one flexible layer and the moulding of said at least one dense layer being simultaneously produced in the thermoforming tool at implementation temperatures of 100 to 250°C and the removal of the multi-layer product being produced without prior cooling with the aid of the incorporation in the dense layer(s) of a thermal crosslinking agent.