Plasticized Rubber Insulation for Complex Geometries
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Solution Overview
Problem
Current insulation materials for high-temperature components, especially those with complex geometries, face challenges such as complexity and cost in application, limited flexibility, absorbency leading to reduced insulation effectiveness, and health hazards due to fiber release, and are often limited to temperatures below 130°C.
Innovation Solution
A method using a high-temperature-resistant, partially uncrosslinked and plastically deformable rubber mixture applied via a pressing device with a mold to ensure efficient and uniform insulation, filling undercuts and providing thermal and acoustic insulation up to 250°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If web-shaped flexible insulation material is wound around components, then the material can be applied to complex geometries, but undercuts on complex components are not filled and the surface becomes uneven
Solution Approach 1:
The patent changes the physical state parameter of the insulation material from a pre-formed web shape to a plasticizable mass that can be molded. By heating the insulation material above its glass transition temperature, it becomes plastically deformable and can be pressed into complex geometries and undercuts, then cooled to maintain the molded shape, achieving both adaptability and surface smoothness
Solution Approach 2:
The patent applies preliminary heating to the insulation material before application to make it plastically deformable. This preliminary action of heating allows the material to be molded into the desired shape and fill undercuts before cooling sets the final form, resolving the issue of uneven surfaces and incomplete undercut filling
2Temperature
If mineral wool is used for high-temperature insulation, then temperature resistance is achieved, but the material is absorbent and can lead to spontaneous combustion with flammable liquids
Solution Approach 1:
The patent uses a composite material consisting of plasticized insulation material containing flame retardant additives. This composite provides both high-temperature resistance and fire safety by incorporating flame retardants that prevent spontaneous combustion, while the plasticized matrix prevents liquid absorbency unlike mineral wool
Solution Approach 2:
The patent converts the potential harm of flammable liquids contacting insulation material into a benefit by using flame retardant additives. These additives ensure that even if flammable liquids contact the insulation, spontaneous combustion is prevented, turning a safety hazard into a safety feature
3Temperature
If mineral wool with lamination is used for high-temperature insulation, then temperature resistance is achieved, but assembly and fixation are complicated and expensive
Solution Approach 1:
The patent extracts the lamination layer from the insulation material structure, using only the essential plasticized insulation material. This simplification eliminates the need for complex lamination and adhesive tape fixation, making assembly easier and more cost-effective while maintaining temperature resistance through the inherent properties of the plasticized material
Solution Approach 2:
The patent enables the insulation material to self-adhere to the component surface through pressure and cooling. The plasticized material is pressed onto the component and, upon cooling, maintains its position without requiring additional lamination or adhesive tapes, making the material self-sufficient for fixation
4Stability of the object's composition
If silicone rubber is crosslinked before application, then structural stability is achieved, but the material loses plastic deformability and cannot adapt to complex geometries
Solution Approach 1:
The patent reverses the sequence of operations by applying the insulation material in a plasticized state first, then crosslinking it after molding. This preliminary application in a deformable state allows adaptation to complex geometries, followed by crosslinking to achieve structural stability, resolving the contradiction between deformability and stability
Solution Approach 2:
The patent inverts the conventional sequence of crosslinking before application. Instead of crosslinking first to gain stability, the material is applied in an uncrosslinked plasticized state for maximum deformability, then crosslinked after molding to achieve stability, reversing the traditional approach to resolve the contradiction
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 method allows for quick, cost-effective insulation of complex components with a smooth surface, reducing heat losses and preventing burns, while maintaining insulation integrity even after exposure to high temperatures.
Implementation Method 1
the rubber mixture being at least partially uncrosslinked and plastically deformable... can be used at temperatures up to 250 °C
Implementation Method 2
the insulating material is applied to the component to be insulated by pressing in a pressing device using a mold
Implementation Method 3
For the thermal and/or acoustic insulation of components
Implementation Method 4
Partially uncrosslinked means both a rubber mixture that contains unused crosslinking chemicals and a rubber mixture that is crosslinked with little or no crosslinking chemicals
Data Source
AI summary
The invention relates to a method for insulating components with a flexible insulating material based on a high-temperature-resistant rubber compound that is at least partially uncrosslinked and plastically deformable. For fast and efficient insulation of components, the insulating material is applied to the component to be insulated by pressing it in a press using a mold.