Seamless Polyurethane Cold Storage Insulation
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Solution Overview
Problem
Traditional insulation components for cold storage devices are complex, expensive, and heavy, with poor sealing and aesthetic issues due to multiple pre-assembled parts, and existing solutions do not adequately address the need for high flowability, mechanical properties, and a smooth surface.
Innovation Solution
A process involving a reaction mixture of isocyanates, polymeric compounds with reactive hydrogen atoms, chain extenders, and catalysts is used to form a seamless polyurethane outer layer around insulating foam, with a functionality greater than 2.2, allowing for improved flowability and mechanical properties, and a smooth surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional multi-part assembly process is used, then structural integrity is achieved, but device complexity and production time increase
Solution Approach 1:
The patent merges the shell and liner into a single integrated polyurethane component formed by injecting reaction mixture into a mold containing insulating foam. This eliminates the need for separate assembly of multiple parts, reducing production complexity while maintaining structural integrity through monolithic construction.
Solution Approach 2:
The single polyurethane component performs multiple functions simultaneously: it serves as the structural shell, the inner liner, and the sealing element. The insulating foam integrated within provides thermal insulation while being encased by the seamless polyurethane outer material.
2Weight of stationary object
If multiple pre-assembled parts are used, then structural stability is achieved, but weight increases
Solution Approach 1:
By combining multiple parts (shell, liner, seals) into a single polyurethane component, the patent eliminates the weight of additional fasteners, joints, and assembly hardware while maintaining structural stability through the inherent strength and seamless construction of the integrated component.
3Productivity
If traditional assembly process is used, then manufacturing capability is maintained, but productivity decreases
Solution Approach 1:
The insulating foam is placed in the mold before the polyurethane reaction mixture is injected, preparing the core structure in advance. This preliminary placement allows the subsequent injection and curing process to proceed continuously without interruption, increasing production speed while maintaining manufacturing capability.
Solution Approach 2:
The patent utilizes the phase transition of the polyurethane reaction mixture from liquid to solid during curing. The reaction mixture is injected in liquid form, allowing it to flow and conform to the mold and insulating foam, then cures to form the solid, structurally stable integrated component in a single continuous process.
4Ease of operation
If conventional polyurethane systems are used, then ease of processing is achieved, but mechanical properties at low temperature deteriorate
Solution Approach 1:
The patent modifies the polyol functionality parameter to greater than 2.2, which changes the molecular structure and crosslinking density of the cured polyurethane. This parameter change enables the material to maintain both good flowability during injection and high elasticity and scratch resistance at low temperatures below 0°C.
Solution Approach 2:
The patent creates a composite polyurethane system combining polyols with functionality greater than 2.2, chain extenders, and isocyanates in specific ratios. This composite formulation achieves optimal balance between processing characteristics (flowability) and service properties (mechanical strength and elasticity at low temperature).
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 resulting insulation component has improved flowability, mechanical properties, and a smooth surface, with high elasticity and scratch resistance even at low temperatures, reducing complexity and weight while enhancing aesthetic appeal and sealing efficiency.
Implementation Method 1
isocyanates, polymeric compound having hydrogen atoms reactive towards isocyanate, optionally chain extenders and/or crosslinkers, catalysts are mixed to give a reaction mixture and the reaction mixture is injected into the mould containing the insulation foam material and cured to form an seamless outer material
Implementation Method 2
an insulating foam material is placed in a mould
Data Source
AI summary
The present invention relates to a process for producing an insulation component in which an insulating foam material is placed in a mold and in which (a) isocyanates, (b) polymeric compound having hydrogen atoms reactive towards isocyanate, (c) chain extenders and/or crosslinkers, and (d) catalysts are mixed to give a reaction mixture and the reaction mixture is injected into the mold and cured to form a seamless outer material enclosing the insulating foam wherein the average functionality of the polyols (b) and the chain extenders and/or crosslinkers (c) and the isocyanates (a) is greater than 2.2. The invention further relates to an insulation component obtainable by such a process and a door or wall component for cold storage that is made from that insulation component.