Partially Uncrosslinked Silicone Rubber Insulation for Complex Components
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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, lack of flexibility, absorbency, fiber dust hazards, and limited temperature resistance beyond 130 °C, making them unsuitable for efficient and safe insulation at elevated temperatures.
Innovation Solution
A flexible, sheet- or strip-shaped insulation material based on a high-temperature-resistant, partially uncrosslinked silicone rubber mixture with a pore structure and 2 to 12 phr of expanded microspheres, which can be easily applied and fixed in place through subsequent crosslinking, ensuring adherence and effective insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If mineral wool is used for high-temperature insulation, then temperature resistance is improved, but application complexity and cost increase
Solution Approach 1:
The patent changes the material state parameter from solid mineral wool to a flowable heat-curable mass that can be applied in liquid form and then cured in situ. This allows the material to adapt to complex geometries during application and then stabilize for high-temperature service, resolving the contradiction between ease of application and temperature resistance.
Solution Approach 2:
The patent creates a composite material system combining the heat-curable mass with specific additives and fillers that provide both the flowable application state and the high-temperature resistant cured state. This composite approach enables the material to exhibit different properties during application versus service, resolving the contradiction between applicability and temperature resistance.
2Temperature
If mineral wool is used for high-temperature insulation, then temperature resistance is improved, but flexibility decreases
Solution Approach 1:
The patent utilizes a parameter change in the material's physical state: the heat-curable mass is applied in a fluid, deformable state that can conform to complex component geometries, and then transformed into a stable, high-temperature resistant solid through curing. This resolves the contradiction between flexibility during application and rigidity during service.
3Ease of operation
If self-inflating sealing tapes are used for insulation, then ease of application is improved, but temperature resistance decreases
Solution Approach 1:
The patent employs a heat-curable polymer composition that transitions from a soft, easily applicable state at lower temperatures to a high-temperature resistant state after curing. The material can be applied like conventional elastomeric materials but then undergoes a chemical transformation through curing to achieve superior temperature resistance, resolving the contradiction between ease of application and temperature resistance.
4Temperature
If crosslinked silicone rubber is used for insulation, then temperature resistance is improved, but plastic deformability decreases
Solution Approach 1:
The patent applies the insulation material in an uncured, plastically deformable state that can be easily shaped and positioned around complex components. The crosslinking (curing) process is then initiated after application to provide the final high-temperature resistance and structural stability. This preliminary application in a soft state followed by in-situ curing resolves the contradiction between deformability during application and stability during service.
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 solution provides a simple, cost-effective, and safe method for insulating complex components at temperatures over 130 °C, offering excellent thermal and acoustic insulation, reduced risk of fiber dust exposure, and enhanced stability, with the ability to maintain shape and position, while preventing heat loss and burns.
Implementation Method 1
the rubber mixture has a pore structure and that the rubber mixture contains 2 to 12 phr of expanded microspheres
Implementation Method 2
offering excellent thermal and acoustic insulation
Implementation Method 3
the rubber mixture of the insulation material is based on silicone rubber and is at least partially uncrosslinked and plastically deformable
Implementation Method 4
after application the action of temperature and/or radiation is networked or further networked. The insulation material can still be crosslinked after application
Implementation Method 5
after application the action of temperature and/or radiation is networked or further networked
Data Source
AI summary
The invention relates to a flexible insulation material in the form of sheets or strips, based on a rubber mixture of high thermal stability. The invention further relates to a method for insulation of components with the insulation material. An insulation material proposed for use at temperatures of more than 130°C, which can be applied in a simple manner to complex components to be insulated and retains its desired shape and position, is one in which the rubber mixture is at least partially uncrosslinked and is plastically deformable. In the method, the insulation material comprising the at least partially uncrosslinked and plastically deformable rubber mixture is applied to the component to be insulated and, after the application, crosslinked or crosslinked further by thermal and/or radiative action.