Method of forming insulating articles with reduced thickness variation

• US 9,108,346 B2
• Filed: 01/08/2013
• Issued: 08/18/2015
• Est. Priority Date: 01/08/2013
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Haskins, Harold, Yang, Xiao Guang, Miller, Theodore James, Marcicki, James Matthew, Maguire, Patrick Daniel
• Primary Examiner(s): HUSON, MONICA ANNE
• Application Number:
  US13/736,427
• Publication Number:
  US 20140191446A1
• Time in Patent Office: 952 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: B29C 2043/148 using different moulds
• CPC Class Codes: B29C 2043/563 combined with mechanical pressure, i.e. mould plates, rams, stampers
• CPC Class Codes: B29C 43/10 Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies
• CPC Class Codes: B29C 43/14 in several steps
• CPC Class Codes: B29C 43/183 the preformed layer being a lining, e.g. shaped in the mould before compression moulding, or a preformed shell adapted to the shape of the mould
• CPC Class Codes: B29C 43/56 Compression moulding under special conditions, e.g. vacuum
• CPC Class Codes: B29K 2105/0854 in the form of a non-woven mat
• CPC Class Codes: B29L 2031/3005 Body finishings
• CPC Class Codes: B29L 2031/7146 Battery-cases

Abstract

In one or more embodiment, a method is provided for forming an insulating article from an insulating material having a first thickness, the method including the step of: compressing the insulating material to form a compressed insulating material having a second thickness smaller than the first thickness; and subsequent to the step of compressing, subjecting the compressed insulating material to a vacuum to form the insulating article.

Claims

1. A method of forming an insulating article from an insulating material having a first thickness, the method comprising:

compressing the insulating material to form a compressed insulating material having a second thickness smaller than the first thickness;

subsequent to the step of compressing, subjecting the compressed insulating material to a vacuum to form the insulating article; and

prior to the step of compressing, depositing the insulating material into a container that includes an opening greater than 1 millimeter subsequent to the step of vacuuming.

2. The method of claim 1, wherein the insulating material is provided to include a glass fiber.

3. The method of claim 1, wherein the container comprises a barrier layer.

4. The method of claim 1, wherein the compressing is carried out at atmospheric pressure.

5. The method of claim 1, wherein the step of compressing is carried out with a compressive load of 14.5 to 22 psi.

6. The method of claim 1, wherein a compressive force is applied onto the container to carry out the step of compressing.

7. The method of claim 1, wherein the container includes at least one of a polymer, a plastic and a metal.

8. The method of claim 1, wherein the opening is closed such that a pressure within the container is smaller than a pressure outside of the container.

9. The method of claim 8, wherein the opening is closed via an application of heat.

10. The method of claim 1, wherein the step of compressing is carried out such that a thickness ratio of a thickness after the compressing relative to a thickness before the compressing is 0.40 to 0.95.

11. A method of forming an insulating article comprising:

depositing insulating material having a first thickness in a container with an opening;

compressing the insulating material at atmospheric pressure to form a compressed insulating material having a second thickness smaller than the first thickness; and

subjecting the compressed insulating material to a vacuum to form the insulating article, the container including an opening greater than 1 centimeter subsequent to the vacuuming step.

12. The method of claim 11, wherein a load of pressure is applied onto the container to carry out the step of compressing.

13. The method of claim 11, wherein the opening is closed such that a pressure within the container is smaller than a pressure outside of the container.

14. The method of claim 13, wherein the opening is closed via an application of heat.

15. The method of claim 11, wherein the step of compressing is carried out such that a thickness ratio of a thickness after the compressing relative to a thickness before the compressing is 0.40 to 0.95.

16. A method of forming an insulation panel, comprising:

providing a pre-sealed insulation panel having a first thickness, the pre-sealed insulation panel including a flexible container and an insulation material disposed within the flexible container, the flexible container including an opening;

compressing the pre-sealed insulation panel to form a compressed pre-sealed insulation panel, the compressed pre-sealed insulation panel having a second thickness smaller than the first thickness;

vacuuming the compressed pre-sealed insulation panel to form a vacuumed pre-sealed insulation panel; and

sealing the opening of the flexible container of the vacuumed pre-sealed insulation panel to form the sealed vacuumed insulation panel, the container including an opening greater than 1 centimeter subsequent to the vacuuming step.

17. The method of claim 16, further comprising subjecting the sealed vacuumed insulation panel to atmospheric pressure.