# US 10,500,809 B2 · Thermally insulating planar component with low structural thickness, in particular for lining the functional spaces of a motor vehicle

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- Number: US 10,500,809 B2
- Document ID: US10500809B2
- Status: Granted
- Kind: B2
- Application number: 15/813,744
- Filed: 2017-11-15
- Published: 2018-05-24
- Granted: 2019-12-10
- Earliest claimed: 2016-11-22
- Assignees: Röchling Automotive SE & Co. KG
- Applicants: Röchling Automotive SE & Co. KG
- Inventors: Klaus Pfaffelhuber
- Web page: https://patentgrep.com/patent/US10500809B2

## CPC

- B32B 3/06: for securing layers together; for attaching the product to another member, e.g. to a support {, or to another product, e.g. groove/tongue, interlocking}
- B32B 3/04: characterised by {at least one} layer folded at the edge, e.g. over another layer {; characterised by at least one layer enveloping or enclosing a material}
- B32B 3/08: characterised by added members at particular parts {(layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18)}
- B32B 3/26: characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids {(foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205); characterised by an apertured layer}
- B32B 3/30: characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)}
- B32B 5/16: characterised by features of a layer formed of particles, e.g. chips, powder {or granules (layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02)}
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 5/245: {another layer next to it being a foam layer}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 7/02: Physical, chemical or physicochemical properties
- B32B 7/04: Interconnection of layers
- B32B 7/05: the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection (using interposed adhesives or bonding materials applied in spaced arrangements B32B7/14)
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 15/046: {of foam}
- B32B 15/085: comprising polyolefins
- B32B 15/14: next to a fibrous or filamentary layer
- B32B 15/16: next to a particulate layer
- B32B 15/20: comprising aluminium or copper {(B32B15/016 and B32B15/017 take precedence)}
- B32B 19/041: {of metal}
- B32B 19/045: {of synthetic resin}
- B32B 19/06: next to a fibrous or filamentary layer
- B32B 27/065: {of foam}
- B32B 27/08: of synthetic resin
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B60R 13/0838: {for engine compartments}
- B32B 2260/021: Fibrous or filamentary layer
- B32B 2260/046: Synthetic resin
- B32B 2262/02: Synthetic macromolecular fibres
- B32B 2262/10: Inorganic fibres
- B32B 2262/101: Glass fibres
- B32B 2264/10: Inorganic particles
- B32B 2264/102: Oxide or hydroxide
- B32B 2264/107: Ceramic
- B32B 2266/0214: Materials belonging to B32B27/00
- B32B 2307/304: Insulating
- B32B 2307/732: Dimensional properties
- B32B 2307/734: Dimensional stability
- B32B 2605/00: Vehicles
- B32B 2605/08: Cars
- E04B 1/803: {with vacuum spaces included in the slab}
- F16L 59/065: using vacuum (F16L59/075 takes precedence)
- F25D 2201/14: using subatmospheric pressure
- Y10T 428/231: Filled with gas other than air; or under vacuum
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B60R: VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001})
- F16L: PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F25D: REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR (refrigerated showcases A47F3/04; thermally-insulated vessels for domestic use A47J41/00; refrigerated vehicles, see the appropriate subclasses of classes B60 - B64; containers with thermal insulation in general B65D81/38; heat-transfer, heat-exchange or heat-storage materials, e.g. refrigerants, or materials for the production of heat or cold by chemical reactions other than by combustion C09K5/00; thermally-insulated vessels for liquefied or solidified gases F17C; air-conditioning or air-humidification F24F; refrigeration machines, plants, or systems F25B; cooling of instruments or comparable apparatus without refrigeration G12B)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A thermally insulating planar component that extends in an extension plane and has a structural thickness orthogonal to the extension plane, the dimensions of the component in the extension plane being many times greater than its thickness measurement orthogonal to the extension plane, the component comprising a vacuum panel having an air-tight, evacuated metal foil envelope that is filled with highly dispersed ceramic powder, the metal foil envelope having two planar envelope walls arranged spaced from one another in the thickness direction and connected to one another by an edge region that spans the distance between the planar envelope walls in the thickness direction, each planar envelope wall having an inner surface that faces the other planar envelope wall and the highly dispersed ceramic powder and an outer surface that faces away from the other planar envelope wall and the highly dispersed ceramic powder is refined such that at least one of the planar envelope walls is designed in at least one deformation section as having a surface structure that increases the surface area of the planar envelope wall over that of a smooth surface structure, the component being curved about at least one curvature axis in the area of the deformation section such that the planar envelope wall is convex on its outer surface in the deformation section.

## Claims

### Claim 1

A thermally insulating planar component that extends in an extension plane and has a structural thickness orthogonal to the extension plane, the dimensions of the component in the extension plane being many times greater than its thickness measurement orthogonal to the extension plane, with the component comprising a vacuum panel having an air-tight, evacuated metal foil envelope that is filled with a highly dispersed ceramic powder, the metal foil envelope having two planar envelope walls arranged spaced from one another in the thickness direction and connected to one another by an edge region that spans the distance between the planar envelope walls in the thickness direction, and each planar envelope wall having an inner surface that faces the other planar envelope wall and the highly dispersed ceramic powder and an outer surface that faces away from the other planar envelope wall and the highly dispersed ceramic powder, at least one of the planar envelope walls is designed in at least one deformation section as having a surface structure that increases the surface area of the planar envelope wall over that of a smooth surface structure, the component being curveable about at least one curvature axis in the area of the deformation section, wherein at least one layer containing plastic is provided on the outer surface of at least one of the planar envelope walls, wherein the plastic-containing layer comprises or is a porous layer of thermoplastically bonded fiber material.

### Claim 2 (depends on 1)

The thermally insulating planar component according to claim 1, wherein the component is curved about the at least one curvature axis in the area of the deformation section such that the planar envelope wall is convex on its outer surface in the deformation section.

### Claim 3 (depends on 2)

The thermally insulating planar component according to claim 2, wherein the planar component is curved about at least two curvature axes that are at least one of spaced from one another and together form an angle.

### Claim 4 (depends on 1)

The thermally insulating planar component according to claim 1, wherein the highly dispersed ceramic powder includes at least one of a metal oxide powder, a silica powder, a magnesia powder and an alumina powder.

### Claim 5 (depends on 1)

The thermally insulating planar component according to claim 1, wherein the at least one deformation section of one planar envelope wall and the at least one deformation section of the respectively other planar envelope wall at least partially face one another in the thickness direction.

### Claim 6 (depends on 1)

The thermally insulating planar component according to claim 1, wherein the plastic-containing layer comprises or is a solid plastic layer.

### Claim 7 (depends on 1)

The thermally insulating planar component according to claim 1, wherein the plastic-containing layer comprises or is a foamed plastic layer.

### Claim 8 (depends on 1)

The thermally insulating planar component according to claim 1, further including a frame that contains plastic, which is connected to the metal foil envelope in at least one extension direction of the extension plane.

### Claim 9 (depends on 8)

The thermally insulating planar component according to claim 8, wherein the frame at least partially surrounding the metal foil envelope along a portion of its edge region.

### Claim 10 (depends on 8)

The thermally insulating planar component according to claim 8, wherein at least one plastic-containing layer is provided on the outer surface of at least one of the planar envelope walls, the at least one plastic-containing layer extends beyond the metal foil envelope and over the frame.

### Claim 11 (depends on 10)

The thermally insulating planar component according to claim 10, wherein the metal foil envelope and the frame are arranged between at least two plastic-containing layers.

### Claim 12 (depends on 1)

The thermally insulating planar component according to claim 1, wherein the at least one of indentations extending toward the other planar envelope wall and protrusions extending away from the other planar envelope wall includes at least one indentations extending toward the other planar envelope wall and at least one protrusions extending away from the other planar envelope wall.

### Claim 13 (depends on 12)

The thermally insulating planar component according to claim 12, wherein the cup-shaped embossments are spherical cup-shaped indentations and protrusions.

### Claim 14 (depends on 13)

The thermally insulating planar component according to claim 13, wherein the spherical cup-shaped indentations and protrusions that alternate with one another in two mutually orthogonal planar directions of the extension plane.

### Claim 15 (depends on 1)

The thermally insulating planar component according to claim 1, wherein each of the two planar envelope walls has at least one deformation section which has a surface structure that increases the surface area of the respective planar envelope wall over that of a smooth surface structure.

### Claim 16 (depends on 15)

The thermally insulating planar component according to claim 15, wherein the at least one deformation section of the each planar envelope wall, in contrast to a smooth surface structure of the each planar wall, includes at least one of indentations extending toward the other planar envelope wall and protrusions extending away from the other planar envelope wall.

### Claim 17 (depends on 16)

The thermally insulating planar component according to claim 16, wherein at least one of the indentations and the protrusions are arranged in a regular pattern.

### Claim 18

A thermally insulating planar component that extends in an extension plane and has a structural thickness orthogonal to the extension plane, the dimensions of the component in the extension plane being many times greater than its thickness measurement orthogonal to the extension plane, with the component comprising a vacuum panel having an air-tight, evacuated metal foil envelope that is filled with a highly dispersed ceramic powder, the metal foil envelope having two planar envelope walls arranged spaced from one another in the thickness direction and connected to one another by an edge region that spans the distance between the planar envelope walls in the thickness direction, and each planar envelope wall having an inner surface that faces the other planar envelope wall and the highly dispersed ceramic powder and an outer surface that faces away from the other planar envelope wall and the highly dispersed ceramic powder, at least one of the planar envelope walls is designed in at least one deformation section as having a surface structure that increases the surface area of the planar envelope wall over that of a smooth surface structure, the component being curveable about at least one curvature axis in the area of the deformation section, the thermally insulating planar component further including a frame that contains plastic, which is connected to the metal foil envelope in at least one extension direction of the extension plane, and wherein the frame comprises or is a thermoplastically bonded fiber material.