3d thermoformed element

An assembly comprising:

• a structural element interposed between an external environment and an internal volume to be thermally and/or acoustically protected,
• and an inner lining member for lining the structural element, the inner lining member comprising a thermal insulating element, which is three-dimensional and under vacuum, the thermal insulating element comprising:
• a porous structure (5) which is three-dimensional,
• an envelope closed in an airtight manner:
• comprising a barrier wall which is thermoformable and airtight,
• in which envelope is enclosed the porous structure whose shape is followed by the barrier wall, and
• in which envelope, at outside ambient temperature and pressure, a pressure of between less than 105Pa and more than 10−2 Pa prevails,
• and in which assembly:
• the structural element is a vehicle body part or a protective tray, and
• the inner lining element is interposed between the external environment and a cooling plate of a battery pack of the electric power supply of the vehicle disposed in the internal volume, which vehicle is of a hybrid or all-electric type, said at least one thermally insulating element being sandwiched between the protective plate and the cooling plate, which comprises channels for circulation of a cooling fluid disposed in thermal exchange with the battery pack.

An assembly comprising:

• a structural element interposed between an external environment and an internal volume to be thermally and/or acoustically protected,
• and an inner lining member for lining the structural element, the inner lining member comprising a thermal insulating element, which is three-dimensional and under vacuum, the thermal insulating element comprising:
• a porous structure which is three-dimensional,
• an envelope closed in an airtight manner:
• comprising a barrier wall which is thermoformable and airtight,
• in which envelope is enclosed the porous structure whose shape is followed by the barrier wall, and
• in which envelope, at an outside ambient temperature and pressure, a pressure of between less than 105Pa and more than 10−2 Pa prevails,
• and in which assembly:
• the structural element comprises a part of a body of a vehicle surrounding a passenger compartment of the vehicle, and
• the assembly further comprises, between the structural element and the thermal insulating element:
• either a layer of air and another part of the structural element which is metallic or plastic or made of a mixing between a synthetic resin and synthetic fibers or mineral fibers or natural fibers,
• either a layer of air at least 20 mm thick and a primary layer of insulation material.

An assembly comprising:

• a structural element interposed between an external environment and an internal volume to be thermally and/or acoustically protected,
• and an inner lining member for lining the structural element, the inner lining member comprising three-dimensional vacuum thermal insulating elements, which each comprises:
• a porous three-dimensional structure,
• an envelope closed in an airtight manner:
• comprising a barrier wall which is thermoformable and airtight,
• in which envelope is enclosed the porous structure whose shape is followed by the barrier wall, and
• in which envelope, at outside ambient temperature and outside ambient pressure, a pressure of between less than 105Pa and more than 10−2 Pa prevails,
• and in which assembly the structural element is a body part of a vehicle comprising:
• outer panels belonging to a fuselage or a body of a vehicle and,
• frames and/or rails and/or stringers, which are individually surrounded by one of said three-dimensional vacuum thermal insulating elements attached to the respective frames and/or rails and/or stringers.

A process for manufacturing a three-dimensional thermal-insulating element under vacuum, in which process:

• a) a compressed porous structure is used, and
• b) said compressed porous structure is arranged in an envelope having an airtight barrier wall, the compressed porous structure being interposed between two major surfaces of the airtight barrier wall, then, by contact between two minor surfaces of said airtight barrier wall, the envelope, in which a reduced pressure of between less than 105Pa and more than 10−2 Pa has been established, is closed with an airtight sealing,
• wherein:
• c) after the airtight sealing of the envelope, the compressed porous structure is given a three-dimensional shape, bent-shaped and/or with reliefs and depressions, by pressing the envelope against a male element and a female element of a mold for bending and/or embossing, which provides a deformation of the airtight barrier wall and the compressed porous structure.

An assembly comprising:

• a three-dimensional structural element having a curved shape and/or reliefs and depressions, interposed between an external environment and an internal volume to be thermally and/or acoustically protected, and
• an inner lining element for lining the three-dimensional structural element, the inner lining element comprising a thermally insulating element which is interposed between the external environment and the internal volume to be protected,
• the thermal insulating element being bent-shaped and/or having reliefs and depressions, engaged at least partly with respectively the curved shape and/or the depressions and the reliefs of the structural element, in order to substantially follow at least part of a contour thereof,
• the thermal insulating element comprising:
• a structure made of a three-dimensional porous material,
• an envelope closed in an airtight manner,
• comprising an airtight barrier wall,
• in which envelope is enclosed the three-dimensional porous material whose shape is followed by the airtight barrier wall, and
• in which envelope, at outside ambient temperature and pressure, a pressure of between less than 105 Pa and more than 10−2 Pa prevails,
• characterized in that:
• the barrier wall is thermoformable and being thermoformed,
• the structure is compressed,
• the bent-shaped is defined by a bending of said thermal insulating element, and/or the reliefs and the depressions are defined by embossings and the thermal insulating element.