Method and materials for manufacturing high-efficiency heating enclosures and appliances

Abstract

A method of making an oven cavity of a cooking appliance, and a cooking appliance made therewith, are provided. The method includes forming a composite sheet via sheet molding compound. The composite sheet includes glass fiber impregnated with silicone polymer. An intermediate assembly is formed by disposing a layer comprising an insulative material onto a first layer of the composite sheet. The intermediate assembly is inserted into a mold. A compression load is applied to the intermediate assembly in the mold to obtain a molded piece. One or more of the molded piece forms a composite body that defines the oven cavity of the cooking appliance. The silicone polymer may include one or more of poly dimethylsiloxane, poly methylphenyl silanol, poly diphenyl silanol, and poly vinyl functional backbone silicones having methyl hydrosilane crosslinkers. The insulative material may include ceramic foam, hollow glass microspeheres, or recycled glass powder.

Dependencies are inferred from the claim text.