METHOD AND HOUSEHOLD APPLIANCE
20210386267 · 2021-12-16
Inventors
- Alexander Sing (Wittislingen, DE)
- Johannes Jall (Höchstädt, DE)
- Heiko Fritz (Herbrechtingen, DE)
- Andreas Hitzler (Holzheim, DE)
Cpc classification
B32B37/10
PERFORMING OPERATIONS; TRANSPORTING
D06F37/267
TEXTILES; PAPER
B29C43/18
PERFORMING OPERATIONS; TRANSPORTING
A47L15/4209
HUMAN NECESSITIES
B32B37/12
PERFORMING OPERATIONS; TRANSPORTING
B29C44/5627
PERFORMING OPERATIONS; TRANSPORTING
B32B7/12
PERFORMING OPERATIONS; TRANSPORTING
B29K2075/00
PERFORMING OPERATIONS; TRANSPORTING
B32B5/245
PERFORMING OPERATIONS; TRANSPORTING
B29C43/02
PERFORMING OPERATIONS; TRANSPORTING
B29C44/5681
PERFORMING OPERATIONS; TRANSPORTING
B29C44/02
PERFORMING OPERATIONS; TRANSPORTING
B29C44/14
PERFORMING OPERATIONS; TRANSPORTING
B32B37/18
PERFORMING OPERATIONS; TRANSPORTING
International classification
B29C43/02
PERFORMING OPERATIONS; TRANSPORTING
B29C43/18
PERFORMING OPERATIONS; TRANSPORTING
B29C44/02
PERFORMING OPERATIONS; TRANSPORTING
B29C44/14
PERFORMING OPERATIONS; TRANSPORTING
B29C44/56
PERFORMING OPERATIONS; TRANSPORTING
B32B37/10
PERFORMING OPERATIONS; TRANSPORTING
B32B37/12
PERFORMING OPERATIONS; TRANSPORTING
B32B37/18
PERFORMING OPERATIONS; TRANSPORTING
B32B7/12
PERFORMING OPERATIONS; TRANSPORTING
Abstract
In a method for producing an insulation arrangement for a functional compartment of a household appliance, a plastic material is foamed to form a foam block. The foam block is divided into blanks and each blank is shaped with a forming press to form an insulation arrangement.
Claims
1-10. (canceled)
11. A method for producing an insulation arrangement for a functional compartment of a household appliance, said method comprising: foaming a plastic material to form a foam block; dividing the foam block into blanks; and shaping each of the blanks with a forming press to form an insulation arrangement.
12. The method of claim 11, wherein the functional compartment is a dishwashing compartment.
13. The method of claim 11, wherein the household appliance is a household dishwasher.
14. The method of claim 11, wherein each of the blanks is shaped with the forming press to form a first insulation element of the insulation arrangement, and further comprising: placing a second insulation element in the forming press before the blank is shaped to form the first insulation element; and connecting the first insulation element to the second insulation element as the blank is shaped with the forming press.
15. The method of claim 14, wherein the first insulation element is connected to the second insulation element with the aid of an adhesive.
16. The method of claim 11, wherein the plastic material is foamed at atmospheric pressure.
17. The method of claim 11, wherein the plastic material is foamed in an open mold.
18. A method for producing an insulation arrangement for a functional compartment of a household appliance, said method comprising: placing a first insulation element in a mold; introducing a liquid plastic material into the mold to foam a second insulation element onto the first insulation element and thereby form the insulation arrangement; and removing the insulation arrangement from the mold.
19. The method of claim 18, wherein the functional compartment is a dishwashing compartment.
20. The method of claim 18, wherein the household appliance is a household dishwasher.
21. The method of claim 18, further comprising surface-treating the insulation element before placing the first insulation element in the mold.
22. A method for producing a household appliance, said method comprising attaching a first insulation element and a second insulation element one after another to a functional compartment in such a way that the first insulation element is arranged between the functional compartment and the second insulation element.
23. The method of claim 22, wherein the functional compartment is a dishwashing compartment.
24. The method of claim 22, wherein the household appliance is a household dishwasher.
25. The method of claim 22, further comprising connecting the second insulation element to an outer casing before the first insulation element and the second insulation element are attached to the functional compartment.
26. A household appliance, comprising: a functional compartment; an insulation arrangement for thermal and/or acoustic insulation of the functional compartment, said insulation arrangement configured to cover in part the functional compartment and including a first insulation element and a second insulation element, said first insulation element arranged between the functional compartment and the second insulation element; and a further second insulation element configured to solely cover part of the functional compartment.
27. The household appliance of claim 26, constructed in the form of a household dishwasher.
28. The household appliance of claim 26, wherein the functional compartment is configured as a dishwashing compartment.
Description
[0027] Further advantageous embodiments and aspects of the invention are the subject matter of the dependent claims as well as of the exemplary embodiments of the invention described below. Furthermore the invention will be described in greater detail with the aid of preferred forms of embodiment, which refer to the enclosed figures.
[0028] In the figures:
[0029]
[0030]
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[0050]
[0051]
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[0054] Elements that are the same or have the same function have been provided with the same reference characters in the figures, unless otherwise specified.
[0055]
[0056] The door 3 is shown in
[0057] The household dishwasher 1 further has at least one dishwashing receptacle 12 to 14. Preferably a number of dishwashing receptacles, for example three dishwashing receptacles 12 to 14 can be provided, wherein the dishwashing receptacle 12 can be a lower dishwashing receptacle or dish rack, the dishwashing receptacle 13 can be an upper dishwashing receptacle or dish rack and the dishwashing receptacle 14 can be a cutlery drawer. As
[0058] The inventive household appliance 1 can in a general way be a household dishwasher, a household washing machine or a household washer/dryer. Depending on the type of household appliance, the functional compartment can be a dishwashing compartment, a washing liquid compartment or a washing drum. A household washing machine of this type is known for example from publication EP 2 049 723 A1, while a household washer/dryer of this type is known from publication DE 33 45 303 A1. The related content of these publications given by way of example is herewith made subject matter of the present description.
[0059]
[0060] The side wall 11 in particular comprises an inner side 16, which is directed towards the dishwashing space 4, and an outer side 17, which is directed away from the dishwashing space 4. The insulation arrangement 15 is provided on the outer side 17. The insulation arrangement 15 comprises a first insulation element 18. The first insulation element 18 is suitable for insulating the dishwashing compartment 2 thermally and/or acoustically. The first insulation element 18 can also be referred to as the thermal and/or acoustic insulation element. The first insulation element 18 has a first surface 19, which is directed towards the outer side 17 of the side wall 11. Furthermore the first insulation element 18 comprises a second surface 20 directed away from the first surface 19. The first insulation element 18 is preferably produced from a foam plastic material, in particular from a foam polyurethane.
[0061] Preferably the first insulation element 18 has an open-pore structure, so that the first insulation element 18 is compressible. The plastic material has the property that, in a cured and/or cross-linked state, it preferably has gluing or preferably adhesive properties. The preferably adhesive properties are provided in particular on the surfaces 19, 20 of the first insulation element 18. In this case the plastic material itself has the preferably adhesive properties without the addition of an adhesive.
[0062] The fact that the first surface 19 preferably has adhesive properties enables the first insulation element 18 to adhere to the dishwashing compartment 2 or to the side wall 11 with the first surface 19 directed towards the dishwashing compartment 2. The connection between the side wall 11 and the first insulation element 18 is free from adhesive in this case. This means that no layer of adhesive is provided between the side wall 11 and the first insulation element 18. This enables the first insulation element 18 to be released from the side wall 11 in a non-destructive manner and also without leaving any residues. In such a case however slight residues can be left on the dishwashing compartment 2. This means that the first insulation element 18 is able to be released easily from the dishwashing compartment 2 but residues can be left on the dishwashing compartment 2. These can be removed by rubbing. In particular the first insulation element 18 can be separated from the dishwashing compartment 2 without aids, such as solvents for example. The connection between the first insulation element 18 and the dishwashing compartment 2 can be a weakly-adhesive glue connection.
[0063] The first insulation element 18 has a thickness d18. The thickness d18 preferably amounts to 5 to 50 mm, further preferably to 10 to 45 mm, further preferably to 15 to 40 mm, further preferably to 20 to 35 mm, further preferably to 25 to 30 mm. A density ρ18 of the first insulation element 18 preferably amounts to 5 to 150 kg/m.sup.3, especially preferably to 50 to 120 kg/m.sup.3, further preferably to 70 to 100 kg/m.sup.3. A specific thermal conductivity λ18 of the first insulation element 18 is preferably less than 0.1 W/(m*K), in particular less than 0.5 W/(m*K). The first insulation element 18 furthermore preferably has a specific thermal capacity c18 of less than 2.000 J(kg*K), preferably of less than 1.600 J(kg*K), further preferably of less than 1.400 J(kg*K).
[0064] As well as the first insulation element 18, the insulation arrangement 15 comprises a second insulation element 21 for acoustic insulation of the dishwashing compartment 2. The second insulation element 21 can also be referred to as an acoustic insulation element. The second insulation element 21 serves in particular as a bulk layer and improves the acoustic properties of the insulation arrangement 15. The second insulation element 21 is likewise provided on the outer side of the dishwashing compartment 2. In this case the first insulation element 18 is positioned between the dishwashing compartment 2 and the second insulation element 21. The second insulation element 21 comprises a first surface 22 directed towards the first insulation element 18 and a second surface 23 directed away from the first surface 22. Preferably the second insulation element 21 is able to be separated in a non-destructive manner from the first insulation element 18. The second insulation element 21 can however also be connected to the first insulation element 18 in a non-releasable manner.
[0065] The second insulation element 21 has a thickness d21. The thickness d21 is smaller than the thickness d18 of the first insulation element 18. For example the thickness d21 can amount to 1 to 10 mm, further preferably to 1 to 8 mm, further preferably to 1 to 5 mm, further preferably to 1 to 3 mm. In particular the first insulation element 18 prevents heat being transmitted from the dishwashing compartment 2 to the second insulation element 21. This means that the second insulation element 21 cannot extract any heat from the dishwashing compartment 2. The energy efficiency of the household dishwasher 1 is thereby improved. In the second insulation element 21 vibrations of the dishwashing container 2 are converted into heat.
[0066] The first insulation element 18, as already mentioned, is suitable for damping vibrations. A loss factor of the plastic material of the first insulation element 18 is high and is tuned to its use in the household dishwasher 1. A “loss factor” here is to be understood with physical vibrations of different natures as the ratio of the loss-affected imaginary part to the loss-free real part of a complex variable. The loss factor of the plastic material of the first insulation element 18 at 20° C. is in particular greater than 0.2, preferably greater than 0.4. Furthermore the hysteresis factor in accordance with the IFD method (hysteresis loss—IFD) as per ASTM D3574 is preferably greater than 15%, preferably greater than 20%, especially greater than 30%, and the recovery time as per ASTM D3574 is preferably greater than 2 s, preferably greater than 4, especially greater than 5 s. The vibrations are partly also passed on to the second insulation element 21. The second insulation element 21 in the insulation arrangement setup 15 essentially makes a surface mass available through its high density.
[0067] The second insulation element 21 preferably has a far higher density than the first insulation element 18. The second insulation element 21 is preferably made of a bitumen material, in particular of a metal and/or stone-filled bitumen material, or of a plastic material, particularly of a metal and/or stone-filled plastic material. For example the second insulation element 21 can be made of a butyl material. The second insulation element 21 is in particular in the form of a plate or a mat. The second insulation element 21 can also be a sheet of metal, in particular a sheet of steel.
[0068] The second insulation element 21 serves to deaden the sound of the dishwashing compartment 2 or to damp vibrations of the dishwashing compartment 2. The second insulation element 21 preferably has as high a loss factor as possible. The loss factor of the material of the second insulation element 21 at 20° C. is preferably greater than 0.08, further preferably greater than 0.15. A density ρ21 of the second insulation element 21 is preferably greater than 1,000 kg/m.sup.3.
[0069] The insulation arrangement 15 can furthermore comprise an optional separation layer 24. The separation layer 24 is positioned between the first insulation element 18 and the second insulation element 21, in particular between the surfaces 20, 22. The separation layer 24 can be a layer of wax, a film, for example a polyethylene film or the like. The separation layer 24 can also comprise a number of films. The separation layer 24 makes possible a non-destructive and residue-free separation of the second insulation element 21 from the first insulation element 18. The separation layer 24, as previously mentioned, is optional, so that the first insulation element 18 and the second insulation element 21 can also be joined inseparably to one another. For example the first insulation element 18 can be foamed directly onto the second insulation element 21. A layer of adhesive can further be provided between the insulation elements 18, 21.
[0070] The household dishwasher 1 furthermore comprises an outer casing 29. The outer casing 29 is arranged on the outer side of the insulation arrangement 15, in particular on the outer side of the second insulation element 25. The outer casing 29 can be a sheet of steel for example. The outer casing 29 can be part of a housing of the household dishwasher 1. The outer casing 29 can in particular also be part of the insulation arrangement 15.
[0071] The outer casing 29 can comprise a first surface 30 directed towards the second insulation element 25 and also a second surface 31 directed away from the second insulation element 25. The outer casing 29 can either lie loosely on the second insulation element 25 or be connected to said element in such a way that the outer casing 29 can be released from the second insulation element 25 without leaving residues and non-destructively. To this end a separation layer 32 can be provided between the second insulation element 25 and the outer casing 29. The separation layer 32 is optional. The separation layer 32 can be constructed identically to the separation layer 28.
[0072] The insulation arrangement 15 can also be designed so that said arrangement does not have the first insulation element 18 at least to some extent. For example the insulation arrangement 15 can have the first insulation element 18 and also the second insulation element 21 on the side wall 10. On the side wall 11 on the other hand the second insulation element 21, as a bitumen mat for example, can be attached directly to the dishwashing compartment 2. The same applies to the floor 7, the roof 8 and the rear wall 9. On the side wall 11 for example partly the insulation arrangement 15 with the first insulation element 18 and the second insulation element 21 and partly just the second insulation element 21 can also be provided. This enables a household dishwasher 1 that is both quiet and also energy-efficient to be realized at a low price. This also results in production advantages.
[0073] Advantages are further produced over the lifetime of the household dishwasher 1.
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[0075]
[0076] The surface treatment of the surface 22 can be a plasma treatment, a corona treatment or the like for example. An additional coating of one of the insulation elements 18, 21 can also be provided. This can be applied in the production process for example to the second insulation element 21. After a contour of the second insulation element 21 has been produced, said element is placed in the mold 29 shown in
[0077] The mold 29 is in particular a die casting mold or a casting mold and comprises a lower mold part 30 and an upper mold part 31. The mold 29 comprises a cavity 32, which is a negative of a geometry of the first insulation element 18. After the second insulation element 21 is placed in the mold 29, as shown in
[0078] To produce the insulation arrangement 15 or the first insulation element 18 respectively two components are mixed for example and are poured into the mold 29. The plastic material can then foam under atmospheric pressure or in a vacuum and fill out the cavity 32 completely. After the complete curing and/or cross-linking of the plastic material, the mold 29, as shown in
[0079] Easier handling of the insulation arrangement 15 is thus possible. A prefabrication of the insulation arrangement 15 is further possible. The dishwashing compartment 2 can be produced separately from the insulation arrangement 15, since the first insulation element 18 is not foamed directly onto the dishwashing compartment 2. A later generation of variants is possible. The production of the insulation arrangement 15 and the attachment of said arrangement to the dishwashing compartment 2 can easily be integrated into the production of the household dishwasher 1. A number of layers or individual parts can be combined in an upstream process to form a one-piece arrangement. This makes easier handling possible in downstream process steps.
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[0084] After the production of the blanks 35, these are placed in a forming press 36 (
[0085] After its removal from the mold (
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[0087] Although the present invention has been described with reference to exemplary embodiments, it is able to be modified in many ways.
REFERENCE CHARACTERS USED
[0088] 1 Household appliance, household dishwasher [0089] 2 Functional compartment, dishwashing compartment [0090] 3 Door [0091] 4 Dishwashing space [0092] 5 Pivot axis [0093] 6 Loading opening [0094] 7 Floor [0095] 8 Roof [0096] 9 Rear wall [0097] 10 Side wall [0098] 11 Side wall [0099] 12 Dishwashing receptacle [0100] 13 Dishwashing receptacle [0101] 14 Dishwashing receptacle [0102] 15 Insulation arrangement [0103] 16 Inner side [0104] 17 Outer side [0105] 18 First insulation element [0106] 19 Surface [0107] 20 Surface [0108] 21 Second insulation arrangement [0109] 22 Surface [0110] 23 Surface [0111] 24 Separating layer [0112] 25 Outer casing [0113] 26 Surface [0114] 27 Surface [0115] 28 Separating layer [0116] 29 Mold [0117] 30 Lower mold part [0118] 31 Upper mold part [0119] 32 Cavity [0120] 33 Foam block [0121] 34 Mold [0122] 35 Blank [0123] 36 Forming press [0124] 37 Lower part [0125] 38 Upper part [0126] 39 Cavity [0127] A Pull-out direction (arrow) [0128] c18 Thermal capacity [0129] d18 Thickness [0130] d21 Thickness [0131] E Push-in direction (arrow) [0132] Step [0133] S2 Step [0134] S3 Step [0135] S10 Step [0136] S20 Step [0137] S30 Step [0138] S40 Step [0139] S100 Step [0140] S200 Step [0141] S300 Step [0142] λ18 Thermal conductivity [0143] ρ18 Density [0144] ρ21 Density