阅读说明：本技术 用于车身前壁的隔音元件和用于这种隔音元件的承载元件 (Sound-insulating element for a front wall of a vehicle body and support element for such a sound-insulating element ) 是由 V·舒尔策 F·里德雷尔 T·卡尔奇 于 2019-12-10 设计创作，主要内容包括：设置在乘客舱和发动机舱之间的用于车身前壁的隔音元件设置有复合部件,该复合部件具有塑料载体层(16)和与其连接的吸音层(18),复合部件具有至少一个第一通道开口。当在其安装状态下观察时,复合部件具有面向乘客舱并由塑料载体层(16)的外侧形成的前侧和靠在前壁上并由背离塑料载体层(16)的吸音层(18)的外侧形成的后侧。至少一个压紧突起(72)在背离塑料载体层(16)的外侧并因此面向吸音层(18)的内侧上在载体层孔的孔边缘处和/或偏离塑料载体层(16)的孔边缘从塑料载体层(16)突出,压紧突起(72)嵌入吸音层(18)的吸音材料中并且其背离塑料载体层(16)的自由端与吸音层(18)的背离塑料载体层(16)的外侧基本对齐。(A sound-insulating element for a front wall of a vehicle body, which is arranged between a passenger compartment and an engine compartment, is provided with a composite part having a plastic carrier layer (16) and a sound absorption layer (18) connected thereto, the composite part having at least one first passage opening. The composite part has, when viewed in its installed state, a front side facing the passenger compartment and formed by the outer side of the plastic carrier layer (16) and a rear side resting against the front wall and formed by the outer side of the sound absorption layer (18) facing away from the plastic carrier layer (16). At least one pressure projection (72) protrudes from the plastic carrier layer (16) on the outer side facing away from the plastic carrier layer (16) and thus on the inner side facing the sound absorption layer (18) at the hole edge of the carrier layer hole and/or at the hole edge facing away from the plastic carrier layer (16), the pressure projection (72) being embedded in the sound-absorbing material of the sound absorption layer (18) and its free end facing away from the plastic carrier layer (16) being substantially aligned with the outer side of the sound absorption layer (18) facing away from the plastic carrier layer (16).)

1. A sound-insulating element for the front wall of the vehicle body, arranged between the passenger compartment and the engine compartment, having

-a composite part comprising a plastic carrier layer (16) and a sound-absorbing layer (18) connected thereto,

-wherein the composite part has, viewed in its mounted state, a front side (20) facing the passenger compartment and formed by an outer surface (24) of the plastic carrier layer (16), and a rear side (22), the rear side (22) lying against the front wall and being formed by an outer side (26) of the sound absorption layer (18) facing away from the plastic carrier layer (16), and

at least one first passage opening (32, 34, 36, 38) in the composite part,

-wherein the first passage opening (32, 34, 36, 38) comprises: a carrier layer aperture (48, 50, 52, 54) formed in the plastic carrier layer (16) having an aperture edge (49, 51, 53, 55); and sound absorbing layer holes (57, 59, 61, 63) formed in the sound absorbing layer (18) and having hole edges,

-wherein at least one pressing projection (72) protrudes from the plastic carrier layer (16) on an inner side facing away from an outer surface (24) of the plastic carrier layer (16) and thus facing the sound absorption layer (18) at a hole edge (49, 51, 53, 55) of the carrier layer hole (48, 50, 52, 54) and/or a hole edge (49, 51, 53, 55) facing away from the plastic carrier layer (16), the pressing projection (72) being embedded in the sound absorption material of the sound absorption layer (18) and its free end facing away from the plastic carrier layer (16) being substantially aligned with an outer side of the sound absorption layer (18) facing away from the plastic carrier layer (16).

2. A sound-insulating element as claimed in claim 1, characterized in that a free end (76) of the at least one pressing projection (72) facing away from the inner side (28) of the plastic carrier layer (16) is covered with a sound-absorbing material.

3. The sound insulating element according to claim 1 or 2, characterized in that a plurality of hold-down protrusions (72) are arranged circumferentially around the carrier layer apertures (48, 50, 52, 54).

4. The sound-insulating element as claimed in one of claims 1 to 3, characterized in that the at least one pressing projection (72) is formed as a pin-shaped projection or as a pressing dome.

5. Soundproofing element according to claim 1 or 2, characterised in that the at least one pressing projection (72) is formed as a collar surrounding the carrier layer hole (48, 50, 52, 54) and having a circumferential direction provided with openings.

6. Sound-insulating element according to one of claims 1 to 5, characterized in that the sound-absorbing material of the sound-absorbing layer (18) projects inwardly beyond the hole edges (49, 51, 53, 55) of the carrier layer holes (48, 50, 52, 54) and forms annular projecting edges (80, 82, 84).

7. Sound-insulating element according to claim 6, characterized in that the projecting edge (80, 82, 84) is aligned with the outer side (24) of the plastic carrier layer (16) or extends along at least a part of the hole edge (49, 51, 53, 55) of the carrier layer hole (48, 50, 52, 54) onto the outer side (24) of the plastic carrier layer (16).

8. The sound insulating element according to any one of claims 1 to 7, characterized in that the at least one second channel opening (32, 34, 36, 38) in the composite part comprises: a carrier layer aperture (48, 50, 52, 54) formed in the plastic carrier layer (16); and sound-absorbing layer holes (57, 59, 61, 63) formed in the sound-absorbing layer (18), wherein the two holes have aligned hole edges.

9. A bearing element for a sound-insulating composite part arranged on a front wall of a vehicle body between an engine compartment and a passenger compartment, comprising

A plastic carrier layer (16) having an outer side and an inner side, to which sound-absorbing material of a sound-absorbing layer (18) of the sound-damping composite part can be applied or on a forming tool having at least two forming tool parts,

-at least one first carrier layer aperture, the aperture edge of which is formed in the plastic carrier layer (16), and

-at least one pressing projection (72) provided on and/or offset from the aperture edge, projecting from the plastic carrier layer (16) and projecting from the interior of the plastic carrier layer (16),

-wherein the plastic carrier layer (16) can be introduced into a forming tool with its outer side against a first forming tool part, the end of at least one pressing projection (72) remote from the inner side of the plastic carrier layer (16) being provided for contacting a second forming tool part for holding the plastic carrier layer (16) against the first forming tool part in the region of the hole edge of the first carrier layer hole.

10. The carrying element according to claim 9, characterized in that the first hole of the plastic carrier layer (16) is arranged to penetrate with radial clearance to the hole edge of the first carrier layer hole by means of a mould core, in particular by means of a mould core arranged on a first or a second moulding tool part of a moulding tool arranged for moulding the sound-absorbing material onto the rear side of the plastic carrier layer (16).

11. The carrying element according to claim 9 or 10, characterized in that the at least one pressing projection (72) is formed according to any one of claims 1 to 8 and/or the plastic carrier layer (16) is provided with a sound-absorbing layer (18) or a sound-absorbing material according to any one of claims 1 to 8.

Technical Field

The invention relates to a sound-insulating element for a front wall of a vehicle body separating a passenger compartment from an engine compartment. The invention further relates to a support element for a sound-damping composite part arranged on a front wall of a vehicle body.

Background

It is known to arrange acoustic insulating elements on the inside of the front wall of the vehicle body, i.e. on the inside of the wall between the passenger compartment and the engine compartment of the vehicle body. As examples of such front wall barrier materials, reference is made to WO-A-2018/192858, US-A-2006/0091699 or DE-A-3733284.

Such a sound-insulating element has a sandwich structure with a plastic carrier layer, also referred to as a heavy layer, and a sound-absorbing layer which is molded onto the plastic carrier layer and is made of a sound-absorbing material, in particular a PUR foam material. The front wall of the body has a plurality of passages for lines, pipes or components. Correspondingly, the sound-insulating element is also provided with a through-hole, which is generally aligned with the passage in the front wall. Depending on the type of element passing through the soundproofing element and through the front wall, it is necessary to protect it from mechanical damage (wear protection). One possible measure to achieve this protection is to foam around the hole edge of the passage opening of the sound-insulating element or to surround it with sound-absorbing material.

The sound-absorbing material is usually moulded onto the plastic carrier layer in a specially designed forming tool, usually a foaming tool, into which the plastic carrier layer is inserted. The plastic carrier layer has previously been produced in another forming tool provided for this purpose. In the region of the edges of the holes of the plastic carrier layer, in which the sound-absorbing material is at least partially embedded, the sound-absorbing material must be able to penetrate at least partially into the carrier layer holes. To some extent, the sound-absorbing material should surround the edges of the holes on both sides of the plastic carrier layer. In both cases, this can lead to the plastic carrier layer "floating" in the molding tool into which it is inserted during the production process, which can lead to unsatisfactory production results. In order to avoid this, the corresponding molding tool for molding the sound-absorbing material onto the plastic carrier layer has a pressing pin which presses the plastic carrier layer along the hole edge, which is at least partially surrounded by the sound-absorbing material. Such a pressing pin of the forming tool increases the manufacturing costs of the forming tool and complicates the cleaning process, which is in principle increasingly difficult to carry out. Furthermore, the sound absorption layer formed with such a molding tool has cavities caused by the hold-down pins, which is acoustically disadvantageous.

It is known from DE-a-102013006300 that the core of a plastic-encased utensil handle can be positioned in the center of the forming tool by means of spacer pins projecting from the core to all sides. This method is not suitable for two-component parts in which one plastic component is provided with a second plastic component on only one side.

DE-C-19833098 discloses a method for producing a padded article having a core and a padded covering surrounding it on all sides.

Disclosure of Invention

The object of the invention is to provide a sound-insulating element for a vehicle body front wall arranged between a passenger compartment and an engine compartment, and a carrier element for such a sound-insulating element, by means of which the expenditure required for maintaining the position of the carrier element in a shaping tool on the tool side for molding sound-absorbing material onto the carrier element can be reduced.

To solve this problem, the invention proposes a sound-insulating element for a front wall of a vehicle body, arranged between a passenger compartment and an engine compartment, wherein the sound-insulating element is provided with

A composite part comprising a plastic carrier layer and a sound-absorbing layer connected thereto,

wherein the composite part has a front side, which faces the passenger compartment when viewed in its installed state and is formed by the outer surface of the plastic carrier layer, and a rear side adjoining the front wall, which rear side is formed by the outer side of the sound absorption layer facing away from the plastic carrier layer, and

at least one first passage opening in the composite part,

-wherein the first passage opening comprises a carrier layer hole having a hole edge formed in the plastic carrier layer and a sound-absorbing layer hole having a hole edge formed in the sound-absorbing layer, and

at least one pressure projection projects from the plastic carrier layer on the outer side facing away from the plastic carrier layer and thus on the inner side facing the sound absorption layer at and/or at the hole edge of the carrier layer hole, which pressure projection engages in the sound absorption material of the sound absorption layer, the free end of the pressure projection facing away from the plastic carrier layer being substantially flush with the outer side of the sound absorption layer facing away from the plastic carrier layer.

Accordingly, the present invention provides the hold-down projections as a part of the plastic carrier layer, i.e., a part of the carrier element of the soundproofing element onto which the sound-absorbing material is molded, instead of the hold-down projections provided on the forming tool. Such pressure projections, which are located at the hole edges or are offset outwardly from the hole edges of the passage openings, i.e. the holes in the plastic carrier layer, form the passages of the sound-insulating element together with the aligned holes in the sound-absorbing layer.

In the sound-insulating element according to the invention, at least one pressing projection, which may be, for example, needle-shaped or dome-shaped, is embedded in the sound-absorbing material of the sound-absorbing layer. Advantageously, a plurality of such pressure projections are present circumferentially around the hole edge of the carrier layer hole. Unlike the prior art in which the hold-down projections (hold-down pins) are part of one of the forming tool parts for molding the sound-absorbing material onto the plastic carrier layer, in the sound-insulating element according to the invention there are no cavities after the sound-absorbing layer has been released from the forming tool; instead, the pressing projections of the plastic carrier layer extend into the sound-absorbing layer and possibly through it.

As described above, the sound-insulating element according to the invention is designed as a composite part and has a plastic carrier layer (so-called heavy layer) and a sound-absorbing layer made of sound-absorbing material (for example PU foam). A composite component constructed in this way in two layers has two outer sides, one of which is formed by the plastic carrier layer and the other by the sound-absorbing layer. The inner sides of the two layers are in contact with each other; the two layers are interconnected on the inner side. In the mounted state, the outer side of the plastic carrier layer faces the passenger compartment; this side of the composite part forms the front side, while the rear side of the composite part is formed by the outer side of the sound-absorbing layer resting against the front wall.

At least one pressure projection now projects from the inner side of the plastic carrier layer in the region of a hole in the carrier layer, the free end of which facing away from the rear side of the plastic carrier layer lies substantially flush with the outer side of the sound absorption layer. In which the free end does not protrude outside the sound-absorbing layer, but is more preferably thinly covered (e.g., at least 1mm and at most 5mm) by the sound-absorbing material.

As already mentioned, it is useful to provide a plurality of hold-down projections around the edge of the hole, which then advantageously take the form of pins or domes. The design of the pressing projection or of the at least one pressing projection should be selected such that the sound-absorbing material can flow around and over the at least one pressing projection when it is moulded onto the plastic carrier layer in the moulding tool. If in a useful embodiment of the invention a collar at least partially surrounding the hole in the carrier layer is used as the pressing projection, the collar should have a groove or an edge groove opening towards the upper edge in its circumferential wall. With such a collar design, sound absorbing material introduced into the forming tool can flow through the collar.

The structure of the sound-insulating element according to the invention described above is used in particular for forming the edge of the hole provided with sound-absorbing material in the plastic carrier layer. The sound-absorbing material has projecting regions which project into the holes of the carrier layer and which project flush with the outer side of the plastic carrier layer or project forward so as to surround the edges of the holes on both sides. In order to prevent undesired shearing of the sound-absorbing material in the region of the hole edges, a hook-like structure can be provided between the plastic carrier layer and the sound-absorbing layer by means of anchoring projections, through-openings or the like formed by the sound-absorbing material. Examples of filling the through-openings of sound-absorbing material in the plastic carrier layer in the penetration region of the sound-insulating element can be found in DE-A-4132571, EP-A-2786851 and JP H07-285138A.

Various embodiments of the invention are subject of the dependent claims.

In an advantageous further development of the invention, the sound-absorbing material of the sound-absorbing layer projects inwardly beyond the hole edge of the carrier layer hole into the first hole and forms an annular projecting edge.

In this embodiment, provision can also advantageously be made for the projecting edge to be aligned with the outer side of the plastic carrier layer or to extend along at least a part of the hole edge of the carrier layer hole to the outer side of the plastic carrier layer. Advantageously, the sound-insulating element according to the invention can also be provided with at least one second passage opening in the composite part, which second passage opening comprises a carrier layer hole formed in the plastic carrier layer and a sound-absorbing layer hole formed in the sound-absorbing layer, both holes having aligned hole edges.

In addition to the sound-insulating element according to the invention described above, the above object is also solved according to the invention by a carrier element for a sound-insulating composite part, which carrier element is arranged on a front wall of a vehicle body, which front wall is arranged between an engine compartment and a passenger compartment, wherein the carrier element is provided with a sound-insulating element

A plastic carrier layer having an outer side and an inner side, to which the sound-absorbing material of the sound-absorbing layer of the sound-damping composite part can be applied or attached in a molding tool having at least two molding tool parts,

at least one first carrier layer aperture formed in the plastic carrier layer, the first carrier layer aperture having an aperture edge, and

at least one pressure projection arranged on and/or offset from the edge of the hole, which pressure projection projects from the plastic carrier layer and from the inner side of the plastic carrier layer,

the plastic carrier layer can be introduced into the forming tool with its outer side abutting the first forming tool part and the end of the at least one pressure projection facing away from the inner side of the plastic carrier layer is arranged for contacting the second forming tool part for holding the plastic carrier layer against the first forming tool part in the region of the hole edge of the first carrier layer hole.

In order to be able to realize the hole edge of the plastic carrier layer provided with the sound-insulating material in such a carrier element, for example, a first hole of the plastic carrier layer can be provided, which is arranged to penetrate with radial clearance to the hole edge of the first carrier layer hole by means of a mold core, in particular by means of a mold core arranged on a first or second molding tool part of a molding tool provided for molding the sound-insulating material onto the rear side of the plastic carrier layer.

The carrier element may advantageously be formed with a compression protrusion structure as described previously in connection with the sound insulating element. Furthermore, the plastic carrier layer of the carrier element can be formed as described above in connection with the invention. In particular, as provided above in the context of the present invention, the plastic carrier layer of the carrier element can be provided with a sound-insulating material and a sound-absorbing layer.

The invention is explained in more detail below by way of examples of embodiments and with reference to the drawings.

Drawings

Figure 1 is an exploded perspective view of a vehicle body with a front wall acoustic barrier member,

fig. 2 is a perspective view of the design of the heavy layer, i.e. the plastic carrier layer, of the sound-insulating element according to fig. 1,

fig. 3 is a cross-sectional view of a molding tool for molding a soundproofing material onto a plastic carrier layer according to fig. 2, wherein the plastic carrier layer is inserted into the molding tool,

figure 4 is a cross-sectional view of the forming tool shown in figure 3 after insertion of a sound absorbing material,

figure 5 is a view from the rear side of the sound-insulating element against the front wall of the vehicle body when the sound-insulating element is mounted,

figure 6 is a perspective view of the sound-insulating element from the rear side,

fig. 7 is a cross-sectional view of the sound-insulating member taken along line VII-VII of fig. 6, and

fig. 8 is a perspective view of an alternative design of the hold-down projections.

Detailed Description

Fig. 1 schematically shows a vehicle body 10 with a front wall 12, on which front wall 12 a sound-insulating element 14 designed as a composite part is arranged. The sound-insulating element 14 is fixed to the front wall 12 at least partially by means of fixing projections (not shown) formed integrally with the sound-insulating element 14, which in the assembled state of the sound-insulating element 14 cooperate with corresponding receiving openings in the vehicle body 10 or the front wall 12, in which the fixing projections are placed. In this respect, reference is made, by way of example, to WO-A-2018/192858, the contents of which are hereby incorporated by reference as part of the subject matter of the present disclosure.

As is known, the acoustic insulating element 14 has a so-called mass-spring system comprising: a plastic carrier layer 16 as a heavy or mass layer made of, for example, EVA/PE, PP, EPDM, TPE, TPO and/or polyurethane foam, each of which has a high weight proportion of high density mineral filler, such as feldspar, of up to 70%; and a sound absorbing layer 18 made of a sound absorbing material (e.g., urethane foam) (see, for example, fig. 6).

In the installed state as shown in fig. 1, the sound-insulating element 14 has a front side 20 facing the passenger compartment and a rear side 22 facing and abutting the front wall. The front side 20 is formed by the outer surface 24 of the plastic carrier layer 16, while the rear side 22 is formed by the outer surface 26 of the sound-absorbing layer 18. The plastic carrier layer 16 and the sound absorption layer 18 are connected to one another at their inner sides 28, 30 facing one another (see also fig. 7).

The sound-insulating element 14 has a plurality of passage openings 32, 34, 36, 38, which in this embodiment have different shapes and are intended to show different types of passages of the sound-insulating element. In addition to the passage openings 34, the other passage openings 34 shown in the figures are provided with sound-absorbing material along the hole edges of the holes in the plastic carrier layer 16. Molding sound absorbing material along the edges of these holes requires a certain amount of positioning aids in the molding tool provided for molding sound absorbing material, as shown in fig. 3 and 4.

Fig. 3 shows a cross section through a two-part forming tool 40 in this embodiment, which has a first forming tool part 42 and a second forming tool part 44. The prefabricated plastic carrier layer 16 is first placed into the mold cavity 46 of the molding tool 40, the outer surface 24 of the plastic carrier layer resting on the inner surface of the first molding tool part 42. The forming tool 40 is then moved together. In this embodiment example, four holes 48, 50, 52, 54 with hole edges 49, 51, 53, 55 are formed in the plastic carrier layer 16. The mold core 56 extends into the bore 54 to completely fill the bore 54. The mould cores 58, 60, 62 each project into the bores 48, 50, 52, which mould cores have a smaller cross section than the bores, so that free spaces 64, 66, 68 remain in the mould cavity 46 between the mould cores and the bore edges 49, 51, 53.

Thus, the free space is filled with sound absorbing material, as shown with reference to fig. 3 and 4, when such material is introduced into the forming tool 40 through, for example, one (in particular several) inlets 70. The mold cores 56, 58, 60, 62 provide holes 57, 59, 61, 63 in the sound-absorbing layer 18 of the baffle element 14, the holes 57, 59, 61, 63 being aligned with the carrier layer holes 48, 50, 52, 54, respectively.

The sound-absorbing material penetrates into the holes 48, 50, 52 (no material penetrates into the holes because the mould core 56 completely fills the holes 54) with the risk that the plastic carrier layer 16 is "punched out" and then "floats" in the mould cavity 46. To prevent this, a pressure projection 72 (in this embodiment all in the form of a pin or dome) projecting from the inner side 28 of the plastic carrier layer 16 is arranged in the region of each hole 48, 50, 52, the pressure projection 72 resting on an inner side 74 of the second molding tool part 44 which delimits the mold cavity 46, or the free end 76 thereof being arranged at a short distance from the molding tool part 44. The hold-down projections 72 hold the plastic carrier layer 16 in place against the inner side 78 of the first forming tool part 42. This prevents the plastic carrier layer 16 from "floating" as the sound absorbing material penetrates and flows around the edges of the holes 48, 50, 52.

Depending on the desired design of the edges which enclose or surround or partially surround the holes 48, 50, 52 with sound-absorbing material, the plastic carrier layer 16 has a different structure in the region of the holes, as shown in fig. 3 and 4 or fig. 6 and 7. For example, the projecting edge 80 in the aperture 48 is aligned with the outer surface 24 of the plastic carrier layer 16, while the respective projecting edges 82, 84 of the apertures 50, 52 surround the aperture edges 51, 53 from both sides. With regard to the design of the holes 52, additional hook structures or similar projections 86 are additionally provided which project from the front side 20 of the plastic carrier layer 16, which are embedded in the sound-absorbing material and thus ensure additional retention of the sound-absorbing layer 18 on the front side 20 of the plastic carrier layer 16.

Fig. 8 shows an alternative embodiment of the hold-down projection 88. In this embodiment, the hold-down tabs 88 are formed as circumferential collars 90 that extend around openings in the plastic carrier layer, indicated at 92. The collar 90 has apertures 94 through which the sound barrier material can pass through the apertures 94 to near or around the edges of the apertures in the plastic carrier layer 92, as shown by the aperture design in fig. 3. In a state where the sound insulating material is provided, the pressing projection 88 is embedded in the material.

List of reference numerals

10 vehicle body

12 front wall

14 Sound insulating element

16 plastic carrier layer

18 sound absorbing layer

20 front side

22 rear side

24 outer surface of the front side

26 outside

28 inner side

30 inner side

32 channel opening

34 opening of the channel

36 channel opening

38 channel opening

40 two-piece forming tool

42 first forming tool part

44 second forming tool part

46 die cavity

48 carrier layer pores

Edge of 49 holes

50 carrier layer pores

51 hole edge

52 carrier layer pores

53 hole edge

54 carrier layer pores

55 hole edge

56 mould core

57 sound absorption layer hole

58 mold core

59 sound-absorbing layer hole

60 mould core

61 sound absorption layer hole

62 mould core

63 Sound-absorbing layer hole

64 free space

66 free space

68 free space

70 inlet

72 hold-down projection

74 inside of the mold cavity

76 press against the free end of the projection

78 inside the mold cavity

80 projecting edge

82 projecting edge

84 projecting edge

86 protrusion

88 hold-down projection

90 collar

92 plastic carrier layer

94 bore of collar

Reference to the literature

WO-A-2018/192858

US-A-2006/0091699

DE-A-37 33 284

EN-A-10 2013 006 300

EN-C-198 33 098

DE-A-41 32 571

EP-A-2 786 851

JP H07-285 138 A