insulating element

Abstract

The invention relates to an insulating element for insulating a structural element in a motor vehicle, comprising a carrier and an expandable material arranged on the carrier. The carrier has at least one cap portion and is configured such that, when a plurality of identical insulating elements are stacked, the cap portions of adjacent insulating elements respectively nest in one another.

Description

Technical Field

[0001] This invention relates to an insulating element for insulating structural components in a motor vehicle. The invention also relates to a system having a plurality of such insulating elements and a method for mounting such insulating elements onto structural components. Background Technology

[0002] In many cases, components, such as the bodies and / or frames of vehicles, especially water, land, or air vehicles, have cavitary structures to achieve lightweight construction. However, these cavities cause various problems. Depending on the type of cavity, it must be sealed to prevent the ingress of moisture and contaminants that can lead to corrosion of the component. It is also often desirable to significantly reinforce the cavity and therefore the component while maintaining a low weight. It is also often necessary to stabilize the cavity and therefore the component to reduce noise that would otherwise be transmitted along or through the cavity. Many of these cavities have irregular shapes or narrow dimensions, making them difficult to properly seal, reinforce, and dampen.

[0003] Therefore, baffles are used, especially in automobile manufacturing and aircraft and shipbuilding, to seal and / or acoustically isolate cavities, or reinforcers are used to strengthen cavities.

[0004] exist Figure 1 The diagram schematically shows the body of a car. The body 10 here has several different cavitary structures, such as pillars 14 and beams or struts 12. These cavity structural elements 12, 14 are typically sealed or reinforced with insulating elements 16.

[0005] The known disadvantages of sealing and / or reinforcing elements to date are that such components often cannot be packaged efficiently. Furthermore, confusion and damage to individual components always occur during transportation. Summary of the Invention

[0006] Therefore, the objective of this invention is to provide an improved insulating element for insulating structural components in motor vehicles, which avoids the disadvantages of the prior art. In particular, this insulating element should be able to be packaged and transported more economically.

[0007] The task is accomplished by an insulating element for insulating structural components in a motor vehicle, the insulating element comprising: a carrier; and an expandable material disposed on the carrier; the carrier having at least one cap and configured such that, when multiple identical insulating elements are stacked, the caps of adjacent insulating elements are nested within each other.

[0008] This solution offers several advantages. First, it provides a stackable insulating element. This insulating element can be stacked vertically for transport and packaged and transported in this stacked state. This results in cost savings in transportation because the insulating element can be packaged more space-efficiently, allowing more insulating elements to be transported within a given volume compared to conventional insulating elements. Furthermore, this stacking of insulating elements offers the advantage of easier identification of confusion between different insulating elements. For example, if a first insulating element is packaged in a container with multiple second insulating elements, this will be immediately noticeable because the first insulating element typically cannot be stacked with the second insulating elements. This significantly reduces confusion.

[0009] The stackable insulating elements proposed herein also have the following advantages: individual insulating elements are less susceptible to damage due to the stacking arrangement for transport and storage. If individual insulating elements are transported loosely in a container as has been the case so far, numerous contacts occur between the insulating elements, which can sometimes lead to damage. However, if the insulating elements are transported in a stacked manner, the number of mechanical contacts between the insulating elements is greatly reduced. Furthermore, the insulating elements can be constructed such that the intended contact areas are robust or resistant to damage, and / or the vulnerable areas of the insulating elements are located in protected positions, such as those covered by adjacent insulating elements during stacking.

[0010] Furthermore, the stackable insulating elements proposed herein have the advantage of facilitating the automated installation of insulating elements onto structural components in motor vehicles. Thus, for example, an entire stack of such insulating elements can be loaded into a robot, which then extracts the individual insulating elements from the stack and installs them accordingly onto the structural components. This automated installation of insulating elements becomes significantly more difficult when they are loosely arranged in a container.

[0011] The use of one or more caps has the following advantages: Firstly, it improves the stackability of the insulating elements by nesting the caps of adjacent insulating elements together during stacking. Secondly, the stacked insulating elements are mechanically secured to prevent lateral movement, and furthermore, the stack height is kept as small as possible by nesting the insulating elements together in a space-saving manner.

[0012] These caps also have the advantage that the manipulation achieved by applying the robot is simplified and made more efficient. For example, the robot's gripper can grip and manipulate the insulating element directly at the cap. In the case of insulating elements with multiple caps, multiple grippers can be used accordingly.

[0013] The term "insulating element" within the scope of this invention includes elements used for isolating and / or sealing and / or enclosing and / or reinforcing and / or insulating structural elements. These different characteristics of such insulating elements may appear individually or in combination with each other.

[0014] The term "cap" in the scope of this invention specifically includes a shaped portion or protrusion on an insulating element carrier having a hollow interior and open sides. Such a cap may have, for example, a hemispherical, dome-shaped, cubic, cylindrical, conical, or irregular shape.

[0015] The terms "upper side" and "lower side" refer, within the scope of this invention, to the two main surfaces or the two largest sides of an insulating element. Since the insulating element is designed to enclose the cross-section of a structural element, this means that the upper and lower sides, in the application state, are each substantially located in the plane of a cross-section to be insulated. Here, the upper or lower side may also have a stepped feature; that is, the upper or lower side does not necessarily have to be constructed to be completely flat.

[0016] Within the scope of this invention, the term "parallel" in relation to the arrangement of insulating elements in a stack of multiple identical insulating elements means that the corresponding identical surfaces and / or edges of the same insulating elements are arranged substantially parallel to each other.

[0017] In one embodiment, the insulating element has exactly three contact positions on its upper and lower sides, which are positioned vertically when adjacent insulating elements are stacked.

[0018] In an alternative extension, the insulating element has exactly four or at least four such contact positions on the upper and lower sides.

[0019] In another alternative embodiment, the insulating element has exactly five or at least five such contact points on the upper and lower sides.

[0020] In one exemplary embodiment, at least one contact position on the upper side and a contact position on the lower side assigned to the contact position are configured such that adjacent insulating elements are fixed in place to prevent horizontal movement when stacked in a vertical direction.

[0021] In one exemplary extension, at least one contact position on the upper side and a contact position on the lower side assigned to the contact position are configured such that a mechanical lock is formed between the respective contact positions during stacking.

[0022] In one exemplary embodiment, the cap forms at least one of these contact locations.

[0023] In one exemplary embodiment, at least one contact location is located in the area of ​​the fixing element.

[0024] Within the scope of this invention, "region of the fixing element" is understood to include the fixing element itself, the base of the fixing element, and the expandable material at the base of the fixing element, the expandable material being used to seal the opening into which the fixing element is inserted in the structural element.

[0025] In one exemplary embodiment, the fixing element is constructed as a clip.

[0026] In one exemplary embodiment, the height of the fixing element along the stacking direction is less than 8 mm, preferably less than 7 mm, and particularly preferably less than 6 mm.

[0027] In one exemplary embodiment, the height of the base of the fixing element along the stacking direction (which includes both the base of the fixing element and the expandable material at the base of the fixing element used to seal the opening into which the fixing element is inserted in the structural element) is at most 130%, at most 120%, or at most 110% of the height of the fixing element along the stacking direction.

[0028] This relatively tall design has the following advantages: it allows for more space-efficient packaging of insulating components.

[0029] In one exemplary embodiment, at least one contact location is configured as a spacer element, which is used to support and / or position the insulating element on the structural element in the state of use of the insulating element in the structural element.

[0030] In one exemplary extension scheme, the spacer elements themselves are configured to be stackable, wherein the total height of two nested stacked spacer elements along the stacking direction is at most 170% or at most 160% or at most 150% or at most 140% or at most 130% of the height of a single spacer element.

[0031] In one exemplary embodiment, the carrier steps form an angle of at least 35° or at least 40° or at least 45° or at least 50° or at least 55° with the stacking direction.

[0032] The advantage of this ladder design is that insulating elements with flatter ladders can be stacked better than those with steeper ladders. A particular problem exists with steeper ladders, where adjacent insulating elements cannot be vertically stacked without horizontal offset.

[0033] In one exemplary embodiment, a step and at least one cap of the carrier are configured such that the cap, together with the step, forms a support surface parallel to the plane of the upper or lower side of the carrier.

[0034] In one exemplary extension, the insulating element includes a step and two caps that together form this support surface.

[0035] Therefore, such insulating elements can be placed directly on a flat surface and stacked one on top of the other, with the stacking direction perpendicular to the flat surface.

[0036] In an alternative embodiment, the insulating element has three caps that together form a support surface parallel to the plane of the upper or lower side of the carrier.

[0037] Therefore, insulating elements can be directly stacked on a flat surface.

[0038] In another alternative embodiment, the insulating element has two caps that together form a support surface parallel to the upper or lower side of the carrier.

[0039] In another alternative embodiment, the insulating element has a cap whose top forms a support surface parallel to the plane of the upper or lower side of the carrier.

[0040] In one exemplary embodiment, all or some of the contact locations are formed by a carrier.

[0041] In one exemplary embodiment, some contact locations are formed of an expandable material.

[0042] In another embodiment, at least one contact site is formed by a carrier, and at least one contact site is formed by an expandable material.

[0043] Since carriers can typically be manufactured with smaller tolerances than expandable materials, it is advantageous that contact locations be formed by carriers as much as possible.

[0044] In one exemplary embodiment, the insulating element has at least one limiting element configured such that when the insulating elements are stacked one on top of the other, one insulating element is limited by the limiting element of the adjacent insulating element to prevent lateral movement in the stacking direction and / or to prevent the insulating element from rotating about the stacking direction.

[0045] In one exemplary embodiment, the limiting element is configured such that when the insulating elements are stacked one on top of the other, the limiting elements of two adjacent insulating elements overlap in the stacking direction.

[0046] In one exemplary extension scheme, the limiting elements overlap by at least 3 mm, at least 5 mm, or at least 7 mm in the stacking direction.

[0047] In one exemplary embodiment, the limiting element has at least one guide surface configured such that, during stacking, the guide surface guides the insulating elements to be stacked, such that the newly stacked insulating elements are disposed substantially coincidentally on the insulating elements in the stacking direction.

[0048] In one exemplary embodiment, at least one spacer element is configured as a motion-limiting element.

[0049] In one exemplary extension, the spacer element is configured to be substantially Y-shaped. For example, the faces of the legs of the Y-shaped spacer element can be configured as guide faces.

[0050] In an alternative extension scheme, the spacer element is substantially U-shaped or V-shaped. The faces of the legs of this U-shaped or V-shaped spacer element can be configured as guide surfaces.

[0051] In one exemplary embodiment, at least one step is configured as a limiting element.

[0052] In one exemplary embodiment, at least one region of the fixing element is configured as a motion-limiting element.

[0053] In one exemplary embodiment, the base of the fixing element is configured as a limiting element. Here, the base may be configured as substantially U-shaped, for example. Furthermore, the faces of the legs of the U-shaped base of the fixing element may also be configured as guide surfaces.

[0054] In one exemplary embodiment, at least one cap is configured as a movement limiting element.

[0055] In one exemplary embodiment, all or some of the motion-limiting elements are formed by a carrier.

[0056] In an alternative implementation, some of the motion-limiting elements are formed of an expandable material.

[0057] In another embodiment, at least one limiting element is formed of a carrier, and at least one limiting element is formed of an expandable material.

[0058] Since carriers can typically be manufactured with smaller tolerances than expandable materials, it is advantageous for movement limiting elements to be formed from carriers whenever possible.

[0059] In one exemplary embodiment, the insulating element has an upper side and a lower side that are oriented substantially in the plane of the cross section of the structural element to be insulated in the use state.

[0060] In one exemplary embodiment, the open side of the cap and / or the top of the cap are oriented substantially parallel to the upper or lower side of the insulating element.

[0061] In one exemplary embodiment, the sidewalls of the cap protrude only from the lower side in the stacking direction.

[0062] In an alternative embodiment, the sidewalls of the cap protrude only from the upper side in the stacking direction.

[0063] In another alternative embodiment, the sidewalls of the cap protrude both from the lower and upper sides in the stacking direction.

[0064] In one exemplary embodiment, the cross-section of the cap is substantially trapezoidal.

[0065] In an alternative embodiment, the cross-section of the cap is substantially shaped as an arc, dome, semicircle, rectangle, triangle, or irregular shape.

[0066] In one exemplary embodiment, the cap has a substantially circular, elliptical, or oval base surface.

[0067] In one exemplary embodiment, the carrier has at least two caps or at least three caps.

[0068] In one exemplary extension scheme, the two caps have different contours.

[0069] In one exemplary embodiment, the cap is configured such that when multiple identical insulating elements are stacked, the caps of adjacent insulating elements are positioned one above the other.

[0070] In one exemplary embodiment, the cap has at least one stop defined at a support portion when stacked.

[0071] In one exemplary extension, a stop is disposed on the sidewall of the cap. Here, the stop can be disposed on the inner side or the outer side of the sidewall.

[0072] In one exemplary embodiment, the maximum cap height along the stacking direction is between 5 mm and 40 mm, preferably between 7 mm and 35 mm, preferably between 7 mm and 30 mm, and preferably between 10 mm and 30 mm.

[0073] In an alternative implementation, particularly in conjunction with the use of ladders in the carrier, a taller cap can be used, and the maximum cap height along the stacking direction is between 10 mm and 80 mm, preferably between 20 and 70 mm.

[0074] In one exemplary embodiment, the maximum cap width on the open side of the cap, measured perpendicular to the stacking direction, is between 5 mm and 40 mm, preferably between 5 mm and 30 mm, preferably between 5 mm and 25 mm, and preferably between 5 mm and 20 mm.

[0075] In one exemplary embodiment, the maximum cap width at the top of the cap, measured perpendicular to the stacking direction, is between 3 mm and 35 mm, preferably between 3 mm and 25 mm, preferably between 3 mm and 20 mm, and preferably between 3 mm and 15 mm.

[0076] In one exemplary embodiment, the maximum cap width at the top of the cap, measured perpendicular to the stacking direction, is at most 95%, preferably at most 90%, preferably at most 85%, preferably at most 80%, preferably at most 75%, preferably at most 70%, preferably at most 65%, preferably at most 60%, preferably at most 55%, preferably at most 50% of the maximum cap width at the open side of the cap, measured perpendicular to the stacking direction.

[0077] In one exemplary embodiment, the stacking height of the insulating elements is at most 80%, preferably at most 70%, preferably at most 60%, and preferably at most 50% of the cap height.

[0078] In principle, different materials can be used as expandable materials, and these materials can be foamed. The material may or may not have reinforcing properties. Typically, expandable materials expand due to heat, humidity, or electromagnetic radiation.

[0079] Such expandable materials typically employ chemical or physical blowing agents. Chemical blowing agents are organic or inorganic compounds that decompose under the influence of temperature, humidity, or electromagnetic radiation, with at least one decomposition product being a gas. Physical blowing agents, for example, can be compounds that transform into a gaseous aggregate state upon increasing temperature. Thus, both chemical and physical blowing agents can create foam structures within polymers.

[0080] The preferred expandable material is thermally foamed, using a chemical blowing agent. Suitable chemical blowing agents include, for example, azodicarbonamide, sulfonyl hydrazine, bicarbonate, or carbonate. Suitable blowing agents can also be sourced from AkzoNobel, Netherlands, under trade names. Or from Chemitura, a US company, under the brand name Commercial purchase. The heat required for foaming can be introduced by an external heat source or an internal heat source, such as an exothermic chemical reaction. Foamable materials are preferably foamed at temperatures ≤250°C, especially 100°C to 250°C, preferably 120°C to 240°C, and most preferably 130°C to 230°C.

[0081] Suitable expandable materials are, for example, non-flowing one-component epoxy resin systems at room temperature, particularly those with increased impact toughness and containing thixotropic agents such as vaporized silica or nanoclay. Such epoxy resin systems, for example, comprise 20 to 50 wt% liquid epoxy resin, 0 to 30 wt% solid epoxy resin, 5 to 30 wt% toughening modifier, 1 to 5 wt% physical or chemical foaming agent, 10 to 40 wt% filler, 1 to 10 wt% thixotropic agent, and 2 to 10 wt% heat-activated curing agent. Suitable toughening modifiers are reactive liquid rubbers based on nitrile rubber or polyether polyol polyurethane derivatives, core-shell polymers, and similar systems known to those skilled in the art.

[0082] Equally suitable expandable materials are one-component polyurethane compositions containing a foaming agent, which are composed of a crystalline polyester containing OH groups, mixed with other polyols, preferably polyether polyols, and polyisocyanates with terminal isocyanate groups. The melting point of the crystalline polyester should be ≥50°C. The isocyanate groups of the polyisocyanate can be terminally capped, for example, with nucleophiles such as caprolactam, phenol, or benzoxone. Furthermore, terminally capped polyisocyanates, for example, are used in powder coating technology and are available from Degussa GmbH, Germany, for example, under the trade name... BF 1350 and Commercially available capped polyisocyanates such as BF 1540 are also suitable. So-called encapsulated or surface-deactivated polyisocyanates, known to those skilled in the art and described, for example, in EP 0 204 970, are also used as isocyanates.

[0083] In addition, two-component epoxy / polyurethane compositions containing a foaming agent, such as those described in WO 2005 / 080524 A1, are also suitable as expandable materials.

[0084] In addition, ethylene vinyl acetate compositions containing foaming agents are also suitable as expandable materials.

[0085] Similarly suitable expandable materials, such as those marketed under the trade name, are also suitable. 240. 250 or 255 is sold by Sika, Inc. of the United States and described in US 5,266,133 and US 5,373,027. This expandable material is particularly preferred for the present invention.

[0086] Preferred expandable materials with reinforcing properties, such as those from Sika Corporation of the United States under the trade name... The material sold under 941. This material is described in US 6,387,470.

[0087] In one exemplary embodiment, the expandable material has an expansion rate of 800% to 5000%, preferably 1000% to 4000%, and more preferably 1500% to 3000%. The advantage of an expandable material with such an expansion rate is that it allows for reliable sealing or insulation of structural elements relative to liquids and sound.

[0088] In one exemplary embodiment, the expandable material is configured as a temperature-inducing material.

[0089] This has the following advantages: a furnace can be used to bake the impregnation liquid, causing the expandable material to expand and thereby insulate the cavity. Therefore, no additional working steps are required.

[0090] The carrier can be made of any material. Preferred materials are plastics, especially polyurethane, polyamide, polyester, and polyolefin; preferably high-temperature resistant polymers such as polyphenylene ether, polysulfone, or polyethersulfone, which are also foamed; metals, especially aluminum and steel; or grown organic materials, especially wood or other (pressed) fibrous materials or glassy or ceramic materials; especially such foamed materials; or any combination of these materials. Polyamides, especially polyamide 6, polyamide 6,6, polyamide 11, polyamide 12, or mixtures thereof, are particularly preferred.

[0091] Furthermore, the carrier can be, for example, solid, hollow, foamed, or have a grid-like structure. The surface of the carrier can typically be smooth, rough, or structured.

[0092] In the case of an insulating element where the expandable material is located on a carrier, the manufacturing method varies depending on whether the carrier is made of a material that can be injection molded. If so, a two-component injection molding method is typically used. First, the first component, in this case, is injected. After the first component has cured, the cavity in the mold is enlarged or adjusted, or the manufactured injection preform is placed into a new mold, and the second component, in this case, the expandable material, is injected onto the first component using a second injection unit.

[0093] If the carrier is made of a material that cannot be manufactured by injection molding, such as metal, then the carrier is placed in a suitable mold and the expandable material is injected onto the carrier. Of course, there is also the possibility of fixing the expandable material onto the carrier using special fixing devices or methods.

[0094] In addition, the carrier can also be manufactured by other methods, such as extrusion.

[0095] The insulating elements have a stacking height that corresponds to the additional height of the stack with the insulating elements along the stacking direction, which is increased when another insulating element is stacked on top of the stack.

[0096] In one exemplary embodiment, the stacking height of the insulating elements is at most 80%, preferably at most 70%, preferably at most 60%, preferably at most 50%, preferably at most 40%, and preferably at most 30% of the total height of the individual insulating elements along the stacking direction.

[0097] This has the following advantages: it allows for more space-efficient placement of insulating elements within a single stack. Furthermore, the increased stability of the entire stack is achieved through stronger vertical nesting of adjacent insulating elements within the stack.

[0098] Furthermore, the task mentioned at the beginning is solved by a system having multiple such insulating elements, which are stacked one on top of the other.

[0099] In one exemplary embodiment, the system includes at least 10, at least 15, at least 20, at least 25, or at least 30 stacked insulating elements.

[0100] In another exemplary embodiment, the system includes up to 150, up to 120, up to 100, up to 80, or up to 60 stacked insulating elements.

[0101] In one exemplary embodiment, the bottom insulating element of the stack rests flat on the base element.

[0102] The advantage of setting up this base element is that it allows insulating components to be stacked on the surface. Furthermore, this base element can be used in automated processes.

[0103] In one exemplary embodiment, each additional insulating element increases the stack height by up to 20 mm, particularly preferably up to 18 mm, particularly preferably up to 16 mm, particularly preferably up to 14 mm, particularly preferably up to 12 mm, and particularly preferably up to 10 mm.

[0104] The close stacking of insulating elements has the advantage of enabling more efficient packaging of the insulating elements.

[0105] In one exemplary embodiment, the stacking height of a single insulating element is at most 80%, preferably at most 70%, preferably at most 60%, preferably at most 50%, preferably at most 40%, and preferably at most 30% of the total height of the single insulating element along the stacking direction.

[0106] The close stacking of insulating elements also has the advantage of enabling more efficient packaging of the insulating elements.

[0107] In one exemplary embodiment, the stacking height of an insulating element is at most 80%, preferably at most 70%, preferably at most 60%, and preferably at most 50% of the cap height.

[0108] Furthermore, the task mentioned at the beginning is also solved by a method for mounting insulating elements onto structural elements in a motor vehicle, the method comprising the steps of: providing a system having stacked insulating elements according to the above description; manipulating the insulating elements by means of an application robot, at least one cap serving as a positioning aid for the application robot.

[0109] In one exemplary implementation, the application robot is simultaneously loaded with multiple systems.

[0110] In one exemplary embodiment, the individual insulating elements are extracted by a robotic arm.

[0111] In one exemplary embodiment, during manipulation, the gripper of the applied robot grips the insulating element at the cap.

[0112] In one exemplary embodiment, the insulating element has at least two caps, and the two caps serve as positioning aids during manipulation. Attached Figure Description

[0113] The details and advantages of the present invention are described below with reference to embodiments and schematic diagrams, the figures of which are as follows:

[0114] Figure 1 An exemplary illustration of the vehicle body is shown;

[0115] Figure 2a and 2b A schematic diagram of an exemplary insulating element is shown;

[0116] Figure 3a and 3b A schematic diagram showing an exemplary cap;

[0117] Figures 4a to 4c A schematic diagram showing an exemplary stack of insulating elements;

[0118] Figure 5 A schematic diagram showing an exemplary stack with two insulating elements; and

[0119] Figure 6a and 6b A schematic diagram of an exemplary insulating element is shown. Detailed Implementation

[0120] Figure 2a and 2bAn exemplary insulating element 16 is schematically illustrated. The insulating element 16 includes a carrier 11 and an expandable material 13 disposed on the carrier. The carrier 11 has an upper side 17 and a lower side 18. Furthermore, the carrier 11 has two caps 6, which in this embodiment have different profiles. One cap 6 has a circular profile, and the other cap 6 has an elliptical profile. Additionally, the insulating element 16 includes spacer elements 4 and fixing elements 3 for pre-fixing the insulating element 16 in a structural element.

[0121] exist Figure 3a and 3b The cap 6 is shown exemplarily in cross-sectional view. Figure 3a The sidewall 22 of the middle cap 6 protrudes only from the lower side surface 18 of the carrier 11, and... Figure 3b The side wall 22 of the middle cap 6 protrudes not only from the lower side 18 of the carrier 11, but also from the upper side 17.

[0122] The cap portion 6 has a cap width 8 measured on its open side 23 and perpendicular to the stacking direction. Additionally, the cap portion 6 has a cap height 7 measured along the stacking direction. Furthermore, the cap portion 6 has a cap cavity 24 and a cap top 21.

[0123] Figures 4a to 4c Partial views of the stack formed by the two insulating elements 16 are shown respectively.

[0124] exist Figure 4a The stacking direction is marked 19. Additionally, the height 20 of the insulating element 16 and the stacking height 15 of the insulating element 16 are shown.

[0125] exist Figure 4b In this structure, the insulating element 16 has a stop 9 on the outer side of the cap wall 22. The stop 9 is constructed and arranged such that the insulating element 16 rests against these stops 9 respectively during stacking.

[0126] Figure 4c An alternative implementation variation is shown, wherein the stop 9 is disposed on the inside of the cap wall 22. The stop 9 is further constructed and disposed such that the insulating element 16 rests abutting vertically at these stops 9 respectively during stacking.

[0127] Figure 5 A stack 1 formed by two insulating elements 16 is shown. In this embodiment, each insulating element 16 has a step 5. In the stacked state, adjacent insulating elements 16 are nested within each other, and this nesting exists in the areas of the step 5, the cap 6, the spacer element 4, and the fixing element 3.

[0128] Furthermore, the insulating element 16 is constructed such that when it is placed on a flat surface, the insulating element 16 is positioned such that the main plane of the carrier 11 is substantially parallel to the flat surface. The steps 5 and the cap 6 of the carrier 11 are constructed such that the cap 6, together with the steps 5, forms a support surface that is parallel to the plane of the upper or lower side of the carrier 11.

[0129] at last, Figure 6a and 6b Two different embodiments relating to the contact position of the insulating element 16 are illustrated schematically.

[0130] According to Figure 6a In the example, the insulating element 16 has three caps 6, which serve as three contact points.

[0131] According to Figure 6b In the example, the insulating element 16 has a cap 6, which serves as one of the three contact positions. Additionally, the insulating element 16 has two further contact positions in the region of the fixing element 3, where in this embodiment the base 2 of the fixing element 3 is configured as a contact position.

[0132] List of reference numerals

[0133] 1. Stacking

[0134] 2. Base of the fixing element

[0135] 3. Fixing elements

[0136] 4. Spacer element

[0137] 5 steps

[0138] 6. Hat section

[0139] 7. Hat height

[0140] 8. Hat width

[0141] 9. Stopping components

[0142] 10 body

[0143] 11 carriers

[0144] 12 structural components

[0145] 13 Expandable materials

[0146] 14 structural components

[0147] 15. Stacking height of insulating components

[0148] 16 insulating elements

[0149] 17 Upper side

[0150] 18 Lower side

[0151] 19 Stacking direction

[0152] 20 Height of insulating element

[0153] 21. Top of the hat

[0154] 22 cap wall

[0155] 23 Open side of the cap

[0156] 24. Cap cavity

Claims

1. An insulating element (16) for insulating structural elements (12, 14) in a motor vehicle, the insulating element (16) comprising: Carrier (11); and An expandable material (13) is placed on the carrier (11). The carrier (11) is characterized in that it has at least one cap (6) and is configured such that when multiple identical insulating elements (16) are stacked, the caps (6) of adjacent insulating elements (16) are nested together, such that the insulating elements are mechanically fixed to prevent lateral movement. The cap (6) has a hollow interior and an open side. The cap (6) has a cubic or cylindrical shape or a substantially trapezoidal cross section and is designed to be used as a positioning aid for applying a robot.

2. The insulating element (16) according to claim 1, wherein, The insulating element (16) has an upper side (17) and a lower side (18) which are oriented substantially in the plane of the cross section to be insulated of the structural element (12, 14) in the use state, and the open side of the cap (6) and / or the top of the cap (6) are oriented substantially parallel to the upper side (17) or the lower side (18) of the insulating element (16).

3. The insulating element (16) according to claim 2, wherein, The sidewall of the cap (6) protrudes only from the lower side (18) in the stacking direction (19), or the sidewall of the cap (6) protrudes only from the upper side (17) in the stacking direction (19), or the sidewall of the cap (6) protrudes from both the lower side (18) and the upper side (17) in the stacking direction (19).

4. The insulating element (16) according to claim 2 or 3, wherein, A step (5) and at least one cap (6) of the carrier (11) are configured such that the cap (6) together with the step (5) form a support surface parallel to the plane of the upper side (17) or lower side (18) of the carrier (11).

5. The insulating element (16) according to any one of claims 1 to 3, wherein, The cap (6) has a base that is substantially circular, elliptical or oval.

6. The insulating element (16) according to any one of claims 1 to 3, wherein, The carrier (11) has at least two caps (6).

7. The insulating element (16) according to claim 6, wherein, The two caps (6) have different outlines.

8. The insulating element (16) according to any one of claims 1 to 3, wherein, The stack height (15) is at most 50% of the height (20) of an insulating element (16), and / or the stack height (15) is at most 80% of the cap height (7).

9. The insulating element (16) according to any one of claims 1 to 3, wherein, The cap (6) is configured such that when multiple identical insulating elements (16) are stacked, the caps (6) of adjacent insulating elements (16) are respectively positioned vertically.

10. The insulating element (16) according to claim 9, wherein, The cap (6) has a stop that is defined at the support portion when stacked.

11. The insulating element (16) according to any one of claims 1 to 3, wherein, The insulating element (16) has at least three contact positions through which adjacent insulating elements (16) are stacked and placed vertically, and the cap (6) forms at least one of these contact positions.

12. A system (1) having a plurality of insulating elements (16) according to any one of claims 1 to 11, wherein, The insulating elements (16) are stacked one on top of the other.

13. The system (1) according to claim 12, wherein, The system (1) includes at least 10 stacked insulating elements (16), and / or the bottommost insulating element (16) of the system (1) is laid flat on the base element (2), and / or the stack height (15) is at most 80% of the cap height (7).

14. A method for mounting an insulating element (16) onto a structural element (12, 14) in a motor vehicle, the method comprising the steps of: Provide a system (1) according to claim 12 or 13, the system having a plurality of stacked insulating elements (16). With the aid of the application robot to manipulate the insulating element (16), at least one cap (6) serves as a positioning aid for the application robot.

15. The method according to claim 14, wherein, During manipulation, the gripper of the application robot grips the insulating element at the cap (6), and / or the insulating element (16) has at least two caps (6), and these two caps (6) serve as positioning aids during manipulation.

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