Front wall insulation designed as a molded part for installation in a motor vehicle

Abstract

A bulkhead insulation (100) made of sound-absorbing material for installation in a motor vehicle, which is designed as a molded part with a spatial shape adapted to the geometric dimensions at the installation location, comprising a central component region (110) for covering the bulkhead and two lateral component regions (120) projecting therefrom for covering the right A-pillar and the left A-pillar, characterized in that the lateral component regions (120) are foldable relative to the central component region (110) and can be folded from a basic position into a transport position and then, upon installation in the motor vehicle, folded back into their intended basic position corresponding to the spatial shape, wherein at least one incision (130) is formed in the sound-absorbing material in each of the lateral component regions (120).which is a complete separating cut made transversely to the front surface (102) and rear surface (101) of the bulkhead insulation (100), which extends in the respective lateral component region (120) from an outer edge over a certain length into the bulkhead insulation (100) and which widens when folded over and closes again when folded back, and wherein on the rear surface (101) of the bulkhead insulation (100) on both sides of the respective incision (130) there are raised portions (140) made of foam material, which can be pressed into vehicle-side assembly openings during installation and provide fastening in the region of the incision (130), and wherein the at least one incision (130) between the front surface (102) and rear surface (101) of the bulkhead insulation (100) runs obliquely and is produced by water jet cutting.

Description

The invention relates to an end wall insulation, designed as a shaped part, made of sound-absorbing material for installation in a motor vehicle, according to the preamble of claim 1.DE 10 2007 032 728 A1 describes an insulation arrangement in a motor vehicle having an insulation element, in particular a sound-insulating molded part, which has at least two layers, of which at least one is designed as an insulation layer and one as a load-bearing layer. These insulation arrangements can be provided at a wide variety of locations of a motor vehicle.DE 20 2004 008 165 U1 describes a sound-insulating component for motor vehicles, for example in the form of a front wall cladding or transmission tunnel cladding, which is formed from at least one plastic molded part made of thermoplastic elastomer. The molded part is adapted to the geometric dimensions at the installation location, e.g. the contour of the end wall, as exactly as required.The closest DE 39 09 389 A1 describes sound insulation for the interior of a vehicle, which can be designed as an end wall insulation.With respect to the prior art, reference is also made to U.S. Pat. No. 6,575,527 B1, U.S. Pat. No. 4,131,702 A, U.S. Pat. No. 2004 / 0 229 019 A1, DE 85 20 334 U1 and DE 19 508 968 A1.Such insulating elements or insulating components designed as a molded part frequently have an unfavorable transport volume, in particular when these cannot be stacked or can be stacked only to a limited extent because of their spatial shape (3D geometry). Furthermore, despite their flexible deformability, such insulating components are sometimes difficult to install, in particular when they are relatively large-area and thus also heavy and / or the installation location in the motor vehicle is poorly accessible.The invention now provides an insulation component, namely an end wall insulation, corresponding to the features of claim 1, which on the one hand has a favorable transport volume and which on the other hand is simple to install. Advantageous embodiments and developments of the insulating component according to the invention are evident from the dependent patent claims, the following description of the invention and the drawing. With the subordinate patent claim, the invention also extends to a motor vehicle, in particular a passenger car, which has at least one insulation component according to the invention, wherein this is in particular an end wall insulation.The insulation component (motor vehicle insulation component) or insulation element (motor vehicle insulation element) according to the invention for installation in a motor vehicle or a vehicle body is manufactured as an end wall insulation from sound-absorbing material and is designed as a molded part with a three-dimensional shape which is adapted to the geometric dimensions at the installation location (of the motor vehicle). This insulating component has a first (structural) component region and at least one second (structural) component region protruding or protruding therefrom. According to the invention, the second component region is foldable relative to the first component region and can be folded or folded (from a basic position) into a transport position and then, during installation in the motor vehicle, be folded back again into its provided basic or desired position (corresponding to the spatial shape). Furthermore, it is provided that in the second component region at least one incision or parting cut is formed in the sound-absorbing material, which widens during folding over and closes again during folding back.An incision is understood to mean a complete separating cut introduced transversely (i.e. perpendicularly or also obliquely; see below) to the front and rear surfaces, which separating cut extends in the second component region from an outer edge over a specific length into the insulating component, such that the insulating component is not cut through but is only cut into it. The incision is produced by water jet cutting (water jet cutting) and can thus also be referred to as a water jet incision. By means of water jet cutting, particularly in comparison with cutting by knives or laser beams, particularly smooth, deposit-free and combustion- or smoke-free cut surfaces can be produced.According to the invention, it is provided that the incision does not function as a hinge, but rather forms a dividing point or dividing line which expands when the second component region is folded or folded over (this folding or folding over is optionally made possible first by the incision and the expansion of the incision) and which is then closed again when the second component region is folded back, in particular in such a way that the cut surfaces contact one another again along the incision. Adhesive bonding of the cut surfaces is not necessary, but can optionally be provided.By folding or folding over the at least one protruding or protruding second component region, as a result of which the insulating component becomes more or less flatter, a considerable reduction in the transport volume can be achieved. Available transport and storage volumes on pallets, in transport boxes, on loading surfaces of trucks, in storage spaces and the like can be better utilized, resulting in environmental and cost advantages.By folding and folding back, the installation of the insulating component into the motor vehicle is also simplified, in particular if the latter is of large-area design. The insulating component can have an area of at least 0.75 m 2, preferably of at least 1.00 m 2 and in particular of at least 1.25 m 2 by which in particular the area size of the front surface and / or of the rear surface is meant. The rear surface is in particular the component side (rear side) which faces the vehicle part (for example a body panel) to which the insulating component is fastened. Accordingly, the front surface is the other component side (front surface).Elevations (foaming) formed on both sides of the incision made of foam material, in particular plastic foam (e.g. PUR foam), are formed or formed on the rear face (see above) of the insulating component, which elevations are pressed into mounting openings (e.g. bodyshell openings) on the vehicle side during the installation of the insulating component, and as a result bring about fastening and / or stabilization of the insulating component in the region of the incision and in particular also bring about sealing of the mounting openings. Preferably, the elevations are integrally formed on an insulating layer (see below) formed from foam material, in particular plastic foam (e.g. PUR foam). These projections have, for example, a height of 15 mm to 25 mm.According to the invention, it is provided that the incision does not extend perpendicularly between the front surface and the rear surface (see above) of the insulating component, but runs obliquely. This can also be referred to as a diagonal cut. As a result, the cut surfaces are larger and the sound insulation or the acoustic insulation effect is improved.The insulating component preferably has two layers. A layer, in particular the front-side layer, is formed as a support layer or heavy layer and is preferably manufactured from EPDM. The other layer, in particular the rear layer, is designed as an insulating layer, preferably as a foamed insulating layer or foam layer, and is manufactured in particular from plastic foam, e.g. from PUR foam. The insulating layer is preferably produced by back foaming the support layer, it also being possible for the elevations (foaming) described above to be formed or formed on both sides of the incision.According to the invention, the insulating component is a so-called front wall insulation for cladding or covering the inside of a body front wall facing the passenger compartment. The bulkhead insulation according to the invention is formed with a central (first) component region for cladding the bulkhead on the inside or passenger compartment side and two lateral (second) component regions protruding therefrom for cladding the right (lower) A-pillar and left (lower) A-pillar on the inside or passenger compartment side, respectively. The lateral second component regions are foldable with respect to the first central component region, which reduces the transport volume and simplifies the installation and the fastening of the front wall insulation.The invention is explained in more detail below with reference to the drawings. FIG. 1 shows a perspective illustration of an insulating component according to the invention. FIG. 2 shows a top view of the front side of the insulating component from FIG. 1 with folded-over lateral component regions. FIG. 3 illustrates a plurality of insulation components stacked in a transport container with folded-over lateral component regions according to FIG. 2.FIG. 1 shows, in a simplified illustration, an insulation component 100 according to the invention, which is an end wall insulation. The front wall insulation 100 is designed as a more or less unstable shaped part, with a central component region (first component region) 110 which is provided for the inside cladding of a front wall of the vehicle body, and with two lateral component regions (second component regions) 120 which project or project therefrom and are each provided in the foot space region for the inside cladding of the right A pillar and the left A pillar.The front wall insulation 100 has, according to the above explanations, a rear face or rear side 101 and a front face or front side 102. The front wall insulation 100 is made of sound-absorbing material and has two layers, wherein the front layer is formed as a support layer and the rear layer is formed as a foamed insulation layer, as indicated by the dashed line course. The total thickness is, for example. 15 mm to 25 mm.According to the invention, a notch 130 is formed in each of the lateral component regions (second component regions) 120, which extends from the outside into these component regions 120 and runs obliquely to the rear and front surfaces 101, 102. A plurality of such cuts 130 may be formed in each of the side component portions 120. The lateral component regions 120 can be folded starting from the shown basic position (first relative position) into a transport position (second relative position), as illustrated in FIG. 1 by the two arc arrows. The cuts 130 thereby gap or are widened, as illustrated in FIG. 2.This folding over or folding in transfers the end wall insulation 100 into a relatively flat state, whereby stacking can be simplified and transport volume present due to the lower stack height can be better utilized, as illustrated in FIG. 3. Reference numeral 200 denotes a transport box or the like. Moreover, the installation in the motor vehicle is simplified. When the lateral component regions 120 are folded back into their basic position, the incisions 130 are closed again, so that the cut surfaces 135 finally touch one another again along the incisions 130 and the insulating function is ensured.On the rear surface of the bulkhead insulation 100, elevations 140 protruding on both sides of the incisions 130 are formed or integrally formed, which are pressed into mounting openings (e.g. bodyshell openings) on the vehicle side during the installation of the bulkhead insulation 100, and as a result bring about local fastening and / or stabilization of the bulkhead insulation 100 in the region of the incisions 130.

Claims

Front wall insulation (100) made of sound-absorbing material for installation in a motor vehicle, which is designed as a shaped part with a three-dimensional shape adapted to the geometric dimensions at the installation location, with a central component region (110) for cladding the front wall and two lateral component regions (120) protruding therefrom for cladding the right A-pillar and the left A-pillar, characterized in that the lateral component regions (120) can be folded relative to the central component region (110) and can be folded over from a basic position into a transport position and then, during installation in the motor vehicle, can be folded back again into its provided basic position corresponding to the three-dimensional shape, wherein in each of the lateral component regions (120) at least one incision (130) is formed in the sound-absorbing material, which incision is a complete cut cut cut introduced transversely to the front surface (102) and rear surface (101) of the front wall insulation (100), which extends in the respective lateral component region (120) from an outer edge over a certain length into the front wall insulation (100) and which expands during folding over and closes again during folding back, and wherein elevations (140) formed from foam material are formed on both sides of the respective incision (130) on the rear surface (101) of the front wall insulation (100), which elevations can be pressed into mounting openings on the vehicle side during installation and bring about fastening in the region of the incision (130), and wherein the at least one incision (130) in each case runs obliquely between the front surface (102) and the rear surface (101) of the front wall insulation (100) and is produced by water jet cutting.Front wall insulation (100) according to Claim 1, characterized in that the lateral component regions (120) are not cut through by the respective incision (130), but are only cut through.The front wall insulation (100) according to claim 1 or 2, characterized in that this front wall insulation (100) has an area of at least 0.75 m 2, preferably of at least 1.00 m 2 and in particular of at least 1.25 m 2.End wall insulation (100) according to one of the preceding claims, characterized in that this end wall insulation (100) has two layers, one of which is designed as a load-bearing layer and one as an insulation layer.Front wall insulation (100) according to claim 4, characterised in that the insulation layer is formed from a foam material and the elevations (140) are integrally formed on this insulation layer.Motor vehicle having an end wall insulation (100) according to one of the preceding claims 1 to 5.

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