INSULATION PANEL, COMPONENT OF A VEHICLE BODY, VEHICLE BODY, VEHICLE AND MANUFACTURING PROCESS

Description

[0001] The invention relates to an insulating panel having the features of claim 1. The invention further relates to a component of a vehicle body, a vehicle body, a vehicle and a method for producing an insulating panel.

[0002] In commercial vehicle construction, metal cover plates are typically used to produce insulation panels arranged parallel to one another with a gap between them. A liquid is injected into the gap and foamed to form an insulating layer. The production of foamed insulation panels is complex and costly, as the foam must displace the air contained in the gap and fill it. Furthermore, there are restrictions regarding the shape and size of the insulation panels produced in this way. Another option for producing insulation panels is glued panels, in which prefabricated insulation layers and cover layers are glued together. Here, too, the shape and size of the insulation panels are subject to restrictions.

[0003] An insulating panel of the type mentioned above with cover layers made of fiber-reinforced plastic materials is known, for example, from WO 99 / 50060 A1, which originates from the applicant. Such insulating panels can be manufactured using a wet-on-wet process, in which glass fiber mats are impregnated with resin and cured. This process is complex and has disadvantages regarding automation. The production of insulating panels with cover layers made of fiber-reinforced plastic materials is improved by the use of the so-called SMC process, which uses a flowable resin mat with isotropic properties and random fiber distribution in the mat plane. The SMC process enables automated production of the insulating panels.

[0004] An example of the use of insulation panels in refrigerated vehicles is shown in DE 10 2013 105 819 A1, which also originates from the applicant. Such commercial vehicles typically include fixtures, such as rail elements, used for load securing or double-decker loading. Connecting these fixtures to insulation panels is problematic because, on the one hand, the fixtures must be mechanically firmly connected to the insulation panels, and, on the other hand, they must have as little impact on the thermal properties of the insulation panels as possible. Furthermore, the automated production of the insulation panels is complicated.

[0005] The invention is based on the object of providing an insulating panel for a vehicle body, in particular a refrigerated vehicle body, that can be easily manufactured and allows for a high degree of automation. The invention is further based on the object of providing a component of a vehicle body, a vehicle body, a vehicle, and a manufacturing method for insulating panels.

[0006] According to the invention, the object is achieved with regard to the insulating panel by the subject matter of claim 1. With regard to the component of a vehicle body, the object is achieved by the subject matter of the independent claim 9, with regard to the vehicle body by the subject matter of the independent claim 10, with regard to the vehicle by the subject matter of the independent claim 11, and with regard to the method for producing an insulating panel by the subject matter of the independent claim 12.

[0007] Specifically, the problem is solved by an insulating panel for a vehicle body, in particular a refrigerated vehicle body, comprising at least one heat-insulating core layer and at least one cover layer made of a fiber-reinforced plastic material. The core layer has at least one recess, which is at least partially filled by the cover layer, so that the cover layer has an increased layer thickness in the region of the recess.

[0008] The invention has several advantages.

[0009] The recess can thus be filled in certain areas by the cover layer. In other words, at least one area of ​​the recess is filled with the cover layer and at least one other area of ​​the recess is not filled with the cover layer. The same applies to several individual areas of the recess. The recess is therefore only partially filled with the cover layer. In the area(s) of the recess not filled by the cover layer, an installation element of the vehicle body can be arranged, which is embedded in the cover layer. The cover layer has an increased layer thickness in some areas of the recess, which surrounds the installation element at least partially or completely. The installation element is thus integrated into the cover layer. This mechanically connects the installation element to the cover layer.

[0010] In contrast to the prior art, the installation element is not placed on the upper side of the cover layer, which is exposed prior to assembly, and connected to it. Instead, the installation element is directly integrated or embedded into the cover layer, which surrounds the installation element and lies directly against the installation element. Since the cover layer is made of a fiber-reinforced plastic material, the integration of the installation element into the cover layer creates a mechanically stable composite that optimally transfers the forces introduced into the installation element into the cover layer. There are practically no restrictions regarding the geometry of the installation element, particularly with regard to the outer contour, because the partial filling of the recess with the cover layer allows it to adapt to the outer contour of the installation element.

[0011] Several installation elements can also be arranged and embedded in a single recess in the manner described above.

[0012] Alternatively, the recess can be completely filled by the cover layer, creating areas with increased stability that can be used, for example, to attach add-on parts to the insulation panel.

[0013] In both cases (fully filled or partially filled recess), the covering layer passes continuously, i.e. monolithically, from the area of ​​the recess to the areas outside the recess, i.e. to the areas of the insulating panel immediately adjacent to the recess.

[0014] Furthermore, the insulating panel according to the invention has the advantage that built-in parts and / or add-on parts can be connected to the insulating panel in an automated manufacturing process.

[0015] For the production of such insulation panels, reference is made to the manufacturing process described in this application and claimed in claim 12. In contrast to the previously mentioned known processes, the cover layer made of fiber-reinforced plastic material is sprayed onto the core layer and then pressed onto it. This process allows for the local adjustment of different layer thicknesses of the cover layer. For this purpose, a larger amount of material is sprayed onto the area of ​​the recess formed in the core layer than into the adjacent area of ​​the recess, where a thinner layer thickness is desired compared to the recess.

[0016] The manufacturing process is therefore highly flexible and suitable for virtually any type of installation element, at least for those commonly used in commercial vehicle construction, such as floor rails or hinge elements for rear doors or other installation elements. The manufacturing process also allows for the formation of stabilizing elements in the insulation panel, as described in detail elsewhere.

[0017] The invention proposes an insulating panel which advantageously has at least one local functional area. The functional area is characterized in that the heat-insulating core layer and the cover layer are correspondingly profiled, wherein the core layer has a recess and the cover layer has a correspondingly counter-profiled inner side, which is achieved by the increased layer thickness of the cover layer in the region of the recess. The local functional area, i.e. geometrically limited to a partial area of ​​the insulating panel, enables further, in particular mechanical, functions in addition to the heat-insulating function of the insulating panel. The mechanical functions can, for example, improve the stability of the insulating panel or the connection of built-in components or attachments.

[0018] The inventive method for producing the insulation panel described above comprises the following steps. First, a core layer made of at least one heat-insulating, in particular foamed, material is provided, wherein the core layer has at least one recess. The core layer including the recess is sprayed with a fiber-reinforced, in particular glass-fiber-reinforced, plastic material, so that a cover layer is formed on the core layer including the recess. The core layer is pressed onto the cover layer to fill the recess with the fiber-reinforced plastic material and to form a flat or smooth outer surface of the cover layer.

[0019] The method according to the invention has the advantage of shortening production times. The spraying of the cover layer onto the core layer can be carried out using robots, similar to the painting of body parts in automobile construction. The production of the insulating panels is therefore easily automated. The method according to the invention is flexible because the spraying of the fiber-reinforced plastic material enables the production of insulating panels with complex geometries. For example, reinforcements, ribs, connecting devices, indentations, inserts, and the like can be produced using the sprayed-on plastic material in conjunction with a correspondingly profiled core layer. The method allows the formation of different regions in one and the same insulating panel, so that the aforementioned local functional regions, or at least one local functional region, can be manufactured with minimal effort.

[0020] The insulation panels can be manufactured with great precision. Furthermore, it has been demonstrated that the bond between the cover layer and the core layer is very good. Furthermore, the insulation panels produced according to the invention are lighter than conventional panels with metal cover layers. This advantage plays a particularly important role in commercial vehicle construction. The insulation panels produced using the process according to the invention are robust, impact-resistant, and exhibit high strength, thus preventing or at least reducing hail damage, for example.

[0021] Compared to known manufacturing methods, the manufacturing method according to the invention is cost-effective both in terms of the manufacturing process and in terms of material costs. The fiber-reinforced plastic materials used in the process according to the invention allow for minimal linear expansion under temperature fluctuations, which is particularly advantageous for refrigerated vehicle bodies. The plastic materials are corrosion-resistant, colorable, electrically non-conductive, acid- and alkali-resistant, and easy to machine. Furthermore, the insulation panels produced according to the invention are lightweight and, as such, buoyant.

[0022] Both the insulating panel according to the invention and the manufacturing method according to the invention comprise the possible embodiment of a core layer with a single cover layer made of a sprayed-on and pressed fiber-reinforced plastic material. Particularly preferred are insulating panels or manufacturing methods in which at least two parallel cover layers made of fiber-reinforced plastic materials are sprayed and pressed onto the core layer to form a sandwich structure. The parallel cover layers form the inner and outer sides of the insulating panel, which in a vehicle, in particular a refrigerated vehicle, on the one hand delimits the loading space and on the other hand forms the outer wall of the vehicle. Particularly preferred are insulating panels or manufacturing methods in which the core layer is surrounded on all sides by the fiber-reinforced plastic material, so that the cover layers completely encapsulate the core layer.

[0023] In an alternative variant of the manufacturing process, it is conceivable that, before or after the core layer is provided, a first opposing side, in particular a bottom-mounted opposing side, of a press is sprayed with a release agent. The first opposing side of the press is then sprayed with the fiber-reinforced plastic material to form a first cover layer. Subsequently, the core layer is placed with a first side, in particular a bottom side, onto the sprayed-on fiber-reinforced plastic material of the first opposing side of the press.

[0024] In a further step of this variant, a second side, in particular a top side, of the applied core layer is sprayed with the fiber-reinforced plastic material to form a second cover layer. Furthermore, a second opposing side, in particular an opposing side located at the top, of the press is sprayed with a release agent. The spraying of the second opposing side with the release agent can take place independently of the other aforementioned process steps. Subsequently, the core layer is pressed onto the cover layers by the press. During the pressing process, a flat or smooth outer surface of the cover layer can be formed.

[0025] Preferred embodiments of the insulating panel according to the invention or of the manufacturing method according to the invention are specified in the subclaims.

[0026] In the insulating panel according to the invention, the cover layer can preferably have an outer side that is flat or smooth at least in the region of the recess. This makes it possible to create a flat or smooth structure over the entire surface of the insulating panel, i.e. also in the region of the recess. In this exemplary embodiment, regions of the cover layer are formed that have different thicknesses, but at the same time form a flat and uniform visible surface overall. For this purpose, the profiling takes place inside the insulating panel, namely through the recess or recesses formed in the core layer according to the invention. In the regions of the insulating panel where an increased layer thickness is desired, the core layer is removed, for example, by milling. Adjacent to the recess or recesses, the core layer is raised, so that a cover layer with a thinner layer thickness is formed there than in the region of the recess.The flat or smooth cover layer, at least in the area of ​​the recess, creates a flat visible surface. This flat visible surface can form the entire insulation panel. The reinforced areas of the insulation panel are directed inward, toward the interior of the insulation panel.

[0027] The outer side of the cover layer is the side of the cover layer facing away from the core layer. The outer side of the cover layer can therefore form either the inner side of the insulation panel or the outer side of the insulation panel. In a refrigerated vehicle body, the inner side of the insulation panel defines the interior volume of the cargo space, i.e., the loading space. The outer side of the insulation panel forms the visible wall or outer boundary of the body.

[0028] Preferably, the cover layer outside the recess has a uniform layer thickness, at least in sections. This creates a uniform sandwich structure of the insulation panel, which is specifically modified in the area of ​​the recess by the increased layer thickness. The cover layer transitions continuously, i.e., monolithically, from the area of ​​the recess to the areas outside the recess.

[0029] In another embodiment, the recess is groove-shaped. The cover layer forms at least one reinforcing rib, which engages positively with the groove-like recess of the core layer. This embodiment has the advantage of improving the stability of the composite of the cover layer and core layer in the region of the recess. The reinforcing rib and the groove-like recess can extend essentially perpendicular to the outer surface of the cover layer, thereby achieving particularly good stability.

[0030] In a particularly preferred embodiment of the invention, at least one insert element is arranged in the recess. This has the advantage that the insert element can be integrated into the cover layer.

[0031] For this purpose, for example, a gap can be formed between the insert element and an edge of the recess, which gap is filled with the fiber-reinforced plastic material of the cover layer. The plastic material of the cover layer in the gap is firmly bonded to the cover layer. The insert element and the cover layer thus form a firmly connected body that is arranged in the recess of the core layer. This improves the mechanical connection between the insert element and the insulation panel.

[0032] Additionally or alternatively, the insert element can have at least one recess filled with the plastic material of the cover layer. The plastic material of the cover layer in the recess is firmly bonded to the cover layer in such a way that the cover layer secures the insert element in a form-fitting manner. Here, too, the advantage of a good mechanical connection between the insert element and the insulation panel is achieved by integrating or embedding the insert element directly into the cover layer. For this purpose, the recess formed in the insert element is filled with the plastic material of the cover layer.

[0033] The recess in the insert element is preferably formed by at least one through-opening in the insert element and / or by at least one edge-side shoulder in the insert element, whereby a particularly good form fit is achieved between the plastic material of the cover layer or generally the cover layer and the insert element.

[0034] In the process according to the invention, the gap or recess is filled with the plastic material of the cover layer by spraying and pressing the fiber-reinforced plastic material.

[0035] In a further preferred embodiment, the insert element is designed as a reinforcement plate for attaching add-on components to the insulation panel and / or for increasing the stability of the insulation panel. This creates further possibilities for adapting the mechanical functions of the insulation panel to the specific requirements of the vehicle body, for example, with regard to load securing.

[0036] Alarm wires are preferably arranged between the core layer and the cover layer and / or within the cover layer. This embodiment is an example of how the functionality of the insulating panel can be expanded without requiring particularly complex manufacturing measures.

[0037] An outer layer can be applied to the cover layer, particularly on the outer side of the cover layer, forming a visible surface. The cover layer made of fiber-reinforced plastic material does not necessarily have to be the final layer of the sandwich structure. It is possible for the cover layer to be bonded to at least one other layer or outer layer. The outer layer can be formed, for example, by a film, a coating, or a paint finish.

[0038] The core layer is preferably made of a foam material. Conventional heat-insulating foam materials are suitable for this purpose.

[0039] The core layer can be composed of several heat-insulating core layer elements, each with similar or different thermal insulation properties. This allows the insulation panel to be even better adapted to the specific requirements of the vehicle body, particularly with regard to thermal properties.

[0040] Within the scope of the invention, a component of a vehicle body, in particular a refrigerated vehicle body, is disclosed and claimed, which has at least one insulating panel according to the invention. Particularly preferably, the entire component is composed of one or more insulating panels according to the invention. Possible components include, for example, a side wall, i.e. the longitudinal wall extending in the direction of travel of the vehicle body, and / or a front wall and / or a ceiling and / or a floor and / or one or both rear doors of the vehicle body. The components of the vehicle body form external parts of the vehicle body insofar as they thermally insulate the loading interior from the environment.

[0041] Within the scope of the invention, a vehicle body, in particular a refrigerated vehicle body, with at least one insulating panel according to the invention is further disclosed and claimed. It is possible for the vehicle body to be constructed partially or entirely from insulating panels according to the invention.

[0042] The vehicle with an insulating panel according to the invention can be, for example, a refrigerated vehicle, in particular a semi-trailer designed as a refrigerated vehicle (refrigerated trailer).

[0043] In a preferred embodiment of the manufacturing method according to the invention, the work steps according to claim 12 can be repeated for several side surfaces of the core layer. This leads to increased stabilization of the insulation panels. At least two opposite, parallel side surfaces of the core layer can be coated and then pressed. It is also possible for all side surfaces of the core layer to be coated and pressed. The core layer is then completely encapsulated by the cover layer(s).

[0044] In a particularly preferred embodiment of the manufacturing method according to the invention, at least one insert element is inserted into the recess before spraying the core layer. The insert element has at least one recess, wherein the fiber-reinforced plastic material fills the recess when the core layer is pressed together with the cover layer. This achieves the above-described embedding of the insert element in the cover layer. The invention is explained in more detail below using exemplary embodiments with reference to the attached schematic drawings.

[0045] In these show Fig. 1 shows a partial section through an insulating panel according to an embodiment of the invention in the region of a recess in the core layer; Fig. 2 shows a cross section through the insulating panel according to Fig. 1 , which is connected to an attachment; Fig. 3 a partial section through an insulating panel according to a further embodiment of the invention in the region of the recess in the core layer; Fig. 4 a cross-section through an insulating panel according to a further embodiment of the invention with a locking rod arranged in the core layer; Fig. 5 a cross-section through an insulating panel according to a further embodiment of the invention with several recesses that are completely filled by the plastic material of the cover layer; Fig. 6 a partial section through an insulating panel according to a further embodiment of the invention in the region of a corner stanchion; Fig. 7 a partial section through an insulating panel according to a further embodiment of the invention in the region of a recess with a multi-profiled insert and reinforcing elements;Fig. 8 shows a partial section through an insulating panel according to a further embodiment of the invention in the region of a completely filled recess; Fig. 9 shows a partial section through an insulating panel according to a further embodiment of the invention with groove-like recesses; and Fig. 10 shows a partial section through an insulating panel according to a further embodiment of the invention with stabilizing recesses.

[0046] The inventive method for producing insulation panels is based on a process developed by the Fraunhofer Institute, known as PUR Fiber Composite Spraying (FCS). This process is well-known and has been used in the past to manufacture plastic components.

[0047] The method according to an exemplary embodiment of the invention comprises at least two steps. In the first step, the fiber-reinforced plastic material is sprayed onto a core layer 10. In the second step, the fiber-reinforced plastic material and the core layer 10 are pressed together to form a composite consisting of a cover layer 11 or cover layer made of a fiber-reinforced plastic material and the core layer 10. The cover layer 11 or the cover layers 11 are sprayed onto the core layer 10 and pressed flat with a press. The spraying and smooth pressing processes open up new possibilities for the production of insulation panels.

[0048] The insulation panel, for example, is a thermal insulation board that is primarily used in refrigerated vehicle construction to create a vehicle body. Other applications are possible.

[0049] A profiled, plate-shaped core layer is used as the core layer 10, which has at least one, in particular several, recesses 13 locally for the desired functionality. Depressions in the core layer, which are created, for example, by material removal, such as milling, or otherwise, form the recesses 13. The shape of the recesses 13 is described in more detail using exemplary embodiments of the various insulating panels. Within the scope of the invention, the recess 13 is at least partially filled by the cover layer 11, so that the cover layer 11 has an increased layer thickness in the region of the recess 13. The cover layer 11 is thus locally reinforced inwards relative to the insulating panel. This allows forces to be optimally introduced into and dissipated from the insulating panel.

[0050] The cover layer 11 can be formed on one side, two sides, or multiple sides of the core layer 10. The cover layer 11 can completely enclose or encapsulate the core layer 10.

[0051] The core layer 10 can be prepared for spraying in a pre-assembly step. For example, the core layer 10 can be bonded to a textile reinforcement layer. The textile reinforcement layer can be arranged, for example, on both sides of the core layer. The textile reinforcement layer adheres to the profile of the core layer 10, in particular the at least one recess 13, and thus reproduces this profile.

[0052] The cover layer 11 can therefore be sprayed either directly onto the core layer 10, i.e., without an intermediate layer, or with an intermediate layer, for example, with a textile reinforcement layer. This embodiment is disclosed and claimed both in connection with the method and in connection with the insulating panel according to the invention or the exemplary embodiments of the insulating panel according to the invention.

[0053] When spraying the fiber-reinforced plastic material, on the one hand, liquid plastic material, for example, polyurethane, and on the other hand, chopped fibers, for example, chopped glass fibers, are fed into a multi-component spray head. Other materials are possible. An example of a multi-component spray head suitable for the process according to the invention and the process used in the following exemplary embodiments is described, for example, in WO 2010 / 100045 A1.

[0054] This multi-component spray head features a Venturi nozzle that, during operation, draws in the cut glass fibers and feeds them into the liquid plastic material in the spray head. This occurs via a Y-tube, which serves to feed the fibers into a spray jet of liquid plastic material as coaxially as possible. This results in the fibers mixing with the liquid plastic material, which exits the spray head and is sprayed onto a substrate, specifically the core layer of the insulation panel to be produced. For further details of the multi-component spray head, please refer to the aforementioned WO 2010 / 100045 A1.

[0055] Other spray heads are possible.

[0056] The device for carrying out this process comprises a plastic high-pressure system, in particular a polyurethane high-pressure system, with a metering device connected to the multi-component spray head. The multi-component spray head is further connected to a cutting unit, to which glass rovings are fed. The fibers are cut to the desired length in the cutting unit. The cutting unit and the multi-component spray head are mounted on a robot arm, enabling automated coating or spraying of the fiber-reinforced plastic material onto the core layer. The various process parameters, such as the amount of plastic material, the feed rate of the multi-component spray head, the track spacing, etc., can be adjusted in a conventional manner by means of a control system.

[0057] The device for carrying out the method also includes a press suitable for processing insulation panels of the desired size. The press has a mold into which the composite of sprayed-on fiber-reinforced plastic material and core layer is placed. By closing the mold, the plastic material disposed therein is pressed onto the core layer.

[0058] The invention is not limited to the device described above.

[0059] In the following, various embodiments are explained in more detail with reference to the attached drawings, which are produced or can be produced on the basis of the method described above.

[0060] The insulation panel is essentially plate-shaped and accordingly has two main surfaces that are spaced apart from one another and arranged essentially parallel to one another. The edge surfaces of the insulation panel are formed between the main surfaces and surround the panel on its circumference. The main surfaces are each larger than the edge surfaces. The insulation panel can be cuboid-shaped, with the main surfaces being flat and arranged parallel to one another. Other geometries of the insulation panel are possible. The insulation panel does not necessarily have to be cuboid-shaped, but can be adapted to the requirements of, for example, refrigerated vehicle construction.

[0061] The insulating panel serves primarily as a heat-insulating wall element and / or as a heat-insulating floor element and / or as a heat-insulating ceiling element and / or as a heat-insulating door element.

[0062] The insulation panels in the Fig. 1-10 are characterized in that the heat-insulating core layer 10 has at least one recess 13. The recess 13 is at least partially filled by the cover layer 11, so that the cover layer 11 has an increased layer thickness in the region of the recess 13.

[0063] This opens up a variety of design options, as the reinforced top layer 11 allows forces to be optimally transmitted and dissipated into the insulation panel. For example, stable installation of built-in elements and attachments, such as inserts, threaded sleeves, threads, etc., is possible. In the area of ​​anchor rails and tier rails, the walls of the vehicle body can be reinforced with appropriately designed insulation panels. The side walls of the vehicle body can be specifically reinforced to better withstand the increased loads during loading, forklift operation, abrasion, etc.

[0064] In the roof area, elongated reinforcement areas of the insulation panels are possible, preferably transverse to the direction of travel, which can be used for mounting the evaporator in refrigerated vehicles and for dissipating the weight forces of the evaporator into the side walls.

[0065] In the embodiment according to Fig. 1, 2 an insert element 16 is integrated into the core layer 10 as a component of the cover layer 11.

[0066] The insert element 16 is a plate-shaped component whose longitudinal dimension is greater than its transverse dimension. Other shapes are possible.

[0067] The insert element 16 has two oppositely arranged, flat sides, which, in the assembled state, are arranged parallel to the main surfaces of the insulation panel. One of the flat sides of the insert element 16 is arranged essentially in one of the two main surfaces of the insulation panel and is covered by the cover layer 11. Another arrangement is possible. The invention is not limited to the Fig. 1 shown insert element. In general, it is advantageous if the insert element 16 has at least one outer surface that can be arranged flush with one of the main surfaces of the insulating panel.

[0068] To accommodate the insert element 16, the core layer 10 has a recess 13 that forms a depression in the core layer 10. The shape of the recess is adapted, at least in sections, to the shape of the insert element 16.

[0069] The insert element 16 is profiled. Specifically, a gap 18 is formed between the edge 17 of the recess 13 and the insert element 16. In the example according to Fig. 1 the gap 18 extends over a partial length or a partial circumference of the insert element 16. The gap 18 is profiled and has in the example according to Fig. 1 a trapezoidal shape. For this purpose, a corresponding edge-side recess is provided in the insert element 16. It is understood that the invention is not limited to such a gap 18. It is also possible for the gap to be unprofiled, i.e., to have a constant width. The gap can, for example, be formed over the entire circumference of the insert element 16. The constant gap 18 could also be formed over a partial circumference.

[0070] Specifically, the insert element 16 has a gap 18 on each of its two sides, in particular a trapezoidal gap 18. The sides of the insert element 16 can have different profiles.

[0071] In addition to or alternatively to the edge-side recess for forming the gap 18, the insert element 16 has a recess 19 in the form of a through-hole extending perpendicular to the upper side of the insert care element 16. It is possible to incorporate multiple recesses 19 into the insert element 16. The geometry of the recess 19 is not limited.

[0072] As in Fig. 1 As can be clearly seen, the gap 18 and the recess 19 are each filled with the fiber-reinforced plastic material of the cover layer 11. This is also shown in Fig. 2 This anchors the insert element 16 in the insulation panel, specifically by embedding the insert element 16 in the cover layer 11. As shown in Fig. 2 As can be seen, the cover layer 11 transitions continuously from the area of ​​the recess 13 into the adjacent areas, so that the filled areas of the recess 13 are integrally or monolithically connected to the adjacent areas of the cover layer 11 around the recess. This results in a stable bond into which forces can be optimally introduced and dissipated.

[0073] As in Fig. 2 As can be clearly seen, the cover layer 11 forms a uniform surface, both in the area of ​​the recess 13 and in the areas immediately adjacent to the recess 13. This is achieved by the fiber-reinforced plastic material sprayed onto the core layer 10 being pressed flat by the press, resulting in a flat visible surface.

[0074] During smooth pressing, the fiber-reinforced plastic material is also pressed into the gap 18 or generally into the recess 13, so that the gap 18 or the recess 19 is optimally filled with the material of the cover layer 11.

[0075] As in Fig. 2 As can be seen, the fiber-reinforced plastic material is completely pressed through the recess 19 formed as a through-hole 20, so that the cover layers 11 on both sides of the core layer 10 are firmly bonded to one another. This further increases the stability of the composite.

[0076] Fig. 1 further shows that the core material 10 is surrounded by the cover layer 11 in the region of the edge surfaces. The cover layer 11 forms an outer side 14a, which forms the visible surface in the region of the main surfaces. The inner side 14b of the cover layer 11 rests either directly or indirectly against the core layer 10 and is profiled inward in the region of the recess 13 or in the region of the recesses 13, so that an increased layer thickness is formed in the region of the recess 13.

[0077] As in Fig. 2 As shown, the insert element 16 is connected to an attachment part 23. In the example according to Fig. 2 The attachment part 23 is, for example, the hinge of a rear door of a vehicle body, in particular a refrigerated vehicle body. The attachment part 23 is firmly connected to the insert element 16, for example, by a riveted connection, screw connection, or a material-to-material connection. Other attachment parts are possible.

[0078] The arrangement of the insert element 16 in the recess 13 and the positive fixation of the insert element 16 in the cover layer 11 creates, on the one hand, a very flat connection of the attachment to the insulation panel and, on the other hand, a mechanically stable connection. The embodiment according to Fig. 2 therefore enables a space-saving and at the same time fixed arrangement of attachments on insulation panels.

[0079] An alternative to the insert element 16 according to the Figuren 1, 2 is in Fig. 3 shown. It can be seen that the recess 19 is groove-shaped and filled with the material of the cover layer 11. The recess 19 is located in the region of the cutout 13. The material of the cover layer 11 located in the recess 19 forms a positive connection between the core layer 10, the insert element 16, and the cover layer 11.

[0080] A further improvement in stability will be achieved by connecting the groove-shaped recess 19 to a through-opening 20 (dashed line representation) so that the plastic material arranged in the recess 19 can flow through the through-opening 20 when the composite is pressed, so that overall the stability of the insulating panel in the region of the insert element 16 is improved.

[0081] In Fig. 4 is an example showing how flexible the process and the insulation panel are. In the example according to Fig. 4 An insert element 16 is embedded in the core layer 10 together with a rotary rod for the door lock as an attachment 23. The recess 13, in which the rotary rod is arranged, is filled with a heat-insulating material so that the cover layer 11 has a constant layer thickness in this area. The insert elements 16 according to Fig. 1-3 can simply follow the example according to Fig. 4 be combined, for example, to produce a rear door. The fixing of the rotating rod and the embedding of the insert element 16 according to Fig. 1-3 can be done in the same work step. Furthermore, it is possible to at least partially or completely replace the heat-insulating element that fills the recess 13 with the cover layer 11 with the increased layer thickness in order to increase stability in the area of ​​the pivot rod.

[0082] Fig. 5 shows an embodiment of an insulating panel integrated into a side wall of a vehicle body. In this example, the insulating panel has locally reinforced areas that are used to connect the insulating panel to attachments 23. In this example, the functional areas 12 are formed at the lower and upper ends of the insulating panel and extend along the lower and upper edges of the insulating panel, respectively. The recesses 13 are completely filled with the fiber-reinforced plastic material of the cover layer 11 and serve to mechanically reinforce the insulating panel at the desired locations.

[0083] As in Fig. 5 As shown by the lower recess 13, the outer side 14a of the cover layer 11 is flat and forms a smooth visible surface both in the area of ​​the recess 13 and in the adjacent area of ​​the insulating panel. The inner side 14b of the cover layer 11 is profiled inwards in the area of ​​the recess 13 relative to the insulating panel. The inner side 14b extends into the interior of the insulating panel. This is achieved by the recess 13 being completely filled by the material of the cover layer 11 or by the cover layer 11. In other words, the shape and depth of the recess 13 determine the inner profiling of the cover layer 11. In the area of ​​the recess 13, the cover layer 11 thus has a greater layer thickness compared to the adjacent areas of the cover layer 11.

[0084] Another example of an insulating panel according to the invention is shown in Fig. 6 shown, which is similar to Fig. 5 has reinforcement in the area of ​​the corners of the insulation panel. For this purpose, a corresponding recess 13 is formed in the core layer 10, which is completely filled with the fiber-reinforced plastic material of the cover layer 11. The mechanically reinforced insulation panel is connected to an attachment 23, for example, a corner stanchion.

[0085] Another example of an insert element 16 is shown in Fig. 7 shown. The Fig. 7 The section shown runs parallel to the cover layer 11 of the main surface (see Fig. 1 , 3 ). The insert element 16 has a multi-contoured shape and forms a circumferential gap 18 between the edge 17 of the recess 13 and the insert element 16. The gap 18 is profiled and has several widenings, each of which is filled with the fiber-reinforced plastic material of the cover layer 11. The widenings are similar to the example according to Fig. 1 trapezoidal in shape. By filling the gap 18 with the fiber-reinforced plastic material, the insert element 16 is firmly embedded in the cover layer 11. For further stabilization of the Fig. 7 In the composite shown, additional recesses 13 are formed in the core layer 10, which are connected to the gap 18 in a groove-like manner. The groove-shaped recesses 13 are also filled with the fiber-reinforced plastic material of the cover layer 11 and stabilize the area surrounding the insert element 16.

[0086] An example of a functional area 12 with a recess 13, which is completely filled with the fiber-reinforced plastic material of the cover layer 11, is shown in Fig. 8 This particularly clearly shows the contour of the cover layer 11, which has an increased layer thickness in the area of ​​the recess 13 and a reduced layer thickness in the area adjacent to the recess 13. Furthermore, it is clearly visible that the plastic material in the area of ​​the recess 13 merges continuously or monolithically into the adjacent areas of the cover layer 11. The outer side 14a is consistently smooth both in the area of ​​the recess 13 and in the adjacent area of ​​the cover layer 11.

[0087] The inner side 14b of the cover layer 11 shows the inner profile of the cover layer 11, which corresponds to the profile or contour of the recess 13. When filling the recess 13 with the fiber-reinforced plastic material, an increased amount of material is provided by appropriate control of the process parameters, for example the speed of the multi-component spray head, which is dimensioned such that the recess 13 is filled. By pressing the fiber-reinforced plastic material with the core layer 10, it is ensured that, on the one hand, the plastic material completely fills the recess 13 or fills the areas of the recess 13 where this is desired. On the other hand, this creates the smooth outer side 14a, which corresponds to the surface of the press mold.

[0088] Fig. 9 shows an embodiment in which groove-shaped recesses 13 extend perpendicular to the cover layer 11. The recesses 13 are filled with the fiber-reinforced plastic material of the cover layer 11 and form ribs that provide local reinforcement of the insulation panel. Furthermore, the ribs contribute to the secure anchoring of the cover layer 11 to the core layer 10.

[0089] In Fig. 9 It is also evident that the core layer 10 is composed of several elements that are uniformly covered by the cover layer 11. The cover layer 11 thus contributes to the fixation of the elements of the core layer 10.

[0090] Another example of an insulating panel according to the invention is shown in Fig. 10 shown. Here, too, profiled recesses 13 are formed in the core layer 10, which are either filled with an insert element 16 (lower illustration) or completely with the fiber-reinforced plastic material of the cover layer 11.

[0091] The insert element 16 can completely fill the recess 13 or, as described in the context of the invention, be fixed in the recess 13 by the material of the cover layer 11. In the embodiment according to Fig. 10 The insert element 16 is combined with a further recess 13, which is completely filled with the material of the cover layer 11. To stabilize the insulation panel, the further recess 13 has groove-shaped reinforcing ribs 15 at the base of the recess 13, which extend perpendicular to the cover layer 11. For this purpose, the recess 13 is correspondingly profiled and completely filled with the material of the cover layer 11.

[0092] The above-mentioned options for forming the recess, combining it with various insert elements or attachments, or filling it completely with the material of the cover layer can be combined as required. List of reference symbols

[0093] 10Core layer 11Cover layer 12Functional area 13Recess 14aOutside of the cover layer 14bInside of the cover layer 15Reinforcing rib 16Insert element 17Edge of the recess 18Gap 19Recess 20Through opening 21Step 22Reinforcing plate 23Attachment

Claims

1. An insulating panel for a vehicle body, in particular a refrigerated vehicle body, having at least one thermally insulating core layer (10) and at least one cover layer (11) consisting of a fibre-reinforced plastic material, characterised in that the core layer (10) has at least one recess (13), which is filled at least in some areas by the cover layer (11) so that the cover layer (11) has an increased layer thickness in the area of the recess (13).

2. The insulating panel according to Claim 1, characterised in that the cover layer (11) has an outer face (14a) which is flat or smooth at least in the area of the recess (13).

3. The insulating panel according to Claim 1 or 2, characterised in that the cover layer (11) has a uniform layer thickness at least in some sections outside the recess (13).

4. The insulating panel according to one of the preceding claims, characterised in that the recess (13) is groove-like, and the cover layer (11) forms at least one reinforcement rib (15), which engages form-fittingly in the groove-like recess (13) in the core layer (10).

5. The insulating panel according to one of the preceding claims, characterised in that at least one inlay element (16) is arranged in the recess (13).

6. The insulating panel according to Claim 5, characterised in that a gap (18) is formed between the inlay element (16) and an edge (17) of the recess (13), which gap is filled with the plastic material of the cover layer (11), wherein the plastic material of the cover layer (11) in the gap (18) is integrally bonded to the cover layer (11).

7. The insulating panel according to Claim 5 or 6, characterised in that the inlay element (16) has at least one cut-out (19), which is filled with the plastic material of the cover layer (11), wherein the plastic material of the cover layer (11) in the cut-out (19) is integrally bonded to the cover layer (11) such that the cover layer (11) fixes the inlay element (16) in a form-fitting manner.

8. The insulating panel according to Claim 7, characterised in that the cut-out (19) is formed by a through-opening (20) in the inlay element (16) and / or by an edge step (21) on the inlay element (16).

9. A component of a vehicle body, in particular a refrigerated vehicle body, comprising a rear door and / or a side wall and / or a front wall and / or a ceiling and / or a floor each having at least one insulating panel according to Claim 1.

10. A vehicle body, in particular a refrigerated vehicle body, having at least one insulating panel according to Claim 1.

11. A vehicle, in particular a refrigerated vehicle, having at least one insulating panel according to Claim 1.

12. A method for producing an insulating panel according to one of the preceding claims, comprising the following steps: - providing a core layer (10) of at least one thermally insulating, in particular foamed, material, wherein the core layer (10) has at least one recess (13); - spraying the core layer (10) and the recess (13) with a fibre-reinforced, in particular glass-fibre-reinforced, plastic material to form a cover layer (11); - pressing the core layer (10) together with the cover layer (11) to fill the recess (13) with the fibre-reinforced plastic material and to form a flat or smooth outer face (14a) of the cover layer (11).

13. The method according to Claim 12, characterised in that at least one inlay element (16), which has at least one cut-out (19), is laid into the recess (13) before the core layer (10) is sprayed, wherein the fibre-reinforced plastic material fills the cut-out (19) when the core layer (10) is pressed with the cover layer (11).