Insulating element

Abstract

The invention relates to an insulating element for insulating a structural element in a motor vehicle, comprising a carrier and at least one elongate expansion element. The carrier comprises at least one securing element for securing the carrier to the structural element, and also at least one receiving element. The elongate expansion element comprises expandable material, and the expansion element is attached to the receiving element of the carrier.

Description

[0001] INSULATION ELEMENT

[0002] The invention relates to an insulating element for insulating a structural element in a motor vehicle.

[0003] Components such as the bodies and / or frames of means of transport and locomotion, particularly waterborne or land-based vehicles or aircraft, often have structures with cavities to enable lightweight construction. However, these cavities cause a variety of problems. Depending on the type of cavity, it must be sealed to prevent the ingress of moisture and contaminants, which can lead to corrosion of the components. It is often also desirable to significantly reinforce the cavities and thus the component, while maintaining their low weight. It is also often necessary to stabilize the cavities and thus the components in order to reduce noise that would otherwise be transmitted along or through the cavity.Many of these cavities are irregular in shape or narrow in size, making them difficult to properly seal, reinforce, and dampen.

[0004] Particularly in automotive engineering, but also in aircraft and boat building, sealing elements (baffles) are used to seal cavities and / or acoustically insulate them, or reinforcing elements (reinforcers) are used to reinforce cavities.

[0005] Fig. 1 schematically illustrates the body of an automobile. The body 10 comprises various structures with cavities, such as pillars 14 and supports or struts 12. Such structural elements 12, 14 with cavities are typically sealed or reinforced with sealing and / or reinforcing elements 16.

[0006] The disadvantage of previously known sealing and / or reinforcement elements is that a custom-fit element must be manufactured for each body shape and each cavity. This leads to high development and manufacturing costs and is particularly disadvantageous for smaller vehicle series.

[0007] It is therefore an object of the present invention to provide an improved insulating element for insulating a structural element in a motor vehicle that avoids the disadvantages of the prior art. The insulating element is intended to offer economic advantages, particularly for small-scale production, and to reduce overall development and manufacturing costs for the insulating elements.

[0008] This object is achieved by an insulating element for insulating a structural element in a motor vehicle, the insulating element comprising: a carrier having at least one fixing element for fixing the carrier to the structural element and at least one receiving element; and at least one elongate expansion element with expandable material, wherein the expansion element is plugged onto the receiving element of the carrier.

[0009] A key concept of the present invention is that, through the use of modular components (supports and expansion elements), a multitude of different insulation elements can be created, which can be used to insulate a multitude of differently shaped cavities. This eliminates the need to create a new insulation element for each new application, which typically entails high costs because new injection molds are required each time. By using individually configurable supports and expansion elements, the same modules can be used repeatedly for different applications.

[0010] Particularly for small series or other applications involving low quantities, it is often not worthwhile to produce separate injection molds for specific insulation elements. By using standardized modules, especially expansion elements, cost-effective solutions can be provided for such applications. In the context of this invention, the terms "insulating element" or "insulation" or "insulated" encompass elements or structures or process steps for sealing and / or closing and / or insulating a structural element. These various properties of such an insulating element can occur individually or in combination with one another.

[0011] In an exemplary embodiment, the expansion element is manufactured by an extrusion process.

[0012] Using an extrusion process to manufacture expansion elements has the advantage that different expansion elements can be produced using a single manufacturing process or device. For example, the cross-section of the elongated expansion elements can be varied, or the length of the elongated expansion elements can be varied. This allows for different expansion elements to be provided depending on the application.

[0013] In an exemplary embodiment, the expansion element is formed only from expandable material.

[0014] In an alternative embodiment, the expansion element comprises a foil-like or band-like insert, which insert is covered on both sides by expandable material.

[0015] In an exemplary further development, the insert is completely enclosed by expandable material.

[0016] In an exemplary further development, the insert is a metal foil or a metal strip, in particular a steel foil or a steel strip.

[0017] In an exemplary development, the insert is arranged substantially centrally in the expansion element. In an exemplary embodiment, the expansion element has one or two or more than two holes.

[0018] Providing such holes has the advantage of making it easier to attach the expansion elements to the carrier. Especially with expansion elements with inserts, it is advantageous if the expansion elements have holes through which the carrier's receiving element can be passed.

[0019] In an exemplary further development, the hole or holes have an elongated floor plan.

[0020] The provision of an elongated hole offers the advantage that in designs with two or more holes and two or more receiving elements, the distances between the holes are less tolerance-critical.

[0021] In an exemplary embodiment, the expandable material has an expansion rate between 1000% and 4000%, in particular between 1500% and 3000%.

[0022] In an exemplary embodiment, the carrier has one or two fixation elements.

[0023] In an exemplary further development, the fixing element or elements are designed as a clip or as a pushpin.

[0024] In an exemplary embodiment, the carrier has one or two or more than two receiving elements.

[0025] In an exemplary embodiment, the carrier is manufactured by an injection molding process.

[0026] In an exemplary embodiment, the at least one receiving element has a barb at a free end. Such barbs offer the advantage that the attached expansion elements cannot, or essentially cannot, fall off the receiving element.

[0027] In an exemplary embodiment, only one expansion element is attached to each receiving element.

[0028] In an alternative embodiment, between two and eight expansion elements are attached to each receiving element, in particular between two and six expansion elements, and in particular between two and four expansion elements.

[0029] In an exemplary embodiment, the carrier comprises two fixing elements and two receiving elements. Between two and eight expansion elements are attached to these two receiving elements, with each of these expansion elements being attached to both receiving elements of the carrier.

[0030] Such an insulation element configuration offers the advantage that, after expansion, the expansion elements form a wall-like expanded material, which is ideal for insulating cross-sections in structural elements. Because the expansion elements are movably attached to the receiving elements, the expansion elements, or rather the expandable material, can move along the receiving elements during expansion. This results in a very strong expansion of the expandable material in the direction of the receiving elements, allowing a cross-section to be insulated very efficiently.

[0031] Expandable material

[0032] In principle, various materials can be used as expandable materials that can be foamed. The material may or may not have reinforcing properties. Typically, the expandable material expands thermally, through moisture, or through electromagnetic radiation. Such an expandable material typically contains a chemical or physical blowing agent. Chemical blowing agents are organic or inorganic compounds that decompose under the influence of temperature, moisture, or electromagnetic radiation, with at least one of the decomposition products being a gas. Physical blowing agents, for example, can be compounds that transform into a gaseous state when the temperature increases. This means that both chemical and physical blowing agents are capable of creating foam structures in polymers.

[0033] The expandable material is preferably thermally foamed using chemical blowing agents. Suitable chemical blowing agents include azodicarbonamides, sulfohydrazides, bicarbonates, or carbonates.

[0034] Suitable blowing agents are also commercially available, for example, under the trade name Expancel® from Akzo Nobel, Netherlands, or under the trade name Celogen® from Chemtura Corp., USA.

[0035] The heat required for foaming can be introduced by external or internal heat sources, such as an exothermic chemical reaction. The foamable material is preferably foamable at a temperature of <250°C, in particular from 100°C to 250°C, preferably from 120°C to 240°C, preferably from 130°C to 230°C.

[0036] Suitable expandable materials include, for example, one-component epoxy resin systems that do not flow at room temperature, which, in particular, exhibit increased impact strength and contain thixotropic agents such as Aerosils or nanoclays. For example, such epoxy resin systems comprise 20 to 50 wt.% of a liquid epoxy resin, 0 to 30 wt.% of a solid epoxy resin, 5 to 30 wt.% toughness modifiers, 1 to 5 wt.% physical or chemical blowing agents, 10 to 40 wt.% fillers, 1 to 10 wt.% thixotropic agents, and 2 to 10 wt.% heat-activated hardeners. Suitable toughness modifiers include reactive liquid rubbers based on nitrile rubber or derivatives of polyether polyol polyurethanes, core-shell polymers, and similar systems known to those skilled in the art.Other suitable expandable materials are blowing agent-containing, one-component polyurethane compositions composed of crystalline, OH-containing polyesters mixed with other polyols, preferably polyether polyols, and polyisocyanates with blocked isocyanate groups. The melting point of the crystalline polyester should be > 50°C. The isocyanate groups of the polyisocyanate can be blocked, for example, with nucleophiles such as caprolactam, phenols, or benzoxalones. Blocked polyisocyanates, such as those used in powder coating technology and commercially available from Degussa GmbH, Germany, under the trade names Vestagon® BF 1350 and Vestagon® BF 1540, are also suitable. Also suitable as isocyanates are so-called encapsulated or surface-deactivated polyisocyanates, which are known to those skilled in the art and are described, for example, in EP 0 204 970.

[0037] Furthermore, two-component epoxy / polyurethane compositions containing blowing agents, as described, for example, in WO 2005 / 080524 Al, are suitable as expandable materials.

[0038] Ethylene-vinyl acetate compositions containing blowing agents are also suitable as expandable materials.

[0039] Likewise suitable expandable materials are sold, for example, under the trade names SikaBaffle® 240, SikaBaffle® 250, or SikaBaffle® 255 by Sika Corp., USA, and are described in patents US 5,266,133 and US 5,373,027. Such expandable materials are particularly preferred for the present invention.

[0040] Preferred expandable materials with reinforcing properties include those sold under the trade name SikaReinforcer® 941 by Sika Corp., USA. These materials are described in US Pat. No. 6,387,470.

[0041] In an exemplary embodiment, the expandable material has a

[0042] Expansion rate of 800% to 5000%, preferably 1000% to 4000%, particularly preferably 1500% to 3000%. Expandable materials with such expansion rates offer the advantage of reliably sealing or insulating the structural element against liquids and sound.

[0043] In an exemplary embodiment, the expandable material is formed as a temperature-induced material.

[0044] This has the advantage that the oven can be used to bake the dip coating fluid, expand the expandable material, and thus insulate the cavity. Thus, no additional work step is necessary.

[0045] The carrier can be made of any desired material. Preferred materials are plastics, especially polyurethanes, polyamides, polyesters, and polyolefins, preferably high-temperature-resistant polymers such as poly(phenylene ethers), polysulfones, or polyethersulfones, which are also particularly foamed; metals, especially aluminum and steel; or natural organic materials, especially wood or other (pressed) fiber materials or glass-like or ceramic materials; especially also foamed materials of this type; or any desired combination of these materials. Particular preference is given to using polyamide, especially polyamide 6, polyamide 6,6, polyamide 11, polyamide 12, or a mixture thereof.

[0046] Furthermore, the carrier can have any desired structure and design. For example, it can be solid, hollow, foamed, or have a lattice-like structure. The surface of the carrier can typically be smooth, rough, or textured.

[0047] The task posed at the beginning is also solved by a system in a

[0048] A motor vehicle, the system comprising: a structural element having a cavity; and an insulating element as described above; wherein the insulating element is arranged in the cavity of the structural element.

[0049] In an exemplary embodiment, the structural element is a portion of a pillar or beam or strut of a body of a motor vehicle.

[0050] Details and advantages of the invention are described below using exemplary embodiments and with reference to schematic drawings. They show:

[0051] Fig. 1 is an exemplary representation of a body;

[0052] Fig. 2a and 2b show a schematic representation of exemplary insulation elements;

[0053] Fig. 3 is a schematic representation of an exemplary insulation element;

[0054] Fig. 4a and Fig. 4b show a schematic representation of exemplary expansion elements;

[0055] Fig. 5 is a schematic representation of an exemplary carrier; and

[0056] Fig. 6a and Fig. 6b show a schematic representation of an exemplary system.

[0057] 2a and 2b show exemplary insulation elements 16. In both exemplary embodiments, only one expansion element 2 is attached to each receiving element 5. The carrier 11 of the insulation element 16 comprises a plurality of receiving elements 5. In addition, the carrier 11 each comprises a fixing element 8 for fixing the carrier 11 to a structural element (not shown). The receiving elements 5 each have a barb 7 at a free end, which prevents the expansion elements 2 from falling off the receiving element 5 after being attached. In Fig. 2b, the carrier also has a support foot 6 in the area of ​​the fixing element 8, so that the carrier 11 is better supported on the structural element. In both exemplary embodiments, the expansion elements 2 are each shown in a cross-section perpendicular to the longitudinal axis of the expansion elements.

[0058] Fig. 3 shows a further exemplary embodiment of an insulating element 16. This insulating element 16 again has a support 11 with a fixing element 8 with a support foot 6 and a receiving element 5 with barbs 7. In this exemplary embodiment, several expansion elements 2 are attached to a receiving element 5.

[0059] Figs. 4a and 4b show two exemplary embodiments of expansion elements 2. Fig. 4a shows a first expansion element 2, which has an elongated hole 4. This expansion element 2 also has an insert 3, which is arranged approximately centrally in the expandable material 13. Fig. 4b shows a second exemplary embodiment of an expansion element 2. This expansion element 2 has two elongated holes 4, which are arranged at a certain distance from one another. In this exemplary embodiment, the expansion element 2 consists exclusively of expandable material 13.

[0060] Fig. 5 shows an exemplary carrier 11. In this embodiment, the carrier 11 has two fixing elements 8 and two receiving elements 5 with barbs 7.

[0061] Finally, Figs. 6a and 6b show a system 1 comprising a support 11 according to Fig. 5 and a plurality of expansion elements 2 according to Fig. 4b. The insulation element 16 is arranged in a structural element 12, 14. Fig. 6a shows a state before expansion of the expandable material 13, and Fig. 6b shows a state after expansion, so that the expanded material 13' is now present. By guiding the expansion elements 2 on the receiving elements 5, a directed expansion is achieved in a plane of the receiving elements 5, so that a cross-section of the structural element 12, 14 can be efficiently foamed or insulated. List of Reference Symbols

[0062] 1 system

[0063] 2 Expansion element 3 Insert

[0064] 4 holes

[0065] 5 Recording element

[0066] 6 Support foot

[0067] 7 Barbs 8 Fixing element

[0068] 10 Body

[0069] 11 carriers

[0070] 12 Structural element

[0071] 13 expandable material 13 'expanded material

[0072] 14 Structural element

[0073] 16 Insulating element

Claims

Patent claims 1. Insulation element (16) for insulating a structural element (12, 14) in a motor vehicle, the insulation element (16) comprising: a carrier (11) which has at least one fixing element (8) for fixing the carrier (11) to the structural element (12, 14) and at least one receiving element (5); and at least one elongated expansion element (2) with expandable material (13), wherein the expansion element (2) is attached to the receiving element (5) of the carrier (11).

2. Insulation element (16) according to claim 1, wherein the expansion element (2) is produced by an extrusion process.

3. Insulation element (16) according to one of the preceding claims, wherein the expansion element (2) is formed only from expandable material (13).

4. Insulation element (16) according to one of claims 1 or 2, wherein the expansion element (2) comprises a foil-like or strip-like insert (3), wherein this insert (3) is covered on both sides by expandable material (13).

5. Insulation element (16) according to one of the preceding claims, wherein the expansion element has one or two or more than two holes (4).

6. Insulation element (16) according to claim 5, wherein the hole (4) or holes (4) have an elongated plan.

7. Insulation element (16) according to one of the preceding claims, wherein the expandable material (13) has an expansion rate between 1000% and 4000%.

8. Insulation element (16) according to one of the preceding claims, wherein the support (11) has one or two fixing elements (8).

9. Insulation element (16) according to claim 8, wherein the fixing elements or the fixing element are designed as a clip or as a pushpin.

10. Insulation element (16) according to one of the preceding claims, wherein the support (11) has one or two or more than two receiving elements (5).

11. Insulation element (16) according to one of the preceding claims, wherein the carrier (11) has been manufactured by an injection molding process.

12. Insulation element (16) according to one of the preceding claims, wherein the at least one receiving element (5) has a barb (7) at a free end.

13. Insulation element (16) according to one of the preceding claims, wherein only one expansion element (2) is attached to each receiving element (5).

14. Insulation element (16) according to one of claims 1 to 12, wherein between two and eight expansion elements (2) are attached to each receiving element (5).

15. System (1) in a motor vehicle, the system (1) comprising: a structural element (12, 14) which has a cavity; and an insulating element (16) according to any one of claims 1 to 14; wherein the insulating element (16) is arranged in the cavity of the structural element (12, 14).

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