Patent Application
20210316674
The present invention relates in general to ventilation devices for the interior of vehicles, wherein such ventilation devices are herein also referred to as “pressure-limiting valve arrangements”.
Ventilation devices or pressure-limiting valve arrangements for the interior of vehicles generally have a frame which surrounds a ventilation opening and on which at least one flap which covers the ventilation opening and which can be pivoted away rests on the outer side.
A pressure-limiting valve arrangement of the type under consideration herein has in particular at least one pressure-limiting valve and/or at least one valve flap, wherein the at least one pressure-limiting valve and/or the at least one valve flap is preferably held in a frame.
Such ventilation devices or pressure-limiting arrangements are generally known in various embodiments.
By way of example, reference should be made in this document DE 35 03 600 A1. In the case of the pressure-limiting valve arrangement known from this prior art, an airflow can pass from the vehicle interior to the outside via the ventilation opening, specifically by said airflow lifting the at least one flap of the pressure-limiting valve arrangement from the frame because of arising pressure conditions. By contrast, the penetration of ambient air into the vehicle interior is successfully prevented by the flap which then rests on the frame.
Accordingly, pressure-limiting valve arrangements of the type under consideration herein serve to dissipate building-up of the air pressure in the vehicle interior, for example when a tailgate of the vehicle is closed. The pressure-limiting valve, which is generally configured as a flap, can open when there is an increased air pressure in the interior of the vehicle, in order to allow air in the interior to escape, as a result of which the air pressure in the interior of the vehicle is dissipated and, for example, the effort for closing the tailgate is reduced.
Furthermore, a vehicle with a pressure-limiting valve arrangement can influence the airflow from the vehicle passenger compartment in order to increase the passenger comfort. Since an air conditioning system sucks up ambient air from outside the vehicle, and introduces the air into the vehicle passenger compartment, venting by means of the pressure-limiting valve arrangement is required in order to achieve proper circulation and to dissipate the buildup of pressure.
However, when the pressure-limiting valve belonging to the pressure-limiting valve arrangement is opened, noise can penetrate through the opening from the outside. In order to reduce the penetration of noise and external elements into the vehicle passenger compartment, pressure-limiting valves can be embodied to be as small as possible, but this limits the speed at which pressure can be compensated for with the aid of the pressure-limiting valve arrangement.
As an alternative thereto, in order to reduce the noise when pressure is being compensated for with the aid of the pressure-limiting valve arrangement, it is conceivable to provide the pressure-limiting valve arrangement with a type of “silencer”. For this purpose, it is known to place a cover onto the pressure-limiting valve arrangement in order thereby to form a silencer space, wherein, when the pressure-limiting valve arrangement is opened, a flow path between the vehicle interior and the external atmosphere runs at least regionally through the silencer space.
However, the manufacturing of covers, which serve as a silencer space, for pressure-limiting valve arrangements is relatively complicated since the cover is a three-dimensional structure which is generally embodied as an injection molded component, wherein the inner walls of the three-dimensional cover have to be provided with corresponding sound absorption materials in a separate working step. Said working step is generally undertaken at manufacturing stations which differ from the manufacturing stations in which the housing of the cover is manufactured and in particular injection molded. As a result, for the manufacturing of the cover, in particular the outlay on installation and the installation costs and thus the overall costs for manufacturing the cover are increased.
On the basis of this problem, the present invention addresses the problem of specifying a cover for a pressure-limiting valve arrangement of a vehicle, wherein the cover can be manufactured with a lower outlay and in particular particularly cost-effectively.
Furthermore, the intention is to specify a corresponding method for producing such a cover for a pressure-limiting valve arrangement of a vehicle.
With regard to the cover, the problem on which the invention is based is solved by the subject matter of independent claim 1, with advantageous developments of the cover according to the invention being specified in dependent patent claims 2 to 10.
With regard to the production method, the problem on which the invention is based is solved by the subject matter of the further independent patent claim 12 and the further independent patent claim 13, with advantageous developments of the method according to the invention being indicated in dependent patent claims 14 and 15.
Accordingly, the invention relates in particular to a cover for a pressure-limiting valve arrangement of a vehicle, wherein the cover has at least one and preferably at least two (or else more) side walls, and a wall region serving as a lid region of the cover. The cover is transferable from a state of manufacture, i.e. a state in which the cover is manufactured, into a state of use, wherein, in the state of manufacture, the at least one side wall and the wall region serving as a lid region are situated at least substantially and/or at least regionally in a common plane. In the state of use, i.e. when the cover is connected to the pressure-limiting valve arrangement, the at least one side wall and the wall region serving as a lid region are, by contrast, situated in mutually different planes.
The advantages which can be achieved with the solution according to the invention are obvious: in particular, the present invention makes it possible for a cover for a pressure-limiting valve arrangement to be completely manufactured preferably in a single working step or at least in a single working station. This simplifies the entire manufacturing sequence, and various processing steps in various stations can be dispensed with. This results in a manufacturing process which is considerably reduced with regard to the outlay and the costs.
In particular, it is possible in this connection that, for the production of the cover according to the invention, first of all an at least substantially flat structure consisting of the at least one side wall and preferably the at least two (or more) side walls, and the wall region serving as a lid region, is provided preferably as an at least substantially flat injection molded component, wherein, subsequently, said at least substantially flat structure can be equipped with a sound absorption material, in particular in an automated manner. Subsequently, then, the at least substantially flat structure is folded to form a three-dimensional shape or brought together in some other way to form a three-dimensional shape which, in the state of use of the cover, constitutes at least one regionally a three-dimensional silencer space for the pressure-limiting valve arrangement.
In particular, it is thus provided that, in the state of use of the cover, the at least one side wall and the wall region serving as a lid region at least regionally delimit a three-dimensional silencer space for the pressure-limiting valve arrangement.
The at least one side wall and the wall region serving as a lid region each have a first surface, which, in the state of manufacture of the cover, face in a common direction, that preferably points perpendicularly to the common plane. Of course, the invention is not restricted to embodiments in which the at least one side wall and the wall region serving as a lid region each have a first surface, which, in the state of manufacture of the cover, face in a direction that preferably points perpendicularly to the common plane. On the contrary, the invention also relates to embodiments in which the at least one side wall and the wall region serving as a lid region each have a first surface, which, in the state of manufacture of the cover, are provided at a slight inclination.
In particular, however, the first surface of the at least one side wall and the first surface of the wall region serving as a lid region, in the state of use of the cover, at least regionally form an inner surface of the three-dimensional silencer space.
For optimum sound absorption, it is provided in particular that a suitable sound absorption material is arranged at least regionally on the first surface of the at least one side wall and/or on the first surface of the wall region serving as a lid region. This in particular involves a porous material, for example rock wool, glass wool or glass fibers, wherein said sound absorption material partially absorbs sound energy, i.e. converts the latter into heat. The effect of the sound absorption is preferably amplified by multiple reflection.
According to realizations of the cover according to the invention, it is provided in this connection that a nonwoven material, for example composed of mineral wool, is used as the sound absorption material. Of course, however, other embodiments are also suitable here for the sound absorption material.
In order to simplify the arranging of the sound absorption material on the first surface of the at least one side wall and/or the first surface of the wall region serving as a lid region, it is provided, according to embodiments of the cover according to the invention, that, for the purpose of at least temporarily fixing the sound absorption material on the corresponding surface of the at least one side wall and/or of the wall region serving as a lid region, at least one connection element, preferably serving as a snap-action and/or latching connection element, is provided on the first surface of the at least one side wall and/or on the first surface of the wall region serving as a lid region.
For example, it is conceivable, for the manufacturing of the cover according to the invention, for the sound absorption material to be initially temporarily fixed on the corresponding regions of the provided at least substantially flat structure, consisting of the at least one side wall and the wall region serving as a cover region, with the aid, for example, of a snap-action and/or latching connection, wherein, subsequently, the sound absorption material is preferably permanently fixed in an automated manner to the corresponding surface region of the at least one side wall and/or of the wall region serving as a lid region. However, instead of a snap-action and/or latching connection, materially bonded connections (for example welded connections or adhesive connections) are also conceivable in order to at least temporarily fix the sound absorption material on the corresponding regions of the provided at least substantially flat structure consisting of the at least one side wall and the wall region serving as a lid region.
Expressed in general terms, different solutions are suitable for fixing the sound absorption material on the corresponding surface of the at least one side wall and/or on the corresponding surface of the wall region serving as a lid region. In particular, at least one materially bonded, form-fitting and/or force-fitting connection is appropriate here.
According to embodiments, the sound absorption material is connected to the corresponding surface region of the at least one side wall and/or to the corresponding surface region of the wall region serving as a lid region with the aid of a spot-welding system which correspondingly travels, preferably in an automated manner, over the at least one substantially flat structure (injection molded component) consisting of the at least one side wall and the wall region serving as a lid region.
Of course, other solutions for fixing the sound absorption material on the surface of the at least one side wall and/or the surface of the wall region serving as a lid region are also suitable.
In order firstly to reduce the weight of the cover and the outlay on material but secondly to retain the necessary stability of the cover, in particular in the state of use thereof, it is provided, according to embodiments of the cover according to the invention, that a corresponding partition is formed in particular on the (second) surface opposite the first surface of the at least one side wall and/or in particular on the (second) surface opposite the first surface of the wall region serving as a lid region. Said partition is preferably formed with the aid of at least one web region which is formed preferably integrally with the material of the at least one side wall and/or with the material of the wall region serving as a lid region.
A partition formed via at least one web region optimizes the flexural rigidity and torsional rigidity of the side walls and/or wall regions of the cover while simultaneously reducing the amount of material.
In a preferred manner, the at least one side wall of the cover is articulately connected to the wall region serving as a lid region in particular via a hinge, preferably film hinge. In particular, it is of advantage in this connection that the at least one side wall, the at least one hinge and the wall region serving as a lid region are formed integrally during a plastic injection molding process.
According to a further aspect of the present invention, it is provided that the cover has at least two side walls, wherein each side wall of the at least two side walls is, in each case via an edge region, articulate the connected to an edge region of the wall region serving as a lid region. In particular, it is provided in this connection that, on a first edge region of a first side wall of the at least two side walls, which first edge region, in the state of use of the cover, directly adjoins a second edge region of a second side wall of the at least two side walls, there is formed at least one first snap-action or latching element, which is formed at least regionally in a manner complementary with respect to a second snap-action or latching element, which is formed in an adjoining manner on the second edge region of the second side wall of the at least two side walls, which second edge region, in the state of use of the cover, directly adjoins the first edge region of the first side wall of the at least two side walls.
This measure which is particularly easy to realize but is nevertheless effective makes it possible to secure the corresponding side walls and wall regions of the cover relative to one another, in the state of use of the cover, and to at least temporarily fix them.
In particular in a development of the last-mentioned embodiment, it is provided, in an advantageous manner, that, on an edge region of the at least one side wall, which edge region, in the state of use of the cover, faces in a direction away from the wall region serving as a lid region, there is formed at least one snap-action and/or latching element in order to connect the cover, when the latter is in its state of use, to a pressure-limiting valve arrangement and, in particular to an edge region or frame region of a pressure-limiting valve arrangement, which is preferably formed as a ventilation grille arrangement.
The invention furthermore relates to a pressure-limiting valve arrangement for vehicles, wherein the pressure-limiting valve arrangement has at least one ventilation grille having at least one valve flap held in a frame, and has a cover of the previously described type according to the invention. It is provided in particular here that the cover is present in its state of use. Furthermore, it is provided in particular that the cover is connected to the ventilation grill, and preferably to the frame of the ventilation grille, preferably via at least one snap-action and/or latching connection via its at least one side wall.
Finally, the invention relates to a method for producing a cover for a pressure-limiting valve arrangement of a vehicle, wherein the method comprises the following method steps:
According to a further aspect, the invention furthermore relates to an optimized method for producing a cover for a pressure-limiting valve arrangement of a vehicle, wherein, in a first method step, a housing of the cover is provided, and, in a second method step, a sound absorption material is at least regionally applied and/or fixed to an inner surface of the housing. The housing here is preferably in the form of an injection molded component and consists of at least one side wall, and preferably at least two side walls, and of a wall region serving as a lid region. In particular, it is provided in this connection that the provided housing of the cover has a shape/shaping which at least regionally constitutes a multi-dimensional, and in particular three-dimensional, silencer space.
During the method step of applying and/or fixing the sound absorption material to the inner surface of the housing, the sound absorption material is in particular transferred from an originally at least substantially flat shape into a shape which at least regionally corresponds to a shaping predefined by the inner surface of the housing.
In the case of the production method of the previously mentioned type, in particular the method step of applying and/or fixing the sound absorption material to the inner surface of the housing comprises the following method steps:
In particular, in this development of the production method according to the invention, it is provided that, with the introduction of the dressed pressing punch into the provided housing of the cover, the at least partially or regionally deformed sound absorption material is fixed at least regionally to the inner surface of the housing.
The fixing takes place preferably with the aid of snap-action or latching elements which are provided on the inner surface of the housing. Alternatively or additionally to such a form-fitting fixing, a force-fitting or materially bonded fixing of the sound absorption material to the inner surface of the housing is, of course, also conceivable. In particular, such fixing can be carried out with the aid of spot welding. Of course, however, other embodiments are also suitable here for fixing the at least partially or regionally deformed sound absorption material to the inner surface of the housing.
According to advantageous realizations of the production method according to the invention of the previously mentioned type, it is provided that the housing of the cover is provided by the housing of the cover being placed in a die-like device.
It is appropriate here that, after the method step of introducing the dressed pressing punch into the provided housing of the cover, the pressing punch is withdrawn again from the die-like device in which the housing of the cover is placed.
In a particularly preferred manner, the pressing punch here has been dressed with the sound absorption material provided, and, with the introduction of the thus dressed pressing punch into the housing of the cover that is provided in the die-like device, the at least partially or regionally deformed sound absorption material is fixed at least regionally to the inner surface of the housing, in such a way that, with the withdrawal of the pressing punch from the die-like device, the housing of the cover with the at least partially or regionally deformed sound absorption material, which is fixed at least regionally to the inner surface of the housing, is, together with the pressing punch, withdrawn from the die-like device.
The advantages which can be achieved with this production method according to the invention can be seen in particular in the fact that, during the production of the sound-insulating cover, all of the method and installation steps required for this purpose can be carried out in or at one and the same station. It is thus no longer required for the housing to be brought to a different workstation, for example for the application of the sound absorption material. As a result, the costs for manufacturing the sound-insulating cover according to the invention can be reduced.
In particular, the production method according to the invention permits automation since all of the method steps necessary for producing the sound-insulating cover can be carried out in an automated manner. This in turn reduces not only the production costs but also leads to smaller deviations in particular in respect of the appropriate shape during the production of the sound-insulating cover according to the invention.
The invention also relates to a cover which has been produced according to the previously described method.
The invention will be described in more detail below with reference to the exemplary embodiments of the cover according to the invention and of the production method according to the invention that are shown in the drawings, in which:
In order to dissipate the buildup of the air pressure in the interior of a vehicle during the closing, for example, of the tailgate, a vehicle can be provided with an opening and with a pressure-limiting valve located in the opening. The pressure-limiting valve can open when there is increased air pressure in the interior of the vehicle, in order to allow air in the interior to escape, as a result of which the air pressure in the interior of the vehicle is dissipated and the effort for closing the tailgate is reduced.
Furthermore, a vehicle with a pressure-limiting valve can influence the airflow from the vehicle passenger compartment in order to increase the passenger comfort. Since an air conditioning system sucks up ambient air from outside the vehicle and the air is introduced into the vehicle passenger compartment, venting by means of the pressure-limiting valve is required in order to achieve proper circulation and to dissipate the buildup of pressure in the passenger compartment.
Since, when a pressure-limiting valve is opened, noise can penetrate from the outside through the opening, it is known in general from the prior art to assign a cover 10 serving as a sound-insulating space (silencer space) to the pressure-limiting valve.
An embodiment of a cover 10, which is known from the prior art, for a pressure-limiting valve arrangement is shown, schematically and in an isometric view, in
The cover 10 which is known in general from this prior art has an overall three-dimensionally formed configuration which is formed by a multiplicity of side walls 20a, 20b, 20c and a wall region 30 serving as a lid region. Latching or snap-action connection elements 50 are provided on corresponding edge regions of the side walls 20a, 20b, 20c, which regions point away from the wall region 30 serving as a lid region, and enable the cover 10 to be connected to the frame of a pressure-limiting valve arrangement via a latching connection.
In order to reduce the sound as efficiently as possible, a sound absorption material (not shown in
However, the manufacturing of a conventional cover 10 which is known from the prior art and as is illustrated, for example, in
The attaching of a sound absorption material to the inner surfaces of the cover 10 is, however, relatively complicated and generally takes place manually since the three-dimensional configuration of the cover 10 means that conventionally usable automation techniques cannot be used or can be used only with a relatively great outlay.
In order to solve this problem, a cover 1 is proposed according to the invention which can be manufactured as a substantially flat injection molded component in one and the same system to an extent such that all the features necessary for the functioning of the cover 1 in the state of use are already formed in the same installation. This applies in particular to the application of sound absorption material 4 to the inner surface of the walls 2a, 2b, 2c, 3 forming the cover 1.
Subsequently, the three-dimensional configuration of the cover 1 is formed—preferably in the form of folding operations.
The exemplary embodiment of the cover 1 according to the invention has a total of three sides walls 2a, 2b, 2c and a wall region 3 serving as a lid region of the cover 1. The side walls 2a, 2b, 2c and the wall region 3 serving as a lid region of the cover 1 are present in planes different form one another in the state of use shown in
As will be described below with reference to the illustrations in
Like the cover 10 which is known from the prior art according to
The production method of the cover 1 according to the invention will be described in more detail below with reference to the illustrations in
Specifically, and as is shown schematically and in an isometric view in
For the articulated connection of the side walls 2a, 2b, 2c to the wall region 3 serving as a lid region, use is preferably made in each case of a film hinge arrangement 7.
The component shown in
A partition is formed with the aid of corresponding webs 6 on the surface, visible in
Furthermore, snap-action or latching elements 5 are formed on edge regions of the side walls 2a, 2b, 2c, which edge regions are not connected articulatedly to the wall region 3 serving as a lid region, said snap-action or latching elements serving, in the state of use of the cover 1 (cf.
Embodiments of suitable snap-action or latching elements 5 are shown in
After the substantially flat component according to
This preferably takes place by fixing a nonwoven material made of sound absorption material 4, said nonwoven material being adapted to the contour of the at least substantially flat component according to
Various embodiments are suitable for fixing the sound absorption material 4 to the first surface of the side walls 2a, 2b, 2c and/or to the first surface of the wall region 3 serving as a lid region. For example, it is conceivable for the nonwoven material to be fixed initially temporarily with the aid of a snap-action or latching connection, wherein subsequently, and preferably in an automated manner, for example with the aid of a spot-welding installation, the final fixing of the sound absorption material 4 to the first surface of the at least substantially flat component takes place.
After the application of the sound absorption material 4 to the first surface of the at least substantially flat component according to
In particular for transportation of the cover 1 or for storage of the cover 1, subsequent fixing in addition to the pre-fixing may possibly be desired. Such subsequent fixing can take place, for example, using a welding or adhesive bonding process. Of course, it is also conceivable in this connection for the cover to be stabilized in some other manner.
In particular, it should be emphasized in this connection that a pre-fixing of the side walls 2a, 2b, 2c to one another and/or to the wall region 3 serving as a lid region of the cover 1 with the aid of snap-action or latching elements 5 is not absolutely necessary. A corresponding pre-fixing is purely optional and can thus also be dispensed with here. A pre-fixing—should this be desirable—can also take place in some other way than with snap-action or latching elements 5, for example with the aid of a latching, adhesive bonding and/or welding connection.
In particular, it is preferred that the fixing of the side walls 2a, 2b, 2c to one another and/or to the wall region 3 serving as a lid region of the cover 1, and the necessary stability of said multi-dimensional form is ultimately achieved by assembling the cover 1 with preferably the frame of a corresponding pressure-limiting valve arrangement.
It should furthermore be emphasized in this connection that the formation of the multi-dimensional cover 1 does not depend on the sequence of folding operations shown in
An alternative production method for producing the cover according to the invention will be described below with reference to
During this production method, first of all a housing 9 of the cover 1 is provided, wherein the housing 9 is preferably embodied as an injection molded component and is composed of at least one side wall 2a, 2b, 2c and preferably at last two side walls, and a wall region 3 serving as a lid region.
As schematically illustrated in
Subsequently, a sound absorption material 4 is applied and/or fixed at least regionally to an inner surface of the previously provided housing 9.
As illustrated schematically in
As is shown schematically in particular in
It is provided in particular here that the pressing punch 100 has an end surface which is preferably matched to the size and/or shaping of the wall regions 3 of the housing 9 of the cover 1, said wall region serving as lid region.
After appropriate dressing of the pressing punch 100 (cf.
On the other hand,
Accordingly, the dressed pressing punch 100 is introduced into the provided housing 9 of the cover 1 in such a manner that the sound absorption material 4 placed at least regionally on the end surface of the pressing punch 100 is deformed at least partially or regionally and lies at least regionally against the inner surface of the housing 9.
As shown schematically and in a partially sectioned illustration in
In the subsequent method step (cf.
Specifically, it is in particular provided here that the pressing punch 100 is dressed with the sound absorption material 4 provided, and, with the introduction of the dressed pressing punch 100 into the housing 9 of the cover 1 that is provided in the die-like device 101, the at least partially or regionally deformed sound absorption material 4 is fixed at least regionally to the inner surface of the housing 9, in such a way that, with the withdrawal of the pressing punch 100 from the die-like device 101, the housing 9 of the cover 1 with the at least partially or regionally deformed sound adsorption material 4, which is fixed at least regionally to the inner surface of the housing 9, is, together with the pressing punch 100, withdrawn from the die-like device 101.
Subsequently, as is shown schematically in
The invention relates not only to a cover 1 for a pressure-limiting valve of the type described previously and to a corresponding production method therefore, but also to a pressure-limiting valve arrangement for vehicles, wherein the pressure-limiting valve arrangement has at least one ventilation grille with at least one valve flap held in a frame, and has a cover 1 of the previously described type, wherein, as illustrated for example in
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2020 110 004.3 | Apr 2020 | DE | national |
