COVER FOR A PRESSURE RELIEF VALVE ASSEMBLY OF A VEHICLE, A PRESSURE RELIEF VALVE ASSEMBLY HAVING SUCH A COVER, AND A METHOD FOR PRODUCING A CORRESPONDING COVER

Abstract

A cover (1) for a pressure relief valve assembly (2) of a vehicle, wherein the cover (1) comprises a base body (19) made of a sound-absorbing material which is uniform in terms of the material composition, wherein the base body as such is designed to be self-supporting and is in particular connectable to an edge region (4) of a pressure relief valve assembly (2).

Claims

1. A cover for a pressure relief valve assembly of a vehicle, wherein the cover comprises a base body made of a sound-absorbing material which is uniform in terms of the material composition, wherein the base body is designed to be self-supporting and is connectable to an edge region of a pressure relief valve assembly.

2. The cover according to claim 1, wherein the base body comprises regions, in particular honeycomb-, rib-, or strut-shaped regions, in which the sound-absorbing material has been manipulated during production of the base body, in particular thermally treated and/or compressed or otherwise compacted, such that the base body has increased rigidity and/or strength at least in these regions.

3. The cover according to claim 1, wherein the base body is formed by reshaping the sound-absorbing material, in particular by pressing, compression molding, and/or deep-drawing.

4. The cover according to claim 1, wherein the base body is a one-piece, in particular monolithic base body and comprises side walls and a cover region, which together delimit a three-dimensional muffler space.

5. The cover according to claim 4, wherein, during the production of the base body, the sound-absorbing material in an end region of the side walls opposite to the cover region has been manipulated, in particular thermally treated and/or compressed or otherwise compacted, at least partly or regionally such that the base body has increased rigidity and/or strength in this region; and or wherein a rim or flange region is formed on the end region of the side walls opposite to the cover region, which projects radially outward at least regionally and via which the base body can be connected to a pressure relief valve assembly and in particular to an edge region of a pressure relief valve assembly which is preferably configured as an air vent assembly; and/or wherein latching connection elements, in particular latching projections, are configured in or on the end region of the side walls opposite to the cover region, via which the base body can be connected, preferably releasably, to a pressure relief valve assembly and in particular to an edge region of a pressure relief valve assembly which is preferably configured as an air vent assembly.

6. The cover according to claim 1, wherein the sound-absorbing material is a sound-absorbing non-woven fabric, in particular made of mineral wool, synthetic fibers, and/or natural fibers; or wherein the sound-absorbing material is a sound-absorbing non-woven fabric, in particular made of plastic fibers of a thermoplastic material.

7. The cover according to claim 1, wherein the cover comprises a base body made of a sound-absorbing material which is uniform in terms of the material composition, wherein the base body is partially supplemented with a plastic to form a self-supporting component and is connectable to an edge region of a pressure relief valve assembly.

8. The cover according to claim 7, wherein, to form the self-supporting component, the base body is provided with the plastic partially by injection molding; or wherein, to form the self-supporting component, the base body is connected to a plastic support structure, in the form of a plastic frame, with the aid of a form-fitting joining connection or with the aid of a material-locking joining connection.

9. The cover according to claim 7, wherein, when the cover is used as intended, said cover comprises inner wall regions facing in the direction of the pressure relief valve assembly and outer wall regions facing away from the pressure relief valve assembly, wherein the plastic is exclusively and in particular partially present on the outer wall regions.

10. The cover according to claim 7, wherein the base body is formed by pressing, compression molding, and/or deep-drawing a semi-finished product comprising the sound-absorbing material by means of a tool, wherein, in a further step, the base body is provided with the plastic by injection molding, wherein, in said further step, the base body is provided with the plastic by injection molding in the same tool; or wherein the base body is formed by pressing, compression molding, and/or deep-drawing a semi-finished product comprising the sound-absorbing material by means of a tool, wherein, in a further step, the base body is fastened to or in a plastic support structure, in particular implemented as a plastic frame, with the aid of a form-fitting joining connection or a material-locking joining connection.

11. A pressure relief valve assembly for vehicles, wherein the pressure relief valve assembly comprises at least one air vent having at least one pressure relief valve received in a frame or edge region and/or having at least one valve flap received in a frame or edge region, and a cover according to claim 1, wherein the base body of the cover is connected to the frame or edge region of the air vent, via at least one side wall of the base body, via at least one snap-fitting and/or latching connection.

12. A method of producing a cover according to claim 1, wherein the method comprises the following method steps: providing a preferably substantially flat sound-absorbing material, in the form of a sheet made of a non-woven material; and reshaping the provided sound-absorbing material such that a base body is formed with side walls and a cover region, which together delimit a three-dimensional muffler space.

12. The method according to claim 12, wherein, during the reshaping step and/or before or after the reshaping step, the sound-absorbing material is regionally manipulated, in particular locally thermally treated and/or compressed or otherwise compacted, such that the base body has increased rigidity and/or strength at least in these regions (5, 8), so that the base body as a whole is a self-supporting body; and/or wherein, after or during the reshaping step, the sound-absorbing material is provided with a plastic, in particular partially on the outer side of the base body, by injection molding; and/or wherein, after the reshaping step, the sound-absorbing material is fastened to or in a plastic support structure, in particular implemented as a plastic frame, with the aid of a form-fitting joining connection or with the aid of a material-locking joining connection.

12. The method according to claim 12, wherein, in order to reshape the provided sound-absorbing material, the sound-absorbing material is reshaped according to a compression molding or deep-drawing process, with the aid of a molding tool comprising an embossing die and a die in the form of a negative mold, wherein the embossing die and/or the die are configured such that, when the sound-absorbing material is being reshaped, the sound-absorbing material is regionally manipulated, in particular thermally treated and/or compressed or otherwise compacted, such that honeycomb-, rib-, or strut-shaped regions are formed in the base body, in which the base body has increased rigidity and/or strength; and/or wherein the embossing die and/or the die comprises projecting regions and/or groove regions which are regionally heatable and which are configured such that, when the sound-absorbing material is being reshaped, the sound-absorbing material is regionally manipulated, in particular thermally treated and/or compressed or otherwise compacted, such that honeycomb-, rib-, or strut-shaped regions are formed in the base body, in which the base body has increased rigidity and/or strength.

15. The method according to claim 12, wherein the base body is formed by pressing, compression molding, and/or deep-drawing a semi-finished product comprising the sound-absorbing material by means of a tool, wherein, in a further step, the base body is partially provided with a plastic by injection molding, wherein, in said further step, the base body is partially provided with the plastic by injection molding in the same tool.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0059] Exemplary embodiments of the solution according to the invention are described in further detail below with reference to the accompanying drawings.

[0060] The following are shown:

[0061] FIG. 1 shows schematically and in an isometric view, a cover known from the prior art for a pressure relief valve assembly of a vehicle;

[0062] FIG. 2 shows schematically and in an isometric view, an exemplary embodiment of the pressure relief valve assembly according to the present invention with a first embodiment of a cover;

[0063] FIG. 3 shows schematically and in an isometric view, the cover of the exemplary pressure relief valve assembly according to FIG. 2;

[0064] FIG. 4A shows schematically, and in an isometric view, a detail of the cover according to FIG. 3;

[0065] FIG. 4B shows schematically and in an isometric view, a second exemplary embodiment of the cover according to the invention;

[0066] FIG. 4C shows schematically and in an isometric view, a detail of a third exemplary embodiment of the cover according to the invention;

[0067] FIG. 5 shows schematically, and in a first isometric view, an exemplary embodiment of a molding tool having an at least substantially flat sound-absorbing material for production of the cover according to FIG. 3;

[0068] FIG. 6 shows schematically and in a second isometric view, the molding tool according to FIG. 3 with the substantially flat sound-absorbing material;

[0069] FIG. 7 shows schematically and in a partially transparent isometric view, the molding tool according to FIG. 5 during the reshaping of the provided sound-absorbing material;

[0070] FIG. 8 shows schematically and in an isometric, partially transparent view, the molding tool according to FIG. 7 at the end of the reshaping operation;

[0071] FIG. 9 shows schematically and in an isometric view, the embossing die of the molding tool according to FIG. 5;

[0072] FIG. 10 shows schematically and in an isometric view, the die (negative mold) of the molding tool according to FIG. 5; and

[0073] FIG. 11 shows schematically and in an isometric view, a further embodiment of a cover for a pressure relief valve assembly.

DETAILED DESCRIPTION

[0074] In order to reduce the build-up of air pressure in the interior of a vehicle, for example when closing the tailgate, a vehicle can be provided with an opening and a pressure relief valve located in the opening. The pressure relief valve can open at an increased air pressure in the interior of the vehicle in order to allow air to escape within the interior, thereby reducing the air pressure in the interior of the vehicle and reducing the effort needed to close the tailgate.

[0075] Moreover, a vehicle having a pressure relief valve can influence airflow out of the vehicle cabin in order to increase passenger comfort. Because an air conditioning system draws ambient air from outside the vehicle and induces air into the vehicle cabin, a venting through the pressure relief valve is required in order to achieve proper circulation and to reduce pressurization in the cabin.

[0076] Because, for example, when a pressure relief valve is opened or even in the closed state of the pressure relief valve, noise can enter the interior of the vehicle from the outside, it is generally known from the prior art to assign to the pressure relief valve a cover serving as a sound-insulating space (muffler space). The cover serving as a sound-insulating space (muffler space) serves on the one hand for corresponding sound absorption and on the other hand also to dampen, in particular, closing noises of the pressure relief valve (flap closing noises).

[0077] One embodiment of a cover 101 for a pressure relief valve assembly 2 as known from the prior art is shown schematically and in an isometric view in FIG. 1.

[0078] The cover 101, which is generally known from this prior art, has, as a whole, a three-dimensional configuration that is formed by a plurality of side walls 106 and a wall region serving as a cover region 107. At corresponding edge regions of the side walls 106 facing away from the wall region serving as cover region 107, latching or snap-fitting connection elements 110 are provided, which allow the cover 101 to be connected to the frame or an edge region 4 of a pressure relief valve assembly 2 via a latching connection.

[0079] In order to achieve the most efficient sound reduction possible, a sound-absorbing material (not shown in FIG. 1) is typically arranged on the respective inner surfaces of the cover 101 in the form of at least one non-woven fabric mat or similar sound-insulating material.

[0080] However, the production of a conventional cover 101 known from the prior art, as shown in FIG. 1 for example, requires at least two automatable process steps that are separately performed and only with greater effort, if at all: in a first process step, the three-dimensional design of the cover 101 must be produced, which is usually carried out automatically as part of a plastic injection molding or plastic injection molding process. In a second process step, the three-dimensional design of the cover 101 must be provided with a sound-absorbing material.

[0081] However, the attachment of a sound-absorbing material to the inner surfaces of the cover 101 is relatively costly and usually takes place manually because, due to the three-dimensional design of the cover 101, commonly applicable automation techniques cannot be employed or only with relatively great effort.

[0082] In order to solve this situation, a cover 1 is proposed according to the invention, which cover no longer comprises an injection-molded component with additional sound-absorbing material, but rather comprises a base body made of a sound-absorbing material, which is uniform in terms of the material composition, wherein the base body is designed to be self-supporting as such and can be connected, in particular, to an edge region 4 of a pressure relief valve assembly 2.

[0083] In this way, it is possible that the cover 1 can be produced, in particular, in one and the same system to the extent that all of the features necessary for the operation of the cover 1 when used as intended are already configured in the same system.

[0084] An exemplary embodiment of such a cover 1 connected to a pressure relief valve assembly 2 according to the invention is shown schematically and in an isometric view in FIG. 2.

[0085] It must be emphasized here that the base body of the cover 1 is, as a whole, uniformly formed from a sound-absorbing material and as such is self-supporting, so that it can be connected to, in particular, an edge region 4 of a pressure relief valve assembly 2 without additional injection-molded parts, etc.

[0086] As can be seen, for example, in FIG. 2 or in FIG. 3, the base body of the cover 1 comprises in particular honeycomb-, rib-, or strut-shaped regions 5, in which the sound-absorbing material has been manipulated during production of the base body, in particular thermally treated and/or compressed or otherwise compacted, such that the base body has increased rigidity and/or strength at least in these regions 5. The honeycomb-, rib-, or strut-shaped regions 5 help to ensure that the base body is designed to be self-supporting as a whole.

[0087] As can furthermore be seen from the illustrations in FIG. 2 and FIG. 3, the base body is a one-piece, in particular monolithic base body and comprises side walls 6 and a cover region 7, wherein the side walls 6 and the cover region 7 ultimately delimit the three-dimensional muffler space of the cover 1.

[0088] During the production of the base body, the sound-absorbing material in an end region 8 of the side walls 6 opposite to the cover region 7 has been manipulated, in particular thermally treated and/or compressed or otherwise compacted, at least partly or regionally such that the base body has increased rigidity and/or strength in this region 8. In this way, the base body in the cover 1 can be connected to the edge region 4 of the pressure relief valve assembly 2 in a defined manner.

[0089] As indicated, for example, in FIG. 3 or FIG. 4, a rim or flange region 9 is formed on the end region 8 of the side walls 6 opposite to the cover region 7, which projects radially outward at least regionally and via which the base body can be connected to a pressure relief valve assembly 2 and in particular to an edge region 4 of a pressure relief valve assembly 2 which is preferably configured as an air vent assembly.

[0090] In this context, for example, reference is made to the illustration in FIG. 2.

[0091] However, as shown in FIG. 4B and FIG. 4C, other embodiments are also conceivable.

[0092] For example, FIG. 4B shows in sections that the base body of the cover 1 can also be configured without a rim or flange region 9, wherein the cover 1 or the base body of the cover 1 is then connected to the edge region 4 of the pressure relief valve assembly 2 via an adhesive or welded bond.

[0093] Alternatively, however, it is also conceivable that latching connection elements 10, in particular latching projections, are configured in or on the end region 8 of the side walls 6 opposite to the cover region 7, via which the base body can be connected, preferably releasably, to a pressure relief valve assembly 2 and in particular to an edge region 4 of a pressure relief valve assembly 2 which is preferably configured as an air vent assembly.

[0094] In this context, for example, reference is made to the illustration in FIG. 4C.

[0095] According to realizations of the cover 1 according to the invention, the sound-absorbing material, from which the base body is completely formed, is a sound-absorbing non-woven fabric, in particular made of mineral wool, synthetic fibers, and/or natural fibers.

[0096] It is also conceivable in this context that the sound-absorbing material is a sound-absorbing non-woven fabric, in particular made of plastic fibers of a thermoplastic material. In particular, the honeycomb-, rib-, or strut-shaped regions 5 of the base body can then, for example, also be formed from thermal treatment of the sound-absorbing material.

[0097] Referring to the illustrations in FIG. 5 to FIG. 10, a production variant of the cover 1 according to the invention is described in more detail below.

[0098] In particular, the flat sound-absorbing material 12 is initially provided in the form of a sheet of a non-woven material, for example.

[0099] Subsequently, the provided sound-absorbing material 12 is reshaped such that a base body is formed with side walls 6 and a cover region 7, which together delimit a three-dimensional muffler space.

[0100] In order to form the sound-absorbing material 12 provided, as shown in FIG. 4 and FIG. 5, for example, the sound-absorbing material 12 can be reshaped using a molding tool, preferably according to a compression molding or deep-drawing process. The molding tool preferably comprises a corresponding embossing die 13 and a die 14 in the form of a negative mold.

[0101] The embossing die 13 and the die 14 preferably comprise punched regions and/or groove regions 17 corresponding to each other and which are complementary to each other and via which holes 18 are introduced into the rim or flange region 9 of the base body of the cover 1 during the compression molding or deep-drawing process. The holes 18 preferably serve to position/orient and fasten the cover 1 to the edge region 4 of a pressure relief valve assembly 2.

[0102] As shown in the isometric views in FIG. 9 and FIG. 10, the embossing die 13 and die 14 have corresponding projecting regions 15, with which the sound-absorbing material 12 is manipulates during the reshaping process, in particular thermally treated and/or compressed or compacted, such that, in the base body, the aforementioned honeycomb-, rib-, or strut-shaped regions 5, in which the base body has an increased rigidity or strength, are formed in particular.

[0103] The other regions of the embossing die 13 or die 14 are designed such that, in the reshaping process, the sound-absorbing material 12 is only marginally compressed or compacted, if at all, so as to maintain the sound-insulating behavior of the sound-absorbing material 12 in these regions.

[0104] In this context, it is in particular also conceivable that the projecting or back-set regions 15 of the embossing die 13 and/or the die 14 can be heated locally, for example with the help of induction or heating coils, in order to cause a thermal deformation during the reshaping process in the corresponding regions of the sound-absorbing material 12.

[0105] Referring now to the illustration in FIG. 11, a further embodiment of a cover 1 for a pressure relief valve assembly 2 will be described

[0106] As shown in FIG. 11, the cover 1 comprises a base body 19 made of a sound-absorbing material which is uniform in terms of the material composition, wherein the base body 19 is partially supplemented with a plastic 20 in order to form a self-supporting composite component and is connectable to an edge region 4 of a pressure relief valve assembly 2. The plastic 20 is partially configured in order to form the self-supporting composite component by injection molding onto the base body 19.

[0107] When the cover is used as intended, said cover comprises inner wall regions facing in the direction of the pressure relief valve assembly 2 and outer wall regions facing away from the pressure relief valve assembly 2, wherein the plastic 20 is preferably exclusively and in particular partially present on the outer wall regions of the base body 19.

[0108] Upon injection of the plastic 20 onto the base body 19, latching means, in particular in the form of latching tabs 21, are formed, which are configured in order to form a latching connection with correspondingly complementary latching means in or on the edge region 4 of the pressure relief valve assembly.

[0109] Preferably, the base body 19 is formed by pressing, compression molding, and/or deep-drawing of a semi-finished product comprising the sound-absorbing material by means of a tool, wherein, in a further step, the base body is provided with the plastic 20 by injection molding. In the further step, the base body 19 is preferably provided with the plastic 20 by injection molding in the same tool.

[0110] The invention is not limited to the embodiments shown in the drawings, but rather results when all of the features disclosed herein are considered together.

LIST OF REFERENCE NUMERALS

[0111] 1 Cover

[0112] 2 Pressure relief valve assembly

[0113] 4 Edge region of the pressure relief valve assembly

[0114] 5 Rib/strut-shaped regions of the base body

[0115] 6 Side walls of the base body

[0116] 7 Cover region of the base body

[0117] 8 End region of the side walls of the base body

[0118] 9 Rim or flange region of the base body

[0119] 10 Latching connection elements

[0120] 11 Pressure relief valve/valve flap

[0121] 12 Flat sound-absorbing material

[0122] 13 Embossing die of the molding tool

[0123] 14 Die of the molding tool

[0124] 15 Projecting rib regions of the embossing die

[0125] 17 Punched region

[0126] 18 Holes

[0127] 19 Base body

[0128] 20 Injected plastic

[0129] 21 Latching means/latching tabs

[0130] 101 Cover (prior art)

[0131] 106 Side walls of the cover (prior art)

[0132] 107 Cover region of the cover (prior art)

[0133] 110 Latching connection element (prior art)