STRUCTURE FOR REDUCING SLOSHING NOISES, DEVICE AND METHOD FOR PRODUCING A STRUCTURE

Abstract

Structure for reducing sloshing noises, said structure being provided for disposal in a liquids container for a motor vehicle, having a random arrangement of mutually interlinked threads, wherein a plurality of the threads at least in portions are connected in a materially integral manner to at least one or a plurality of further threads of the structure, wherein the structure has at least one side in the region of which a planar cover of the random arrangement of mutually interlinked threads is provided at least in portions.

Claims

1-21. (canceled)

22. A structure for reducing sloshing noises, said structure being provided for disposal in a liquids container for a motor vehicle comprising a random arrangement of mutually interlinked threads, wherein a plurality of the threads at least in portions are connected in a materially integral manner to at least one or a plurality of further threads of the structure, wherein the structure has at least one side in the region of which a planar cover of the random arrangement of mutually interlinked threads is provided at least in portions, wherein the planar cover has been formed in that threads assigned to the at least one side at least in portions have been fused and/or welded to one another so as to form the planar cover, and the at least one side of the structure is completely spanned by the planar cover, or the at least one side of the structure is covered across the entire area by the planar cover.

23. The structure as claimed in claim 22, wherein: at least one web which has a separation face along which the structure has been assembled is provided; wherein the web is part of the planar cover, and/or wherein the web is contiguous to the planar cover.

24. The structure as claimed in claim 22, wherein at least two planar covers which are disposed on sides of the structure that face away from one another are provided.

25. The structure as claimed in claim 22, wherein the structure in a volumetric portion that is contiguous to a longitudinal side and/or an end side and/or a cover side has a higher thread density than in an inner volumetric portion that is contiguous to the volumetric portion of higher thread density.

26. A device for producing a structure for reducing sloshing noises, said structure being provided for disposal in a liquids container for a motor vehicle comprising: an extrusion device for producing a random arrangement of mutually interlinked threads, wherein a plurality of the threads at least in portions are connected in a materially integral manner to at least one or a plurality of further threads; and at least one post-processing installation which is specified for producing an at least in portions planar cover on at least one side of the structure, wherein the planar cover has been formed in that threads assigned to the at least one side at least in portions have been fused and/or welded to one another so as to form the planar cover, and the at least one side of the structure is completely spanned by the planar cover, or the at least one side of the structure is covered across the entire area by the planar cover.

27. The device as claimed in claim 26, wherein the post-processing installation has a heating device which is specified for fusing and/or welding threads of the structure so as to form the at least in portions planar cover, wherein the heating device has one heating mirror.

28. The device as claimed in claim 27, wherein the heating mirror for compressing the random arrangement of mutually interlinked threads during a thermal input, is movable along an extruding direction and counter to an extruding direction of the random arrangement of mutually interlinked threads.

29. The device as claimed in claim 26, wherein the post-processing installation has a cooling device which is specified for cooling threads that have been fused and/or welded so as to form the at least in portions planar cover, wherein the cooling device has one cooling mirror.

30. The device as claimed in preceding claim 29, wherein the cooling mirror is movable along an extruding direction and counter to an extruding direction of the random arrangement of mutually interlinked threads.

31. The device as claimed in claim 27, wherein the post-machining installation has at least one anti-stick layer which is provided for bearing on the random arrangement of mutually interlinked threads and which is specified for supplying heat by way of the heating device and/or for discharging heat by way of the cooling device.

32. The device as claimed in claim 31, the anti-stick layer is provided on a plate which is movable relative to a heating device and/or a cooling device transversely to an extruding direction of the random arrangement of mutually interlinked threads.

33. The device as claimed in claim 26, wherein the post-processing installation has at least one separation installation for assembling the structure.

34. The device as claimed in claim 26, wherein: an installation for guiding and directing the extruded random arrangement of mutually interlinked threads is provided, having a deflection installation for deflecting once, twice, or multiple times, the extruded random arrangement of mutually interlinked threads, wherein the deflection installation is specified for deflecting the extruded random arrangement of mutually interlinked threads at least in portions in a meandering manner, and/or having a buffer installation which for releasing an additional extrusion path is specified for diverting the extruded random arrangement of mutually interlinked threads transversely to the extruding direction.

35. A method for producing a structure, comprising the following method steps: extruding and interlinking threads so as to form a random arrangement of mutually interlinked threads, wherein a plurality of the threads at least in portions are connected in a materially integral manner to at least one or a plurality of further threads; producing an at least in portions planar cover on at least one side of the structure, wherein the random arrangement of mutually interlinked threads is deflected at least twice, deflected in a meandering manner, wherein the planar cover is generated by actuating a heating mirror in the direction of a curvature formed by the deflection of the random arrangement of mutually interlinked threads, and/or the random arrangement of mutually interlinked threads is continuously extruded, wherein fusing and/or welding of threads is performed, wherein the continuously extruded random arrangement of mutually interlinked threads is guided transversely to the extruding direction into a buffer accumulator, wherein the threads prior to feeding to the buffer accumulator are at least in part dried.

36. The method as claimed in claim 35, the producing of an at least in portions planar cover on at least one side of the structure is performed by fusing and/or welding threads of the structure so as to form the at least in portions planar cover.

37. The method as claimed in claim 35, wherein the fusing of threads of the structure so as to form the at least in portions planar cover is performed by placing the threads so as to bear on a heating device.

38. The method as claimed in claim 36, wherein cooling by a cooling device is performed after the fusing and/or welding of the threads.

39. The method as claimed in claim 37, wherein the heating device and/or the cooling device and/or a heat transmission plate are/is moved in the direction of the random arrangement of mutually interlinked threads so as to be brought to bear on and compress the random arrangement of mutually interlinked threads.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0086] The invention will be described in more detail hereunder by means of a drawing illustrating an exemplary embodiment. In the drawing, in each case in a schematic manner:

[0087] FIGS. 1A, 1B show a structure according to the invention;

[0088] FIG. 2 shows a device and a method for producing a structure; and

[0089] FIG. 3 shows a device and a method for producing a structure.

DETAILED DESCRIPTION

[0090] FIG. 1 shows a structure 2 for reducing sloshing noises. The structure 2 is provided for disposal in a liquids container for a motor vehicle. The structure 2 has a random arrangement of mutually interlinked threads 4 which in the region of the outer shell faces thereof are locally welded to one another. The enlargement in FIG. 1A shows one such local welding 5.

[0091] A plurality of the threads 4 at least in portions is connected in a materially integral manner to at least one or a plurality of further threads 4 of the structure 2.

[0092] The structure 2 has at least one side 6 in the region of which at least in portions a planar cover 8 of the random arrangement of mutually interlinked threads 4 is provided.

[0093] The planar cover 8 has been formed in that threads 4 assigned to the at least one side 6 have been at least in portions fused and/or welded to each other so as to form the planar cover 8. The planar cover 8 presently is composed of the material of the threads 4. The threads 4 are presently composed of a thermoplastic plastics material.

[0094] FIG. 1B describes the case in which the at least one side 6 of the structure 2 is covered across the entire area by the planar cover 8. In the case of FIG. 1B, the planar cover 8 of the side 6 is therefore without gaps. According to alternative design embodiments it can be provided that the planar cover has gaps in the region of which the threads have not been welded and/or fused, or refused, respectively, to each other so as to form a continuous face.

[0095] A web 12 which has a separation face 14 along which the structure 2 has been assembled is provided.

[0096] The web 12 is part of the planar cover 8 and is contiguous to the planar cover 8. The web 12 is presently formed so as to be integral to the planar cover 8 by fusing or refusing, respectively, the threads 4 of the structure 2. The web 12 is composed of a solid material, and the separation face 14 is closed across the entire area.

[0097] The structure 2 according to FIG. 1B presently has a second planar cover 16. The second planar cover 16 is disposed on a side 18 of the structure 2 that faces away from the side 6 according to FIG. 1B, and has likewise been formed by fusing or refusing, respectively, and/or welding the threads 4.

[0098] The structure 2 according to FIG. 1B in volumetric portions 24, 26 that are contiguous to a longitudinal side 20 and to a longitudinal side 22 has in each case a higher thread density than in an inner volumetric portion 28 that is contiguous to the volumetric portions 24, 26 of higher thread density.

[0099] The structure 2 is presently substantially cuboid, or occupies a cuboid volume, respectively.

[0100] FIG. 2 shows an extrusion device 32 for producing a random arrangement of mutually interlinked threads 4. In the production of the random arrangement of mutually interlinked threads 4, a plurality of threads 4 at least in portions are connected in a materially integral manner to at least one or a plurality of further threads 4.

[0101] A post-processing installation 34 which is specified for producing the at least in portions planar cover 8, 16 of sides 6, 18 of the structure 2 to be produced is provided.

[0102] The post-processing installation 34 has a heating device 36. The heating device 36 is specified for fusing and/or welding threads 4 of the structure 2 so as to form the at least in portions planar cover 8, 16. The heating device 36 has a heating mirror 38. The heating mirror 38 is movable along an extruding direction 40, counter to the extruding direction 40, and transversely to the extruding direction 40 of the random arrangement of mutually interlinked threads 4.

[0103] The post-processing installation 34 has a cooling device 42 which is specified for cooling threads 4 that have been fused and/or welded so as to form the at least in portions planar cover 8, 16, wherein the cooling device 42 has a cooling mirror 44.

[0104] The cooling mirror 44 is movable along an extruding direction 40, counter to the extruding direction 40, and transversely to the extruding direction 40 of the random arrangement of mutually interlinked threads 4.

[0105] The post-processing installation 34 has an anti-stick layer 46 which is provided on a plate 48. The anti-stick layer 46 of the plate 48 is provided so as to bear on the random arrangement of mutually interlinked threads 4. A thermal input from the heating device 36 to the random arrangement of mutually interlinked threads takes place by way of the plate 48. A thermal output by way of the cooling device 42 likewise takes place by way of the plate 48.

[0106] A further heating installation 39, a further cooling installation 41, and a further heat transmission plate 43 can be provided.

[0107] The heating device and the cooling device on a side of the plate 48 that faces away from the thread structure 4 can be brought to bear on the plate so as to effect a temperature change. The heating mirror can thus be removed from the position on the plate 48 illustrated in FIG. 2, wherein the cooling mirror 44 is subsequently brought to bear on the plate 48. The plate 48 acts in each case as a heat transmitting element for the thermal input to the threads 4 for the thermal output from the planar cover 8, 16.

[0108] An installation 52 for guiding and directing the extruded random arrangement of mutually interlinked threads 4 is provided. The installation 52 for guiding and directing has a deflection installation 54 which is specified for deflecting in a substantially meandering manner the extruded random arrangement of interlinked threads 4.

[0109] The installation 52 for guiding and directing moreover has a buffer installation 56 which is specified for diverting the extruded random arrangement of mutually interlinked threads 4 transversely to the extruding direction 40 so as to release an additional extrusion path 58.

[0110] A method for producing a structural 2 will be described hereunder, said method having the following method steps: [0111] extruding and interlinking threads 4 so as to form a random arrangement of mutually interlinked threads 4, wherein a plurality of the threads 4 at least in portions is connected in a materially integral manner to at least one or a plurality of further threads; [0112] producing an at least in portions planar cover on at least one side of the structure.

[0113] In order for the random arrangement of mutually interlinked threads 4 to be provided, a plastics material is initially melted in an extruder 60 and guided through a die 62 such that a thread matrix 64 is provided, the threads 4 of said thread matrix 64 running in a mutually parallel manner and having a mutual spacing.

[0114] The thread matrix 64 is guided over rollers 66, wherein the rollers 66 have a smaller mutual spacing than the width of the thread matrix. On account thereof, outer threads 68 of the thread matrix are inwardly offset in the direction of inner threads 70 of the thread matrix 64, said outer threads 68 welding in the region of the circumferential shell faces thereof. The arrangement of randomly mutually interlinked threads which are locally welded to one another formed in this way can subsequently be cooled and set, in particular in a water bath 72.

[0115] The arrangement of randomly mutually interlinked threads 4 can be set on account of the at least partial cooling. In particular, the random arrangement of mutually interlinked threads 4 can be formed so as to be in particular monolithic. This means that each thread 4 of the random arrangement of mutually interlinked threads 4 is locally welded to at least one further thread 4 in the region of the external shell face thereof, or in any case is not releasable in a non-destructive manner from the structure.

[0116] The arrangement of randomly mutually interlinked threads 4 continuously extruded in this way is subsequently fed to post-processing.

[0117] Planar covers 8, 16 are produced by fusing and welding threads 4 with the aid of the post-processing installation 34. During the discontinuous welding procedure, the strand of the random arrangement of mutually interlinked threads 4 that continues to be continuously extruded is extruded in an ongoing manner at a constant rate, wherein the material is guided transversely to the extruding direction 40 into the buffer installation 56 so as to avoid a backlog ahead of the post-processing installation 34.

[0118] After the discontinuous welding in the region of the post-processing installation 34, the buffer accumulator is depleted again, and the material guided in the loop 58 of the buffer accumulator 56 is fed to the post-processing installation 34.

[0119] As is to be derived from the drawing, the continuously extruded arrangement of randomly mutually interlinked threads 4 in the region of the post-processing installation 34 is stacked in a meandering manner such that simultaneous welding of a plurality of planar covers 8, 16 is enabled.

[0120] The welding is performed in the region of an outer curvature 74, wherein the respective separation installation 50 is provided on a fold 76 that faces away from the outer curvature. The separation element 50, or the separation installation 50, respectively, can be actuated after the welding or refusing, respectively, of the threads 4 so as to form the planar covers 8, 16, such that only a narrow web 12 from solid material remains.

[0121] A structure 2 can subsequently be separated from the continuous material with the aid of the separation installation. Alternatively or additionally, the separating of the structure 2 from the continuous material can be performed by manual cutting, or by a downstream separate cutting installation.