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. A baffle structure for a motor vehicle, comprising: an inner volumetric portion with planar faces, the inner volumetric portion comprising a random arrangement of at least partially interlinked, integrally connected threads, and at least one planar cover region, wherein the planar cover region comprises a portion of the threads fused together which form a higher density region of connected threads than in the inner volumetric portion, wherein the planar cover region has planar dimensions equal to or greater than a longitudinal planar face of the inner volumetric portion, wherein the baffle structure is cuboid and has two longitudinal sides opposite each other, two cover sides opposite each other and two end sides opposite each other, wherein a diagonal dimension of each of the two end sides is shorter than a diagonal dimension of each of the two longitudinal sides and a diagonal dimension of each of the two cover sides, and wherein the planar cover region is provided at both of the end sides.

2. The baffle structure as claimed in claim 1, further comprising: at least one web which has a separation face along which the baffle structure is assembled, wherein the web is part of the planar cover region, and/or wherein the web is contiguous to the planar cover region.

3. The baffle structure as claimed in claim 1, wherein the baffle structure in a volumetric portion that is contiguous to the end side has a higher thread density than in an inner volumetric portion that is contiguous to the volumetric portion of higher thread density.

4. A baffle structure for a motor vehicle, comprising: an inner volumetric portion with planar faces, the inner volumetric portion comprising a random arrangement of at least partially interlinked, integrally connected threads, and at least one planar cover region, wherein the planar cover region comprises a portion of the threads fused together which form a higher density region of connected threads than in the inner volumetric portion, wherein the planar cover region has planar dimensions equal to or greater than a longitudinal planar face of the inner volumetric portion, wherein the baffle structure has two longitudinal sides opposite each other, two cover sides opposite each other and two end sides opposite each other, wherein the baffle structure is an extrudate having a machine direction and a transverse direction, wherein the two longitudinal sides and the two cover sides extend in the machine direction, and the two end sides extend in the transverse direction, and wherein the planar cover region is provided at both of the end sides.

5. The baffle structure as claimed in claim 4, further comprising: at least one web which has a separation face along which the baffle structure is assembled, wherein the web is part of the planar cover region, and/or wherein the web is contiguous to the planar cover region.

6. The baffle structure as claimed in claim 4, wherein the baffle structure in a volumetric portion that is contiguous to the end side has a higher thread density than in an inner volumetric portion that is contiguous to the volumetric portion of higher thread density.

7. The baffle structure as claimed in claim 4, wherein: the baffle structure comprises a plurality of layers of the extrudate, which form a stack on one another.

8. The baffle structure as claimed in claim 7, wherein: the plurality of layers of the extrudate are folded over one another to form the stack.

9. The baffle structure as claimed in claim 7, wherein: the plurality of layers of the extrudate which form the stack also form the planar cover region.

10. The baffle structure as claimed in claim 4, wherein: the integrally connected threads are of a plurality of threads, and comprise more than 90% of the plurality of threads.

11. The baffle structure as claimed in claim 4, wherein: the integrally connected threads are welded to each other.

12. The baffle structure as claimed in claim 4, wherein: the planar cover region is formed completely of the integrally connected threads.

13. The baffle structure as claimed in claim 4, wherein: the threads are formed of thermoplastic.

14. The baffle structure as claimed in claim 4, wherein: the threads are formed of polyethylene or polypropylene.

15. The baffle structure as claimed in claim 4, wherein: the baffle structure is a liquid container baffle structure.

16. The baffle structure as claimed in claim 4, wherein: the baffle structure is a fuel tank baffle structure.

17. A baffle structure for a motor vehicle, comprising: an inner volumetric portion with planar faces, the inner volumetric portion comprising a random arrangement of at least partially interlinked, integrally connected threads, and at least one planar cover region, wherein the planar cover region comprises a portion of the threads fused together which form a higher density region of connected threads than in the inner volumetric portion, wherein the planar cover region has planar dimensions equal to or greater than a longitudinal planar face of the inner volumetric portion, wherein the baffle structure has two longitudinal sides opposite each other, two cover sides opposite each other and two end sides opposite each other, wherein the baffle structure is an extrudate having a machine direction and a transverse direction, wherein the two longitudinal sides and the two cover sides extend in the machine direction, and the two end sides extend in the transverse direction, and wherein the planar cover region is provided at one of the end sides by a compressed fold that forms the higher density region of connected threads than in the inner volumetric portion.

18. The baffle structure as claimed in claim 17, wherein: the compressed fold comprises a curvature compressed as to be planar.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) 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:

(2) FIGS. 1A, 1B show a structure according to the invention;

(3) FIG. 2 shows a device and a method for producing a structure; and

(4) FIG. 3 shows a device and a method for producing a structure.

DETAILED DESCRIPTION

(5) 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.

(6) 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.

(7) 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.

(8) 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.

(9) 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.

(10) A web 12 which has a separation face 14 along which the structure 2 has been assembled is provided.

(11) 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.

(12) 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.

(13) 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.

(14) The structure 2 is presently substantially cuboid, or occupies a cuboid volume, respectively.

(15) 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.

(16) 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.

(17) 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.

(18) 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.

(19) 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.

(20) 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.

(21) A further heating installation 39, a further cooling installation 41, and a further heat transmission plate 43 can be provided.

(22) 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.

(23) 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.

(24) 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.

(25) A method for producing a structural 2 will be described hereunder, said method having the following method steps: 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; producing an at least in portions planar cover on at least one side of the structure.

(26) 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.

(27) 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.

(28) 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.

(29) The arrangement of randomly mutually interlinked threads 4 continuously extruded in this way is subsequently fed to post-processing.

(30) 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.

(31) 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.

(32) 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.

(33) 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.

(34) 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.