CN113878891A - 用于制造多层的热防护件的方法和设备 - Google Patents

用于制造多层的热防护件的方法和设备 Download PDF

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CN113878891A
CN113878891A CN202110634659.2A CN202110634659A CN113878891A CN 113878891 A CN113878891 A CN 113878891A CN 202110634659 A CN202110634659 A CN 202110634659A CN 113878891 A CN113878891 A CN 113878891A
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metal layer
edge section
fold
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mould
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C·索恩塔格
T·杜普迈尔
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Benteler Automobiltechnik GmbH
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Abstract

本发明涉及用于制造多层的热防护件的方法和设备。为了制造热防护件而将第一金属层、隔热层和第二金属层置入第一压制模具中，使得第一金属层的边缘区段相对于第二金属层的边缘区段伸出。隔热层相对于第一金属层和第二金属层的边缘区段向后缩进。随后使第一金属层和第二金属层的边缘区段相对于隔热层的水平面变形，第一金属层和第二金属层的边缘区段共同沿一个方向弯折，且第一金属层的边缘区段的伸出的翼边逆着变形方向调整成直立折叠部，直立折叠部具有折弯端和自由端。第二金属层的边缘区段的自由端容纳在第一金属层的边缘区段与直立折叠部之间。随后将夹层结构转移到第二压制模具中。在那里将直立折叠部围绕第二金属层的边缘区段翻折成卷边。

Description

用于制造多层的热防护件的方法和设备
技术领域
本发明涉及一种根据权利要求1前序部分特征的用于制造多层的热防护件的方法，本发明还涉及一种用于制造多层的热防护件的设备。
背景技术
在车辆上的各种应用中使用热防护件，以便防止或减少热传递到特定区域或从特定区域传递热。在机动车中，热防护件主要(但不仅仅)在如下区域中使用，在所述区域中，热的构件(如排气装置组件或发动机组件)设置为与热敏的构件、机组或区域相邻。在机动车的乘员舱和排气系统之间使用热防护件也是常见的，以便减少从发动机和排气组件的热传递。
多层的热防护件由于DE202011106603U1而属于现有技术，其中，各金属层在边缘侧通过翻边连接。
EP1775437A1也公开了一种热防护件，所述热防护件具有第一金属层和第二金属层，所述第一金属层和所述第二金属层通过如下方式相互连接，即第一金属层的外边缘区段基本上完全环绕地围绕第二金属层的外边缘翻折到第二金属层上。此外，将外边缘区段的至少一部分区域焊接到第二金属层上并且随后使第一金属层和第二金属层三维成型。
在已知的实施方式中的热防护件具有第一金属层和第二金属层连同设置在各所述金属层之间的隔热层。为了制造，通常用两个位于外部的金属层和位于内部的隔热材料来制造夹层结构。所述制造以多个工艺步骤进行。在此，通常深冲第一金属层，以便产生环绕的90°折叠边缘。随后定位隔热层并且在其上定位第二金属层。在下一步骤中，借助模具调整环绕的折叠边缘，从而各金属层在边缘侧通过翻边连接。然后在进一步的方法步骤中，将折叠边缘在两个平坦的板之间压紧。
发明内容
从现有技术出发，本发明的任务在于，更合理地设计一种用于制造多层的热防护件的方法和设备，并且特别是减少为了将至少两个金属层在边缘侧连接所需的制造步骤。
根据本发明，所述任务的解决方案在于一种根据权利要求1所述的方法和一种用于制造多层的热防护件的设备。
根据本发明的方法的有利的改进方案是各从属权利要求的主题。
用于制造多层的热防护件的方法，该热防护件具有第一金属层和第二金属层连同设置在各所述金属层之间的隔热层，并且各所述金属层在边缘侧通过翻边连接，所述方法规定以下处理方式：
-将第一金属层、隔热层和第二金属层置入到第一压制模具中。为此，可以事先由第一金属层、隔热层和第二金属层形成被置入到第一压制模具中的夹层结构。有利地，所述夹层结构可以由第一金属层、隔热层和第二金属层在第一压制模具中形成。第一金属层、隔热层和第二金属层在第一压制模具中这样设置，即第一金属层的边缘区段相对于第二金属层的边缘区段伸出，并且隔热层相对于第一金属层和第二金属层的边缘区段向后缩进。
-然后使第一金属层的边缘区段和第二金属层的边缘区段相对于隔热层的水平面变形，其中，第一金属层的边缘区段和第二金属层的边缘区段共同沿一个方向弯折，并且第一金属层的边缘区段的伸出的翼边逆着变形方向调整成直立折叠部，该直立折叠部具有折弯端和自由端。
-随后，将所述夹层结构转移到第二压制模具中并在那里将所述夹层结构容纳在上模具与下模具之间，并且将所述压制模具闭合，其中，上模具和下模具朝向彼此运动，并且在闭合运动时在直立折叠部的自由端与下模具接触之前，上模具与直立折叠部的折弯端接触，并且使第一金属层的边缘区段的直立折叠部翻折成围绕第二金属层的边缘区段的卷边。
第一金属层和第二金属层连同容纳在它们之间的隔热层的接合在两个压制模具中在两阶段式的过程中实现。通过制造过程的合理的实施方案可以节省压制模具或成型模具。将用于制造热防护件的先前通常为三个的制造步骤减少到两个制造步骤。
各金属层特别是具有大约0.2mm的厚度的金属箔。各金属层可以由钢和其它耐热的金属(包括轻金属)制成。隔热层由具有优选大约0.8mm的厚度的隔热材料制成。在此，可以涉及有机纤维材料或纤维纸或类似的、特别是层状的阻热材料。
为了制造热防护件，由第一金属层、隔热层和第二金属层形成夹层结构。这在第一压制模具中进行。所有的层都借助定位辅助器保持在压制模具中。所述定位辅助器例如可以由定位销形成。特别是，借助在下模具中的定位辅助器来形成和保持夹层结构。但是，定位辅助器例如也可以由层本身构成，例如其方式为使三个部件，即第一金属层、隔热层和第二金属层通过冲压铆接而连接。当然也可以将各个层力锁合地定位在上模具与下模具之间。
第一金属层的尺寸设定为大于第二金属层的尺寸。因此，第一金属层在平面上具有较大的尺寸。在第一压制模具中这样进行定位，即第一金属层的边缘区段相对于第二金属层的边缘区段伸出。这样设定隔热层的尺寸并且所述隔热层在两个金属层之间这样设置，使得所述隔热层或所述隔热层的边缘相对于第一金属层和第二金属层的边缘区段向后缩进。隔热层的面积小于第二金属层的面积。第二金属层的面积又小于第一金属层的面积。
第一变形步骤规定，第一金属层的边缘区段和第二金属层的边缘区段相对于隔热层的水平面变形，其中，第一金属层的边缘区段和第二金属层的边缘区段共同沿一个方向弯折。在该变形过程中，第一金属层的边缘区段这样成型到压制模具的成型容纳部中，使得第一金属层的边缘区段的伸出的翼边逆着变形方向调整成直立折叠部。所述直立折叠部具有在从边缘区段到直立折叠部的过渡处的折弯端以及具有自由端。折弯端意味着，直立折叠部以相对尖锐的弯曲部来调整。
随后，将由第一金属层和第二金属层连同设置在它们之间的隔热层构成的夹层结构转移到第二压制模具中并且在那里容纳在上模具与下模具之间。然后将第二压制模具闭合，其中，上模具和下模具相对于彼此运动或者朝向彼此运动。在闭合运动时，更确切地说，在直立折叠部的自由端与下模具接触之前，上模具与直立折叠部的折弯端接触。由于向下运动和杠杆作用(在所述杠杆作用中，折弯端支撑在上模具的壁上并且相对于该壁向外运动)，故直立折叠部的自由端向下并且向内沿朝向隔热层的方向运动或者说弯曲。随着第二压制模具的合拢，直立折叠部围绕第二金属层的边缘区段倒下并且被翻折成卷边。于是，第一金属层的上部的边缘区段和位于所述上部的边缘区段下方的直立折叠部大致彼此平行地延伸。在第一金属层的边缘区段与直立折叠部之间容纳有第二金属层的边缘区段。
制造仅需要两个压制模具和两个制造步骤。
在第一压制模具中，直立折叠部调整为，使得在第一金属层的直立折叠部与边缘区段之间围成锐角，该锐角设计为特别是小于或等于(≤)50°。在直立折叠部贴靠在压制模具中时，在第一接触点处的接触导致折弯端的转动运动，使得自由端向内运动。这种处理方式有利地支持翻折过程并且确保直立折叠部在下一个制造步骤中可靠地向内朝向隔热层运动，而直立折叠部的折弯端相对地远离隔热层向外运动。
第二金属层的边缘区段的自由端容纳在第一金属层的直立折叠部与边缘区段之间。特别是，在第一压制模具中对第一金属层的边缘区段的伸出的翼边进行调整之后，第二金属层的边缘区段的自由端容纳在第一金属层的边缘区段与直立折叠部之间。
在第二压制模具的闭合运动中，直立折叠部的折弯端相对于隔热层向外运动、即远离隔热层运动，而直立折叠部的自由端相对于隔热层向内运动、即沿朝向隔热层的方向运动。
此外，本发明还涉及一种用于制造多层的热防护件的设备，尤其是所述设备可以用于实施根据本发明的方法，所述设备包括：
-第一压制模具，所述第一压制模具具有第一模具半部和第二模具半部，在第一模具半部中设置有成型轮廓，所述第一模具半部和所述第二模具半部能相对于彼此运动，使得在第一金属层、隔热层和第二金属层以如下方式置入在所述第一压制模具中时，即第一金属层的边缘区段相对于第二金属层的边缘区段伸出并且隔热层相对于第一金属层和第二金属层的边缘区段向后缩进，第一金属层的边缘区段和第二金属层的边缘区段被第二模具半部挤压到第一模具半部的成型轮廓中并且因此相对于隔热层的水平面变形，其中，第一金属层的边缘区段和第二金属层的边缘区段共同沿一个方向弯折，并且第一金属层的边缘区段的伸出的翼边逆着变形方向被调整成直立折叠部，该直立折叠部具有折弯端和自由端；
-第二压制模具，所述第二压制模具具有上模具和下模具，第二压制模具构造为，使得在第一压制模具中产生的由第一金属层、隔热层和第二金属层形成的夹层结构在打开的第二压制模具中被容纳在上模具与下模具之间，并且当所述第二压制模具闭合时所述上模具和所述下模具朝向彼此运动，并且在闭合运动时在直立折叠部的自由端与下模具接触之前，上模具与所述直立折叠部的折弯端接触，并且使第一金属层的边缘区段的直立折叠部翻折成围绕第二金属层的边缘区段的卷边。
根据一种实施方式，所述第一压制模具构造为用于将所述直立折叠部调整为，使得在第一金属层的直立折叠部与边缘区段之间围成的角度小于或等于50°。
根据一种实施方式，所述第一压制模具构造为用于将夹层结构形成为，使得第二金属层的边缘区段的自由端容纳在第一金属层的直立折叠部与边缘区段之间。
根据一种实施方式，所述第二压制模具构造为，使得在所述第二压制模具的闭合运动中，直立折叠部的折弯端与上模具接触并被向下挤压，从而所述折弯端相对于隔热层向外运动，并且所述直立折叠部的自由端相对于所述隔热层向内运动。
附图说明
下面借助附图更详细地说明本发明。在附图中：
图1和图2示出第一压制模具的局部连同两个制造情形的视图，以及
图3至图6示出第二压制模具的局部连同在制造热防护件时用于在边缘侧连接所述热防护件的各金属层的制造流程。
具体实施方式
借助图1至图6描述在不同的制造阶段中对多层的热防护件1的制造。这些视图应理解为是示意性的并且是技术上简化的以及是不按比例尺的。
根据本发明所制造的多层的热防护件1(对此参见图6)具有第一金属层2和第二金属层3连同设置在所述金属层2、3之间的隔热层4。第一金属层2和第二金属层3在边缘侧通过翻边连接。这特别是环绕地、特别是围绕热防护件1的整个周边环绕地实现。
为了制造多层的热防护件1，提供第一金属层2和第二金属层3以及隔热层4。第一金属层2和第二金属层3特别是具有大约0.2mm的厚度的金属箔。隔热层4由隔热材料或热防护材料、例如有机纤维纸制成并且具有大约0.8mm的厚度。
隔热层4在其水平延伸中具有面积。所述面积设计为小于第二金属层3的面积。第二金属层3的面积的大小又设计为小于第一金属层2的面积。
将第一金属层2、隔热层4和第二金属层3置入到第一压制模具5(图1和图2)中。由第一金属层2、隔热层4和第二金属层3形成的夹层结构6这样构造，即第一金属层2的边缘区段7相对于第二金属层3的边缘区段8伸出，并且隔热层4相对于第一金属层2和第二金属层3的边缘区段7、8向后缩进(对此参见图1)。随后，使第一压制模具5的第一模具半部9和第二模具半部10相对于彼此运动，其中，第一金属层2的边缘区段7和第二金属层3的边缘区段8相对于隔热层4的水平面HE变形。在此，第一金属层2的边缘区段7和第二金属层3的边缘区段8共同沿一个方向(箭头U1)弯折，相反，第一金属层2的边缘区段7的伸出的翼边11逆着变形方向(箭头U2)变形为直立折叠部12。在模具半部9中设置有成型轮廓13，边缘区段7和边缘区段8被第二模具半部10挤压到该成型轮廓中。伸出的翼边11构造为比成型轮廓13的开口长。第二金属层3的边缘区段8以其端侧与成型轮廓13的开口侧的边缘大致齐平。
直立折叠部12具有折弯端14和自由端15。在第一金属层2的直立折叠部12与边缘区段7之间围成的角度α小于或等于(≤)50°(对此参见图3)。在图3中示出的用于阐明的实施例中，角度α为大约45°。第二金属层3的边缘区段8的自由端被容纳在第一金属层2的直立折叠部12与边缘区段7之间。
变形方向U1对应于第一压制模具5的第一模具半部9相对于第二模具半部10的运动方向。直立折叠部12沿相反的方向U2被调整。
然后将夹层结构6转移到第二压制模具16中。第二压制模具16在图3至图6中示意性地示出。第二压制模具16具有上模具17和下模具18。由第一金属层2和第二金属层3连同置入它们之间的隔热层4构成并且在边缘侧预成型的夹层结构6容纳在上模具17与下模具18之间。随后将压制模具16闭合，其中，上模具17和下模具18朝向彼此运动。上模具17和下模具18的运动以及在此时施加的力在图4至图6中由箭头F表明。显然，也可以分别仅使上模具17或下模具18相对于相应的另一个模具运动。
在压制模具16中，第一金属层2的边缘区段7和第二金属层3的边缘区段8又逆着第一制造步骤的变形方向U1折回。在这个闭合运动中，上模具17与直立折叠部12的折弯端14接触。可以看出，直立折叠部12的折弯端14在图平面内相对于第一金属层2、隔热层4和第二金属层3的面延伸朝向上模具17突出。
直立折叠部12的折弯端14与上模具17接触。由此，折弯端14被向下挤压。在此，折弯端14根据箭头A向外滑动。第一金属层2的边缘区段7向下弯曲。同时，直立折叠部12的自由端15根据箭头I向内运动。在进一步的闭合运动中，直立折叠部12的自由端15与下模具18接触。第一金属层2的边缘区段7的直立折叠部12倒下并且翻折成围绕第二金属层3的边缘区段8的卷边19。
在图3中，在第一金属层2的上侧20与上模具17之间的竖直距离用Δx1来表明。在直立折叠部12的自由端15与下模具18之间的距离由Δx2来表明。在第一制造步骤中通过使第一金属层2和第二金属层3的边缘区段7、8弯折以及将第一金属层2的边缘区段7的伸出的翼边11调整成直立折叠部12来将几何布局实施为，使得在第二压制模具16中在闭合运动时，在直立折叠部12的自由端15与下模具18接触之前，直立折叠部12的折弯端14与上模具17接触并且被该上模具向下挤压。在边缘区段7的长度上在折弯端14与弯曲点21之间作用的杠杆臂使得直立折叠部12向内倒下。由此，在第二压制模具16中一次性实现折边连同构造卷边19。
热防护件1的制造以合理的方式在两个制造步骤和两个压制模具5和16中进行。
附图标记列表
1 热防护件
2 第一金属层
3 第二金属层
4 隔热层
5 第一压制模具
6 夹层结构
7 第一金属层2的边缘区段
8 第二金属层3的边缘区段
9 第一压制模具5的第一模具半部
10 第一压制模具5的第二模具半部
11 夹层结构6的翼边
12 直立折叠部
13 成型轮廓
14 直立折叠部12的折弯端
15 直立折叠部12的自由端
16 第二压制模具
17 上模具
18 下模具
19 卷边
20 第一金属层2的上侧
21 弯曲点
HE 隔热层4的水平面
U1 变形方向箭头
U2 变形方向箭头
A 箭头
F 箭头
I 箭头
α 角度

Claims (9)

1.一种用于制造多层的热防护件(1)的方法，所述热防护件具有第一金属层(2)和第二金属层(3)连同设置在各所述金属层(2、3)之间的隔热层(4)，各所述金属层(2、3)在边缘侧通过翻边连接，其特征在于，
-将第一金属层(2)、隔热层(4)和第二金属层(3)置入到第一压制模具(5)中，第一金属层(2)的边缘区段(7)相对于第二金属层(3)的边缘区段(8)伸出，并且隔热层(4)相对于第一金属层(2)和第二金属层(3)的边缘区段(7、8)向后缩进；
-使第一金属层(2)的边缘区段(7)和第二金属层(3)的边缘区段(8)相对于隔热层(4)的水平面(HE)变形，第一金属层(2)的边缘区段(7)和第二金属层(3)的边缘区段(8)共同沿一个方向弯折，并且第一金属层(2)的边缘区段(7)的伸出的翼边(11)逆着变形方向调整成直立折叠部(12)，该直立折叠部具有折弯端(14)和自由端(15)；
-之后，将由第一金属层(2)、隔热层(4)和第二金属层(3)形成的夹层结构(6)转移到第二压制模具(16)中并且在那里将所述夹层结构容纳在上模具(17)与下模具(18)之间，并且随后将所述第二压制模具(16)闭合，所述上模具(17)和所述下模具(18)朝向彼此运动，并且在闭合运动时在直立折叠部(12)的自由端(15)与下模具(18)接触之前，上模具(17)与所述直立折叠部(12)的折弯端(14)接触，并且使第一金属层(2)的边缘区段(7)的直立折叠部(12)翻折成围绕第二金属层(3)的边缘区段(8)的卷边(19)。
2.根据权利要求1所述的方法，其特征在于，将所述直立折叠部(12)调整为，使得在第一金属层(2)的直立折叠部(12)与边缘区段(7)之间围成的角度(α)小于或等于50°。
3.根据权利要求1或2所述的方法，其特征在于，将第二金属层(3)的边缘区段(8)的自由端(15)容纳在第一金属层(2)的直立折叠部(12)与边缘区段(7)之间。
4.根据权利要求1至3中任一项所述的方法，其特征在于，在第二压制模具(16)的闭合运动中，直立折叠部(12)的折弯端(14)相对于隔热层(4)向外运动，并且所述直立折叠部(12)的自由端(15)相对于所述隔热层(4)向内运动。
5.一种用于制造多层的热防护件(1)的设备，所述设备包括：
-第一压制模具(5)，所述第一压制模具具有第一模具半部(9)和第二模具半部(10)，在第一模具半部(9)中设置有成型轮廓(13)，所述第一模具半部(9)和所述第二模具半部(10)能相对于彼此运动，使得在第一金属层(2)、隔热层(4)和第二金属层(3)以如下方式置入在所述第一压制模具(5)中时，即第一金属层(2)的边缘区段(7)相对于第二金属层(3)的边缘区段(8)伸出并且隔热层(4)相对于第一金属层(2)和第二金属层(3)的边缘区段(7、8)向后缩进，第一金属层(2)的边缘区段(7)和第二金属层(3)的边缘区段(8)被第二模具半部(10)挤压到第一模具半部(9)的成型轮廓(13)中并且因此相对于隔热层(4)的水平面(HE)变形，其中，第一金属层(2)的边缘区段(7)和第二金属层(3)的边缘区段(8)共同沿一个方向弯折，并且第一金属层(2)的边缘区段(7)的伸出的翼边(11)逆着变形方向被调整成直立折叠部(12)，该直立折叠部具有折弯端(14)和自由端(15)；
-第二压制模具(16)，所述第二压制模具(16)具有上模具(17)和下模具(18)，第二压制模具(16)构造为，使得在第一压制模具中产生的由第一金属层(2)、隔热层(4)和第二金属层(3)形成的夹层结构(6)在打开的第二压制模具(16)中被容纳在上模具(17)与下模具(18)之间，并且当所述第二压制模具(16)闭合时所述上模具(17)和所述下模具(18)朝向彼此运动，并且在闭合运动时在直立折叠部(12)的自由端(15)与下模具(18)接触之前，上模具(17)与所述直立折叠部(12)的折弯端(14)接触，并且使第一金属层(2)的边缘区段(7)的直立折叠部(12)翻折成围绕第二金属层(3)的边缘区段(8)的卷边(19)。
6.根据权利要求5所述的设备，其特征在于，所述第一压制模具(5)构造为用于将所述直立折叠部(12)调整为，使得在第一金属层(2)的直立折叠部(12)与边缘区段(7)之间围成的角度(α)小于或等于50°。
7.根据权利要求5或6所述的设备，其特征在于，所述第一压制模具(5)构造为用于将夹层结构(6)形成为，使得第二金属层(3)的边缘区段(8)的自由端(15)容纳在第一金属层(2)的直立折叠部(12)与边缘区段(7)之间。
8.根据权利要求5至7中任一项所述的设备，其特征在于，所述第二压制模具(16)构造为，使得在所述第二压制模具(16)的闭合运动中，直立折叠部(12)的折弯端(14)与上模具(17)接触并被向下挤压，从而所述折弯端(14)相对于隔热层(4)向外运动，并且所述直立折叠部(12)的自由端(15)相对于所述隔热层(4)向内运动。
9.根据权利要求5至8中任一项所述的设备，其特征在于，所述设备用于实施根据权利要求1至4中任一项所述的方法。
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