DE102020116141A1 - Insulating element for recreational vehicles and a process for its production - Google Patents

Abstract

The invention relates to a method for producing an insulating element (11) for recreational vehicles, such as. B. box van, comprising the following steps: a) providing an openable and closable mold (1) with a receiving part (3) having a receiving space (2) and a cover part (4), the mold (1) having a cavity in the closed state (10) and wherein the receiving part (3) and the cover part (4) are connected to one another when the mold (1) is closed and are at least partially separated from one another when the mold (1) is open;b) arranging at least one decorative element (8 ) in the receiving space (2) of the receiving part (3) of the mold (1); c) applying hardenable plastic material (9) to the at least one decorative element (8); d) allowing the plastic material (9) to harden in the closed mold (1) e) opening the mold (1) and removing the insulating element (11) formed in this way.

Description

The invention relates to a method for producing an insulating element for recreational vehicles, such as. B. panel van and an insulating element which can be produced in particular by the method according to the invention.

To insulate the roof and / or the side walls of recreational vehicles, such as box vans, a large number of individual insulation elements made of plastic, such as foam, have been glued to the surfaces to be insulated. After these insulation elements have been glued, a desired decoration, such as plywood, fabric or leather, is then applied to the insulation elements, in particular screwed or glued on. Often there is a screw connection in the side walls or the roof.

However, the procedure described, which is known from the prior art, has various disadvantages. When the insulation elements are glued in, this creates butt joints between the individual insulation elements, which act as thermal bridges. For example, with an average-sized panel van, up to 65 individual blanks have to be glued onto a roof. Due to the resulting thermal bridges, the thermal insulation naturally suffers, which is a problem especially in winter, as the thermal bridges hardly allow a comfortable interior temperature to be built up or maintained in the vehicle. This is also a disadvantage in summer, since it is only inadequately possible to prevent the internal temperature in the vehicle from also increasing sharply at high external temperatures.

Another disadvantage of the known method is that it is very cumbersome and time-consuming due to the large number of insulating elements to be glued in. In addition, several work steps are necessary in the vehicle. First of all, the insulation elements have to be glued in place. Then the desired decorative surface, such as wood, fabric, leather, etc., must be applied to the insulation elements. This is also associated with a high expenditure of time. It is also a disadvantage that many individual parts which have to be installed have to be delivered to the installation site.

The present invention is based on the object of providing a method which overcomes the disadvantages of the prior art. The present invention is based in particular on the object of providing a method for producing an insulating element with which insulating elements can be produced quickly and easily and with which insulating elements a simple and quick installation in the vehicle is then possible.

Another object of the invention is to provide an insulating element with which the above. Tasks can be solved.

1. a) Bereitstellen eines öffen- und schließbaren Formwerkzeugs mit einem einen Aufnahmeraum aufweisenden Aufnahmeteil und einem Deckelteil, wobei das Formwerkzeug im geschlossenen Zustand einen Hohlraum bildet und wobei das Aufnahmeteil und das Deckelteil im geschlossenen Zustand des Formwerkzeugs miteinander verbunden und im geöffneten Zustand des Formwerkzeugs zumindest teilweise voneinander getrennt sind;
2. b) Anordnen mindestens eines Dekorelements im Aufnahmeraum des Aufnahmeteils des Formwerkzeugs;
3. c) Aufbringen von härtbarem Kunststoffmaterial auf das mindestens eine Dekorelement;
4. d) Härten lassen des Kunststoffmaterials im geschlossenen Formwerkzeug;
5. e) Öffnen des Formwerkzeugs und Entnehmen des so gebildeten Dämmelements.

The above object is achieved according to the invention by a method for producing an insulating element for recreational vehicles, such as. B. Box van solved, which includes the following steps:

1. a) Providing an openable and closable molding tool with a receiving part having a receiving space and a cover part, wherein the molding tool forms a cavity in the closed state and wherein the receiving part and the cover part are connected to one another when the molding tool is closed and at least partially when the molding tool is open are separated from each other;
2. b) arranging at least one decorative element in the receiving space of the receiving part of the molding tool;
3. c) applying hardenable plastic material to the at least one decorative element;
4. d) allowing the plastic material to harden in the closed mold;
5. e) opening the mold and removing the insulating element thus formed.

Due to the fact that in the method according to the invention a decorative element is first positioned in the molding tool, to which the insulating plastic material is then applied, which finally hardens on the decorative element, an insulating element can be produced in a simple manner, which has an insulating layer and a decorative layer. This insulation element can then be installed in the vehicle in a single assembly step. A previous laborious gluing of insulation elements is completely eliminated. With the method according to the invention, precisely fitting insulating elements with directly molded decorative surfaces can be produced. Large, flat parts can be produced and assembled in one piece, such as insulating elements that are the size of the roof of a recreational vehicle. Because a continuous insulating layer is formed on the decorative element without any joints, no thermal bridges are created, which ensures the winter suitability of a recreational vehicle, in which one is supposed to live for a longer period of time. As already mentioned above, the insulating element produced with the method according to the invention can be installed in the vehicle in just one work step. In addition, inherently rigid insulating elements can be produced, in particular when rigid foam, in particular with a density of 30 to 70 kg / m ^{3, is used} as the plastic material.

In the method according to the invention, an inside of the cover part of the molding tool is advantageously not flat, preferably profiled. So the inside of the cover part z. B. be provided with ribs so that the insulating element produced, for example, has the shape of the surface to be insulated, such as the roof of a vehicle to be insulated. As a result, an insulating element can be produced which is perfectly adapted to the contour of the surface to be insulated.

When the plastic material is foamed onto the decorative element, there is an integral connection between the decorative element and the plastic material. No additional adhesive is required for this material connection. When insulating a vehicle with the aid of an insulating element produced by the method according to the invention, no individual insulating elements have to be glued to a surface to be insulated. This also rules out the fact that z. B. If the outside temperature is high, the bonded insulation elements become detached due to a failure of the adhesive layer.

The cover part is preferably coated with release agent prior to step d). Alternatively, a separating film can be used. This is preferably provided with glass fiber particles on the hard foam side. The other side has a separating effect on the cover part. The glass fiber particles have a stiffening effect, as they contain the so-called warpage when they cool down. Alternatively, it is possible that release agents are added to the curable plastic material. The release agent in the plastic then migrates during the molding process in the direction of the warm molding surface of the cover element of the molding tool and wets it. In both cases it is ensured that the finished insulation element can be removed from the mold without any problems.

In a preferred variant of the method, line elements, in particular cables or conduits and / or cutout-forming elements, in particular a window or door frame, are positioned in the receiving space of the receiving part of the molding tool before work step c). In this way, the elements mentioned do not have to be incorporated subsequently. In the case of a door or window frame, the hardenable plastic is only distributed outside of these elements in the mold. As an alternative to this procedure, window and door openings, for example, can also be subsequently cut out of the finished insulating element. However, these working steps are omitted if the elements mentioned are already positioned in the molding tool in the method according to the invention.

The decorative element can be designed in the manner of a plate, preferably as a wooden panel, in particular a plywood panel and / or as a flexible, sheet-like element, in particular made of textile material or leather. It is also possible that a combination of the above. Materials is used in the method according to the invention. This makes it possible to generate a decorative surface from different materials. For this purpose, it is only necessary to position the desired decorative elements within the framework of method step b) of the method according to the invention in the receiving space of the receiving part of the molding tool.

The decorative element, in particular the plywood panel, can already have various elements for functional integration. For example, the decorative element can have metal plates, in particular aluminum plates. These plates are used to hold fasteners, in particular screws. The fact that the plates are only arranged at the points where fastening means are provided, a drastic weight reduction can be achieved. Furthermore, the decorative element can also have holders, empty pipes, etc.

The curable plastic material is preferably polyurethane, in particular polyurethane with a foam density of approx. 30 to approx. 70 kg / m ³ . Such a plastic material can be used to produce particularly good insulating and inherently rigid insulating elements. In addition, with such a plastic material, a reduction in the thickness of the decorative element, in particular a plywood panel in roof elements, can be achieved due to the high inherent rigidity of the plastic material. With a plastic material with the foam density mentioned above, a weight reduction of the entire insulating element of up to 70% can be achieved.

As already explained above, the insulating element produced with the method according to the invention can be a roof element of a recreational vehicle, in particular a panel van, which in particular spans the entire roof surface of the recreational vehicle.

The present invention also relates to an insulating element for recreational vehicles, such as. B. panel van, comprising a plate-like and / or planar decorative element and a plastic layer foamed onto the decorative element. The insulating element according to the invention has the same advantages that have already been set out in the method according to the invention.

The decorative element is advantageously a wooden panel, in particular a plywood panel. In a further embodiment, the decorative element is a textile material or leather.

The plastic layer is advantageously polyurethane, in particular polyurethane with a foam density of approx. 30 to approx. 70 kg / m ³ .

The plastic layer can advantageously have water drainage channels on the side facing away from the decorative element for water management. These water drainage channels serve in particular to drain off condensation or condensation water, as a result of which the insulating element can be kept essentially free of water. These water drainage channels can be introduced into the plastic layer, for example, by milling. However, it is also conceivable that the channels are molded into the plastic layer during the manufacturing process. For this purpose, the cover element of the molding tool used has corresponding contours.

The present invention also relates to a recreational vehicle, in particular a box van, comprising at least one insulating element according to the invention, which is produced in particular by a method according to the invention.

The at least one insulating element is advantageously arranged on a side wall or the roof of the vehicle, it being preferably screwed or glued to the side wall and / or the roof. Adhesive has the advantage that it is acoustically decoupling.

Further features of the invention emerge from the following description of preferred exemplary embodiments of the invention in conjunction with the drawings and the subclaims. The individual features can be implemented individually or in combination with one another.

• 1 bis 6: den schematischen Ablauf eines erfindungsgemäßen Verfahrens;
• 7: eine perspektivische Darstellung eines erfindungsgemäßen Dämmelements.

In the drawings show:

• 1 until 6th : the schematic sequence of a method according to the invention;
• 7th : a perspective view of an insulating element according to the invention.

• Wie in 1 gezeigt ist, wird zunächst ein zweiteiliges, öffen- und schließbares Formwerkzeug 1 mit einem einen Aufnahmeraum 2 aufweisenden Aufnahmeteil 3 und einem Deckelteil 4 bereitgestellt. 1 zeigt das Formwerkzeug 1 im geöffneten Zustand, in dem die Formteile 3 und 4 voneinander getrennt sind. In den 1 bis 6 sind die Formteile 3 und 4 im Querschnitt dargestellt.

Based on 1 until 6th a preferred method variant of a method according to the invention will now be illustrated:

• As in 1 is shown, first a two-part, openable and closable mold 1 with a recording room 2 having receiving part 3 and a cover part 4th provided. 1 shows the molding tool 1 in the open state in which the molded parts 3 and 4th are separated from each other. In the 1 until 6th are the molded parts 3 and 4th shown in cross section.

The inside 5 of the lid part 4th of the molding tool 1 is formed profiled in the present embodiment, the surface of the inside a plurality of ribs 6th having. The ground is against it 7th of the receiving part 3 , which is the recording room 2 limited towards the bottom, flat.

The next step is a decorative element in the form of a plywood panel 8th in the recording room 2 of the receiving part 3 positioned. This is in 2 shown. Before or after inserting the plywood sheet 8th becomes the inside 5 of the lid part 4th coated with release agent.

The next step is now plastic material in the form of polyurethane 9 with a foam density of 50 kg / m ³ on the plywood sheet 8th upset. This is in 3 shown.

The next step is the molding tool 1 closed. In the closed state, it forms between the receiving part 3 and the lid part 4th a closed space 10 from which of the polyurethane 9 is gradually filled in completely. This is in the 4th and 5 shown. Now the cover part 4th heated, so it also causes the polyurethane to heat up 9 inside the room 10 comes. This heating serves to accelerate the hardening of the polyurethane foam 9 on the plywood sheet 8th in the room 10 of the molding tool 1 .

Finally the molding tool 1 opened again and the finished insulating element 11 , which has a decorative surface made of plywood 8th and an insulating layer made of the polyurethane 9 has, removed from the mold. This insulation element 11 can now be used, for example, as an insulating element for a recreational vehicle roof and screwed to such a roof. The insulating element has a profiled top 16 with ribs 17th on.

7th shows a perspective view of a further insulating element according to the invention 12th in the form of a roof element. The insulation element 12th is profiled and has longitudinal ribs 13th on. In addition, the insulating element 12th Recesses 14th for skylights or skylights. Also the insulation element 12th has a plywood sheet (not shown here) and a polyurethane layer that is firmly bonded to the plywood sheet 15th on.

The insulation elements according to the invention 11 and 12th have a temperature resistance of -30 ° C to 70 ° C. They also have a lambda coefficient of thermal conductivity of 0.020 to 0.040 W / mK. Due to the closed PU layer 9 or. 15th the insulation elements 11 and 12th no water (especially sweat or condensation) can get into the insulation elements from the outside 11 and 12th penetration. This is also a major advantage of the insulating elements according to the invention.

Claims (10)

Method for producing an insulating element (11) for recreational vehicles, such as. B. Panel van, comprising the following steps: a) Providing an openable and closable molding tool (1) with a receiving part (3) having a receiving space (2) and a cover part (4), wherein the molding tool (1) forms a cavity (10) in the closed state and wherein the receiving part (3) and the cover part (4) are connected to one another in the closed state of the molding tool (1) and are at least partially separated from one another when the molding tool (1) is open; b) arranging at least one decorative element (8) in the receiving space (2) of the receiving part (3) of the molding tool (1); c) applying hardenable plastic material (9) to the at least one decorative element (8); d) allowing the plastic material (9) to harden in the closed mold (1); e) opening the mold (1) and removing the insulating element (11) thus formed. Procedure according to Claim 1 , characterized in that an inner side (5) of the cover part (4) of the molding tool (1) is not flat, preferably profiled. Method according to one of the Claims 1 or 2 , characterized in that the cover part (4) is coated with release agent or provided with a release film before step d), the release film preferably having glass fiber particles on the side facing away from the cover part. Method according to one of the preceding claims, characterized in that, prior to step c), line elements, in particular cables or conduits and / or cut-out elements, in particular a window frame and / or door frame, are positioned in the receiving space (2) of the receiving part (3) of the molding tool (1) will. Method according to one of the preceding claims, characterized in that the decorative element is designed in the manner of a plate, preferably as a wooden panel, in particular a plywood panel (8) and / or as a flexible, sheet-like element, in particular made of textile material or leather. Method according to one of the preceding claims, characterized in that the hardenable plastic material is polyurethane, in particular polyurethane (9) with a foam density of approx. 30 to approx. 70 kg / m ³ . Method according to one of the preceding claims, characterized in that the insulating element is a roof element (11, 12) of a recreational vehicle, in particular a van. Insulating element for recreational vehicles, such. B. panel van, comprising a plate-like and / or planar decorative element (8) and a plastic layer (9) foamed onto the decorative element (8). Leisure vehicle, in particular box van, comprising at least one insulating element (11, 12) according to Claim 8 , in particular produced by a method according to one of the Claims 1 until 7th . Recreational vehicle after Claim 9 , characterized in that the at least one insulating element (11, 12) is arranged on a side wall or the roof of the vehicle, wherein it is preferably screwed to the side wall and / or the roof.

Images