CN101048267B - 用于制造包含内设短管的塑料油箱的方法 - Google Patents

用于制造包含内设短管的塑料油箱的方法 Download PDF

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CN101048267B
CN101048267B CN2005800367132A CN200580036713A CN101048267B CN 101048267 B CN101048267 B CN 101048267B CN 2005800367132 A CN2005800367132 A CN 2005800367132A CN 200580036713 A CN200580036713 A CN 200580036713A CN 101048267 B CN101048267 B CN 101048267B
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mould
bed die
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parison
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比约恩·克里埃尔
泽格·杜邦
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Nergy Automotive Systems Research SA
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    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
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Abstract

本发明提供了一种通过在模具中模塑一个型坯用于制造包含内设短管的塑料油箱的方法，在该方法中，利用凹形底模和能够进入该底模的凸模并通过局部变形该型坯来模塑所述短管，上述两个部件之一被固定到模具而另一个部件被固定到位于模具内的模芯，或者与之相反。

Description

用于制造包含内设短管的塑料油箱的方法
本发明涉及一种用于制造包含内设短管的塑料油箱的方法；涉及用于实施所述方法的装置，以及由这种方法/装置得到并使用该内设短管用于连接其注油管、输送管或法兰的汽油箱。
在各种类型的机动车上携带的油箱通常必须满足与其设计的使用类型相关的不透过性和渗透性标准以及它们必须满足的环境要求。在欧洲和全世界我们正受到相当严格的、涉及限制污染物向大气中以及向一般环境中排放的要求。因而油箱的设计迅速演变为要求这样的技术，其能够在不同的使用条件下更好地保证不透过性和安全性。此外，人们也正在努力使由连接于油箱的管道和各种附件产生的损失降至最小程度。例如，管道、尤其是注油管、输送管以及法兰与油箱的连接可能产生渗透性的问题。为了减少这些问题，提出了各种解决办法，其大多数要求中间部件或短管。然而，在此短管处仍然可以产生不透过性的问题。
因此，美国专利申请2002/0130515提出了一种方法，该方法包括在吹塑后者(油箱)期间直接将短管结合到油箱中。然而，这种解决办法导致短管的壁厚不恒定，这对于不渗透接合是不理想的，此外，可以导致冲击强度以及另外的材料成本的问题(为了全部获得至少所需要的最小厚度，必须具有多余的厚度)。
因此，本发明的一个目的是提供一种在通过模塑制造塑料油箱时也允许使短管结合进入塑料油箱中的方法，但这样做时使用了一种使短管的壁厚非常均匀的方法和装置，因而可以避免上述问题。
为此，本发明涉及一种通过在模具中模塑一型坯来制造包含内设短管的塑料油箱的方法，在该方法中，通过利用一凹形底模和能够进入该底模的一凸模(凸形的模子)将该型坯局部变形来模塑该短管，上述两个部件之一被固定到该模具而另一个部件被固定到位于该模具内的模芯，或者与之相反。
术语“油箱”是指在不同的和变化的环境和使用条件下能够储存燃料的密封油箱。这种油箱的一个实例是固定到机动车辆的油箱。
根据本发明的油箱由塑料制成。
术语“塑料”是指任何包括至少一种合成树脂聚合物的材料。
所有类型的塑料都是适用的。特别适宜的塑料是热塑性塑料。
术语“热塑性塑料”是指任何热塑性聚合物，包括热塑性弹性体、以及其掺合物(掺和物)。术语“聚合物”是指均聚物和共聚物(尤其是二元或三元共聚物)。上述共聚物的实例包括但不限于无规共聚物、线性嵌段共聚物、其它嵌段共聚物以及接枝共聚物。
任何类型的熔点低于分解温度的热塑性聚合物或共聚物都是合适的。熔程至少10℃的合成热塑性塑料是特别适宜的。上述材料的实例包括那些其分子量呈现多分散性的材料。
尤其是，可以使用聚烯烃、热塑性聚酯、聚酮、聚酰胺以及其共聚物。也可以使用聚合物或共聚物的掺合物，其可以是聚合物材料和无机、有机和/或天然填料(诸如但不限于碳、盐以及其它无机衍生物、天然纤维或聚合物纤维)的掺合物。还可以使用由粘结在一起的叠合层组成的多层结构，其包括至少上述聚合物或聚合物之一。
一种经常使用的聚合物是聚乙烯。用高密度聚乙烯(HDPE)已获得极好的结果。
油箱的壁可以由单层热塑性塑料或两层热塑性塑料制成。一个或多个其它可能的附加层可以有利地包括对液体和/或气体形成一阻挡层的材料层。优选地，以这样的方式选择阻挡层的特性和厚度，以便尽可能限制与油箱的内表面接触的液体和气体的渗透性。优选地，这种阻挡层是基于阻透树脂，也就是说，基于对燃料不渗透的树脂，如EVOH(一种乙烯和部分水解的醋酸乙烯酯的共聚物)。可替换地，可以对油箱进行表面处理(氟化作用或磺化作用)，其目的是使它不(渗)透燃料。
根据本发明，通过模塑一型坯来制造油箱。“型坯”是指一预成型坯(通常挤压成型)，在它已被模塑成所需要的形状和大小以后，其用来构成油箱的壁。这种预成型坯并不一定要制成单件。
因此，有利地，型坯事实上包括两个分开的部份，其可以例如是两个片材。然而，优选地，这些部份来自切割一个和相同的挤压管状型坯，如在以本申请人公司名义的申请EP 1110697中所描述的并且为此目的将其内容以引用方式合并入本申请。根据这种变形例(variant)，在单个型坯被挤压后，它沿着其整个长度、沿着两个直径方向相反的线被切割，以获得两个分开的部分(片材)。
通过与两个分开挤压片材(因而其厚度是恒定的)的模塑相比较，这种方式使得可以使用可变厚度(也就是说，沿着它们的长度，厚度不是恒定的)的型坯，其是借助于适当的挤压装置(通常是一种装有可调节阳模(充头)的挤压机)而获得。采用这样的型坯是考虑到在模塑期间在型坯的一些点处出现的厚度减小(这由模具中材料的非恒定变形率所致)。
根据本发明，局部变形该型坯以模塑一个用来将管道、输送管或法兰连接于油箱的短管。优选地，这是一个油箱注油管，其通常是具有相对复杂几何形状、与油箱分开模塑的部件。它也可以是用于连接例如通风管道或油管的输送管，或法兰支撑附件。这种短管通常具有一个基本上为圆筒形的形状、一个大致和油箱的壁一样厚的壁、以及一个适合于获得管道(其连接于短管)的稳固机械连接的长度。所述短管可以带有螺纹(例如，通过拧紧带有互补螺纹的法兰进行固定)。
短管的模塑通常独立于油箱本身的模塑来进行。它可以发生在后一模塑操作之前或之后。出于实用理由，它优选发生在模塑油箱之前，或者无论如何在这种模塑操作的最后步骤(例如，其可以是组装两个在同一模具中分开模塑的壳体的步骤)之前。确实，由于其它原因(例如，用于加入附件)，某些方法需要在模塑油箱之前插入模芯，然后此步骤可以使得良好地用于(至少部分地)模塑短管。
一般说来，根据本发明的方法包括至少以下步骤：
-将一个型坯引入模具内；
-将模芯引入模具内，并在型坯内；
-闭合该模具；
-借助于通过所述模芯的吹胀和/或在模具的后面抽真空而将型坯稳固地压靠在模具上；
-通过在底模内移动(移位)模来模塑短管。
因此，根据本发明，利用两个互补部件来模塑短管：凸模(或冲头)和凹形底模，两者具有适宜的形状和大小，以致该模可以进入底模，并且在这种情况下，通过材料的局部压缩来模塑该短管。上述两个部件之一被固定到模芯而另一个则被固定到模具。其意思是，如果底模固定于模芯(在凹入短管的情况下)，那么模固定于模具，反之亦然(在凸出短管的情况下)。因而这两个部件，在给定时间点，一个部件能够相对于另一个部件移动，因为模必须能够进入底模以便模塑该短管。一般说来，通过适宜的液压油缸型的装置来移动两个部件之一。有利地，该装置由模芯来承载(因而移动部件也是如此)。
在必须模塑带有螺纹的短管的情况下，所述螺纹可以被加入模中以致在其模塑以后，必须通过从模具拧开所述部件(短管)而从模具中取出油箱。
有利地，以补偿厚度减小的方式进行短管的模塑，该厚度减小具有形成在短管的最后部份(离型坯最远的端部)中的自然倾向。
同样考虑这一端部的结果，并且想进一步促进在短管附近的固定壁厚度，优选地，在从底模中取出模期间沿短管周围压该型坯。
在根据本发明的方法中，可以通过吹塑该型坯来模塑油箱(利用加压流体(通常为空气)将型坯有力地压向模具)。在此方法中，在吹制和/或形成该短管之前，型坯有时已经受过压缩流体的影响，这是考虑到要确保型坯被有力地紧抵在模具上。因而，例如，在吹制和/或模塑该短管之前通过模芯的吹胀将型坯压向模具证明是有利的。因此，在这样的情况下，在从模具中取出模芯之前，将需要对模具进行脱气，以便(尤其是)避免留在里面的压缩流体过于突然的膨胀以及伴随的噪声。
因此，根据一个优选的变形例，根据本发明的方法包括以下步骤：
-将一个型坯引入模具中；
-将一个模芯引入模具中，并在该型坯内；
-闭合该模具；
-借助于通过吹胀所述模芯和/或在模具后面抽真空而将型坯有力地压靠在模具上；
-通过在底模内移动(移位)移动部件来模塑该短管；
-进行脱气；
-打开模具以取出模芯；
-再次在该型坯上闭合模具，并吹制该型坯以便产生油箱；
-从模具中移走油箱。
可以以任何适当的方式进行脱气步骤。通常是首先刺穿该型坯(例如通过用针对其进行刺孔)，然后使流体流出模具(例如利用一个阀)。
可替换地，可以通过热成形该型坯来模塑油箱(即，通过将熔融材料和模具壁之间的空间抽真空，将该型坯(＝熔融材料的一个或两个片材)有力地压向该热成形模具的壁)。
吹胀(吹制或吹模)产生良好的结果，尤其是考虑到制造周期的持续时间。对于给定的制造速率，此方法因而需要较低的机器投资(与热成形相比，不管是真空热成形(如上文所述)还是压缩热成形(利用模芯或阳模))。
根据本发明，在模塑了结合有短管的油箱以后，必须切去短管的末端以便脱开它。通过任何适当的方式进行这种切割。优选地，利用转刀(圆盘剪)或任何能够进行切割而不产生切屑的其它工具进行这种切割。
本发明还涉及适合于应用上述方法的装置。根据此方面，本发明涉及包括模芯和模具的装置，两个部件之一装备有凹形底模而另一个装备有凸模，其能够进入底模以形成短管。
如上所述，可以将螺纹加入模以便获得一个带有互补螺纹的部件(像法兰)能拧于其上的短管。
优选地，如上文所述，两个部件(模和底模)具有适宜的形状和大小，以致可以压模该短管而避免在其末端的壁厚的减小。
同样，为了能够在取出模时在短管周围施加局部压力，如上文所述，这种装置的模或底模优选被固定于装备有至少一个弹簧的支架。这种支架有利地具有这样的形状、大小以及位置，以致当移动部件(通常是由模芯支撑的部件)被取出时，该支架通过所述弹簧被环绕该短管而压抵在型坯上，从而在该处保持局部压力。这种压力的强度和持续时间取决于弹簧的规格。可替换地或此外，可以通过吹制压力(blowing pressure)来实现弹簧的功能。
有利地，尤其是在短管用于固定注油管的情况下，它被模制向油箱的内部(所谓的凹入短管)，以致位于由油箱壁限定的容积内。就使用的装置而论，这意味着固定于模芯的部件优选是底模，因而固定于模具的部件是模。凹入短管的一个优点是，在整个吹制周期(和/或可能地在后吹制/后冷却周期期间)可以限定外壳直径的尺寸。这可改善这种外壳(其最终构成短管的内表面)的公差以及，通过这样做可改善焊接的质量(焊接任何其它的可能进入此短管的构件，例如利用热丝)。在凸出短管的情况下(其中固定于模芯的那个移动部件是模)，仅在短管成形期间通过模芯，然后通过吹制压力来限定尺寸。
优选地，凹入短管基本上是圆筒形并呈现一进口锥度，即，在油箱表面和圆筒形短管的表面之间的过渡被倒圆角。优选地，这种倒圆(rounding)具有至少5mm、或甚至10mm的圆角半径。然而，有利地，这种半径不超过20mm。如果在车辆环境中有可获得的空隙，则更大些是有利的，因为这会改善抗冲击强度。这样的进口锥度的存在使得部件的组装更容易并且限制形成应力集中(stressraiser)的危险。
在某些情况中，有利的是，可以将法兰(或具有适当几何形状的其它联接器)和短管模塑成整体，以便更容易地将外部件连接于所述短管。最后，本发明还涉及通过如上所述的方法或装置可以获得的塑料油箱。尤其是，它涉及这样的油箱，其包括内设短管，并且内设短管的壁厚固定在+/-0.1mm内(在这种情况下，可以说具有0.1mm的公差)。
这样的油箱有利地具有固定于所述短管的注油管、输送管或法兰。可以用任何已知的方式进行这种固定。因此，例如，它可以是通过机械夹紧(例如利用管夹，或在短管和注油管、输送管或法兰带有互补螺纹的情况下仅通过螺纹连接)、通过焊接等。
一种特别适宜的方式(除如上所述的螺纹连接之外)是利用包括加热丝(即，金属丝，当电流通过时，其在电场效应下变热并如此进行到足够的程度以致它熔化塑料并产生焊接)的联接器进行焊接。特别优选地，所述联接器以及利用它进行的焊接是在美国专利2003/0168853中所描述的，为此目的将其内容以引用方式合并入本申请。尤其是，联接器具有这样的形状，其适合于促进加热丝与电源的连接。具体地，利用根据本发明的方法模塑的短管的精确尺寸(尤其是精密公差)特别好地适合于这种焊接方法并且使得可以获得特别均匀的焊接以及重复地如此进行。
本发明非限制性地说明于图1至图3中，其中相同的数字表示相同的构件，即：模芯(1)、固定于模芯的移动部件(2)以及模具(3)。
图1所示的变形例是这样一个实施例，其中固定于模芯(1)的移动部件(2)是模，并且其中底模被固定于模具(3)。这是其中模与短管接触因而仅在短管形成期间限定该短管尺寸凸出短管的情况。
另一方面，在图2和图3所示的变形例中，固定于模芯(1)的移动部件(2)是底模，并且模被固定于模具(3)。这是凹入短管的情况，并且该模仍然与该短管接触，因而也是在油箱的模塑期间限定该短管的尺寸。
在图2所示的变形例中，当借助于模芯从模中移走底模时，在短管中以及短管周围会发生全面减压。相反，在图3所示的变形例中，由于存在装备有两个弹簧(5)的支架(4)，当移走底模时，支架仍然与短管的外周接触一段较长的时间(直到弹簧拉回所述支架)，使得可以在此时保持对材料的压制并且，在这种情况下，可以获得更好的厚度均匀性。
在所示的每一种情况下，必须可以使短管脱离该模。为使其成为可能，在某些情况下必须在模具中提供另外的移动部件，这是用图中的第二箭头(其并不引导自移动部件(2)本身)所指示的。

Claims (16)

1.一种通过在模具中模塑一个型坯用于制造包含一内设短管的塑料油箱的方法，在所述方法中，通过利用一个凹形底模和一个能够进入所述底模的凸模而局部变形所述型坯来模塑所述短管，其中，所述短管的模制是独立于箱体本身的模制来进行，其中所述凹形底模和所述凸模中的一个是可活动地连接至所述模芯和所述模具中之一的活动件，而所述凹形底模和所述凸模中的另一个被固定至所述凹形底模和所述凸模中的另一个。
2.根据权利要求1所述的方法，其特征在于，所述油箱是基于HDPE的并且包括一层阻挡材料或已经经过表面处理，以便使它不渗透燃料。
3.根据权利要求1所述的方法，其特征在于，所述型坯由切割一挤压出的管状型坯得到的两个片材构成。
4.根据权利要求1-3任一项所述的方法，其特征在于包括以下步骤：
-将一个型坯引入所述模具；
-将所述模芯引入所述模具内，并在所述型坯内；
-闭合所述模具；
-借助于通过所述模芯的吹胀和/或在所述模具后面的抽真空，将所述型坯有力地压向模腔；
-通过所述凹形底模和所述凸模的相对移动来模塑所述短管。
5.根据权利要求4所述的方法，其特征在于，所述模和底模具有适宜的形状和大小，以致可以压模所述短管而避免在其末端的壁厚的减小。
6.根据权利要求4所述的方法，其特征在于，所述凸模或凹形底模通过至少一个弹簧连接至一个支架，所述支架具有一定的形状、大小以及位置，以致当所述活动件被撤回时，所述支架被环绕该短管而压抵在所述型坯上。
7.根据权利要求5所述的方法，其特征在于，所述油箱是中空吹塑的或热成形的。
8.根据权利要求6所述的方法，其特征在于，所述油箱是中空吹塑的或热成形的。
9.根据权利要求1-3，5-8任一项所述的方法，其特征在于，所述注油管、输送管或法兰通过螺纹连接或通过焊接固定于所述短管，其中所述焊接使用了结合到一个焊接联接器中的加热丝。
10.适合于实施权利要求1至3任一项所述方法的装置，包括一个模具和位于所述模具内的模芯，所述两个部件中一个装备有一个凹形底模而另一个装备有一个凸模，所述凸模能够进入所述凹形底模以模塑一个短管，其中，所述凸模或凹形底模中的其中一个是一个可活动地连接至所述模芯的活动件。
11.根据权利要求10所述的装置，其特征在于，所述凸模或所述凹形底模通过至少一个弹簧连接至一个支架。
12.根据权利要求10所述的装置，其特征在于，所述凸模被固定于所述模具而所述凹形底模被固定于所述模芯。
13.适合于实施权利要求4所述方法的装置，包括一个模具和位于所述模具内的模芯，所述两个部件中一个装备有一个凹形底模而另一个装备有一个凸模，所述凸起的模能够进入所述底模以模塑一个短管，其中所述凹形底模和所述凸模中的一个是可活动地连接至所述模芯和所述模具中之一的活动件，而所述凹形底模和所述凸模中的另一个被固定至所述凹形底模和所述凸模中的另一个。
14.根据权利要求13所述的装置，其特征在于，所述凸模或所述凹形底模通过至少一个弹簧连接至一个支架。
15.根据权利要求13所述的装置，其特征在于，所述凸模被固定于所述模具而所述凹形底模被固定于所述模芯。
16.根据权利要求14所述的装置，其特征在于，所述凸模被固定于所述模具而所述凹形底模被固定于所述模芯。
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US20090152263A1 (en) 2009-06-18
FR2877256B1 (fr) 2008-10-03
KR20070083850A (ko) 2007-08-24
FR2877256A1 (fr) 2006-05-05
KR101249579B1 (ko) 2013-04-01
CN101048267A (zh) 2007-10-03
DE602005026845D1 (de) 2011-04-21
US8741207B2 (en) 2014-06-03
WO2006045838A1 (en) 2006-05-04
JP2008517807A (ja) 2008-05-29
EP1817149B1 (en) 2011-03-09
JP4864897B2 (ja) 2012-02-01
ATE500943T1 (de) 2011-03-15
EP1817149A1 (en) 2007-08-15

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