CN101687366B - 用于将附件紧固到塑料燃料箱上的方法 - Google Patents

用于将附件紧固到塑料燃料箱上的方法 Download PDF

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Publication number
CN101687366B
CN101687366B CN200880023842.1A CN200880023842A CN101687366B CN 101687366 B CN101687366 B CN 101687366B CN 200880023842 A CN200880023842 A CN 200880023842A CN 101687366 B CN101687366 B CN 101687366B
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molded
annex
aperture
storage tank
fastening
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CN101687366A (zh
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埃尔韦·勒穆瓦纳
弗雷德里克·雅诺
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Nergy Automotive Systems Research SA
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Inergy Automotive Systems Research SA
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    • B60K15/00—Arrangement in connection with fuel supply of combustion engines or other fuel consuming energy converters, e.g. fuel cells; Mounting or construction of fuel tanks
    • B60K15/03—Fuel tanks
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    • B29L2031/00—Other particular articles
    • B29L2031/737—Articles provided with holes, e.g. grids, sieves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K15/00—Arrangement in connection with fuel supply of combustion engines or other fuel consuming energy converters, e.g. fuel cells; Mounting or construction of fuel tanks
    • B60K15/03—Fuel tanks
    • B60K2015/03328—Arrangements or special measures related to fuel tanks or fuel handling
    • B60K2015/03453—Arrangements or special measures related to fuel tanks or fuel handling for fixing or mounting parts of the fuel tank together
    • B60K2015/03467—Arrangements or special measures related to fuel tanks or fuel handling for fixing or mounting parts of the fuel tank together by clip or snap fit fittings
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture

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Abstract

用于将一个附件紧固到一个塑料燃料箱的壁上的方法，这种紧固是在所述储箱被模制制造的同时通过使用一种工具的模制铆接发生的，为此目的，对该附件在其多个紧固点中的至少一个处配备了一个孔口，通过该孔口来进行模制铆接。根据本发明，一个凹形起伏至少部分地围绕这个孔口，所述起伏具有一种尺寸以及形状，该尺寸和形状适合于在该模制铆接的过程中能够与该工具的一个突出部分协作。

Description

用于将附件紧固到塑料燃料箱上的方法
本发明涉及将附件紧固到塑料燃料箱的壁上的一种方法。
在不同种类的车辆上的燃料箱总体上必须满足用于设计它们的用途的类型相关的密封和渗透标准以及它们必须遵循的环境要求。在欧洲以及世界各地，我们目前正经历着对这些要求的相当程度的收紧，这些要求涉及到限制在大气中以及整体上在环境中的污染物排放。
为限制这些排放，特别予以注意的是在储箱内部放置这些附件(通风管线、阀门、挡板、加强件、等等)，以此限制穿过储箱壁的开口的数目，本申请人已经开发了初步模制一个型坯的一种方法，该型坯包括至少一个缝隙，用于在储箱实际模制的过程中将多个附件引入其中(并且固定到其上)，并且因此避免了钻出多个开口(具体见申请EP1110697)。
本申请人还已经开发了用于这种紧固的一种特别的方法(原位的模制铆接，申请WO2006/008308的主题，其内容为此目的作为参考结合在本申请之中)并且还开发了该方法的一种改进，这种改进考虑的事实是当储箱在模制之后冷却下来时，该储箱经历了相当大的收缩(典型地约3％)。这种改进的方法是本申请人名下的国际申请EP2007/051326的主题，其内容也作为参考结合在本申请之中。
已经在这个申请的图5中说明的一个附件是用于一个阀门的一个支架，该支架包括与其模制为一体的两个柔性接片，并且这些接片各自配备有一个孔口，该孔口使模制铆接能够进行。然而，本申请人已经观察到，对于在这个图中所展示的该接片的几何形状(多个简单的弯曲的舌形件，它们在紧固区域中装备有一个孔口)，难于将这些附件装载到内芯上(这些舌形件有一种趋势要滑到在内芯上为它们提供包围形状之外)，并且此外，施加在该紧固件上的机械应力不是均匀分布的。
因此，本发明的目的是提供该模制铆接区域的一种改进的几何形状，这使之有可能确保该附件相对于将执行该模制铆接的工具的自动定中心，并且使之有可能在此过程中获得应力的一种更好的分布。
为此目的，本发明涉及将一个附件紧固到一个塑料燃料箱的一个壁上的一种方法，这种紧固是在通过模制来制造所述储箱的同时通过使用一种工具的模制铆接而发生，为此目的，对该附件在其多个紧固点中的至少一个处配备了一个孔口，通过该孔口来进行模制铆接。根据本发明，一个凹形起伏至少部分地围绕这个孔口，所述的起伏具有一种尺寸以及形状，该尺寸和形状适合于在模制铆接过程中能够与该工具的一个突出部分(凸形起伏)协作，这个突出部分事实上压入该凹形起伏之中，以便进行该模制铆接。
术语“燃料箱”应理解为是指一个密封的储箱(或由一个壁界定的空心体)，该储箱在不同以及变化的使用和环境条件下能够储存燃料。这种储箱的一个实例是机动车辆装配的储箱。
根据本发明的燃料箱是由一种塑料制成。
术语“塑料”是指包括至少一种合成树酯聚合物的任何材料。
任何类型的塑料都可能是适合的。特别适合的塑料属于热塑性塑料的类别。
术语“热塑性塑料”应理解为是指包括任何热塑性的聚合物，包括热塑性弹性体并且还包括它们的共混物。术语“聚合物”应理解为表示均聚物和共聚物(尤其是二元或三元的共聚物)二者。此类共聚物的实例有(非限制性地)：不规则的共聚物类、直链嵌段共聚物类、其他嵌段共聚物类以及接枝共聚物类。
熔点在分解温度之下的任何类型的热塑性聚合物或共聚物都是适合的。具有在至少10摄氏温度上分布的一个熔化范围的合成的热塑性塑料是特别适合的。这类材料的实例包括在它们的分子量中呈现多分散性的那些材料。
具体地讲，有可能使用聚烯烃类、热塑性聚脂类、聚酮类、聚酰胺类以及它们的共聚物类。还可以使用聚合物或共聚物的共混物，类似地还有可能使用带有无机的、有机的和/或天然填充剂的聚合体材料的一种共混物，这些填充剂是(例如，但不限于)：碳、盐类以及其他无机衍生物类、天然的或聚合的纤维类。还有可能使用多层结构，这些多层结构包括堆叠层和结合层，这些层包括以上说明的这些聚合物或共聚物中的至少一种。
经常使用的一种聚合物是聚乙烯。用高密度聚乙烯(HDPE)已经获得了优异的结果。
该储箱的壁可以包括一个单个的热塑层、或者包括两层。有利的是，一个或多个其他可能的附加层可以由液体和/或气体的一种阻挡材料制成的多个层来构成。优选地，阻挡层的性质和厚度被选择为以此使与该储箱的内表面接触的液体和气体的渗透性最小化。优选地，这个层是基于一种阻挡树酯，即不渗透燃料的一种树酯，如EVOH(一种部分水解的乙烯/乙烯基乙酸酯共聚物)。可替代地，该储箱可以经受一种表面处理(氟化作用或磺化作用)，其目的是使该储箱不渗透燃料。
根据本发明的储箱优选包括基于EVOH的一个阻挡层，该阻挡层位于以HDPE为基础的这些外层之间。
在本发明的背景中，术语“附件”应理解为是指：
任何功能性的物品或装置，它总体上是与该燃料箱在其通常使用或工作的模式中相关联并且它与该燃料箱合作以便完成某些有用的功能；或者
用于一个或多个此类装置的一个支架。
此类装置的非限制性的实例是：液体泵、液面计、输送管、在该燃料箱内部的储存区或隔板、通风装置(阀门、管道、等)、电子单元以及多个加固条。
根据实施本发明的方法的一个有利的方式，该附件事实上是一种预先组装的结构，该结构包括一个支架以及通过任何适合的紧固手段被紧固到其上的一个或多个完全相同的或不同的装置。这些手段的实例是夹子紧固、螺钉紧固、焊接、等等。同样有利的是使该预先组装的结构支承允许连接额外装置的手段，这些额外装置将有可能随后被紧固。这些手段同样是夹子紧固装置、有盖的孔或圆形形状的用于螺钉紧固的有螺纹的突起、可以焊接的表面区域、等等。在相同的概念中，该附件可以由一个简单的支架构成，该支架包括用于随后紧固一个或多个装置的适当手段。换言之，该附件优选地包括一个支架，该支架或配备有用于该燃料箱的一个或多个功能性装置(并且它可以是该附件的盖子)的紧固手段，或者直接支承一个或多个这样的装置。
根据本发明，该附件的这些紧固点中的至少一个配备有一个孔口，该孔口使得能够进行模制铆接(冶金学的领域中通常的方法，这包括由熔化的材料在原位模制一个铆钉，已经使该融化的材料经过有待被紧固的部分中的一个孔口溢出并且然后被留在那里使其凝固，优选地是在将被溢流的该部分已在一定程度上变平之后，以便给予它一个铆钉的形状)。
优选地，该模制铆接孔口是由一个紧固接片制成的，该紧固接片是作为该附件的一个部分被模制或被附接到其上。这可以是配备有至少一个孔口的该附件的一个简单的部分(作为它的整个包络的一部分)或在其配备有一个孔口的整个包络上的一个突出部分。
这种紧固接片可以具有任何形状：配备有一个或多个孔口的舌形件；围绕该附件并且包括几个孔口的凸缘、等等。
优选地，该附件装备有几个紧固接片，如果有可能则使这些紧固接片均等地分布在附件上。更特别优选地是，每个紧固接片包括几个孔口，从而在一个机械应力过程中(例如，简单地由重力来施加)将负载分配在附件上。
根据本发明，由一个凹形起伏围绕该模制铆接孔口或这些孔口。术语“凹形”事实上应理解为是指没有盖的一种空心形状，该形状的底部是由围绕该孔口或这些孔口的附件的一部分形成的，并且该形状指向该储箱的内部。这个起伏可以由一个基本上圆柱形的壁构成，该壁基本上垂直于储箱的壁。它可以具有一个连续或不连续的侧壁。它优选是不连续的，或在任何情况中：配备有多个开口，这些开口在这个起伏上给予一定的活动性(可变形性)和/或允许这些卡扣铆钉的一种视觉检查(例如，在一台摄影机的帮助下：见下文)。
这个起伏可以包括一个舌形件或突出部分，其目的是要确保夹紧该部件(即，将它紧固到内芯上，例如使用一个小活塞顶起该舌形件)。使该部件保持(夹紧)非常接近其紧固接片的事实使之有可能确保这个接片完全由该工具控制，并因此与其相对被定位在一个良好的位置中。如果这种夹紧是在离该紧固接片太远处进行，则在该接片与该夹紧点之间的材料的变形之后使该部件的接片不能附接到一个良好的位置上。
在该孔口位于一个紧固接片的(或该附件的任何其他部分的)一个末端上的情况中，该凹形起伏能够产生在这个接片/部分的壁的一个简单的延伸中。
在本发明的背景之中，尽管该附件被紧固到储箱的壁上，优选的是它相对于它在该储箱的壁上的紧固点可以活动。此外，优选地该附件被紧固到储箱的壁上的全部这些点配备有一个紧固部分，这样该附件相对于储箱的壁上的所有对应的紧固点可以活动。
这种活动性可以通过不同方式来获得。在该附件包括至少一个紧固接片的情况中，它足以确保这是处于一个柔性的舌形件的形式，即一个扁平的(但是它可以被弯曲、折叠、等等)部分具有一个厚度、一个形状和/或一种构成材料，它们在附件被紧固到该储箱的壁上时相对于该储箱的壁给予该附件一个相对的活动性。优选地，附件被紧固到储箱上的这些点中的每一个配备有这样一个柔性的舌形件。
根据本发明的这个变体的这些紧固接片优选地是基于一种耐热的材料，以防止这些紧固接片的夸张性变形。如POM(聚甲醛)、PA(聚酰胺)、PBT(聚对苯二甲酸丁二醇酯)以及金属的材料是特别适合的。HPPE是不太值得推荐，因为它在使用温度下可以变形，至少对于一般要考虑的(2至3mm)的厚度。
更特别优选地，每个紧固接片配备有一个圆形的孔口，该孔口优选地基本上位于它紧固到该储箱上的区域的中心处(即在该模制铆接过程中与该型坯接触的区域)，并且这个圆形的孔口优选地由几个(2、3、4或更多)缝隙围绕，这些缝隙优选地均等地分布在围绕该中心孔口的一个圆周上，其目的是增加该紧固的承载强度(该部件在该模制铆接区域中通过它的重量作用在仍然熔融的塑料上)。总体上讲，该接片的紧固区域位于这个接片的一个弯曲的(折叠的)末端处。
根据本发明，该附件是在它模制时被紧固到该储箱的壁上并且该附件相对于该紧固部分的活动性优选足够能够补偿模制之后的收缩，这在HDPE储箱的情况中是大约3％。
燃料箱的模制总体上开始于一个型坯。术语“型坯”应被理解为是指总体上被挤出的一个预成形件，它旨在被模制成所要求的形状和尺寸后形成该储箱的壁。总之，塑料燃料箱是通过热压成形的扁平片或通过一个挤出管状型坯的吹气模制来进行模制的，它不必须被制成一件式的。
该储箱优选地通过吹气模制一个型坯来进行模制的，该型坯由两个分离的部分构成，例如，它们可以是两个薄片。然而，这些部分优选地从如在以上提到的申请EP1110697中所说明的同一个挤出的管状型坯中切出而产生，为此目的，该申请的内容结合在本申请之中作为参考。
根据这个变体，一旦一个单一的型坯已被挤出，将这个型坯沿其整个长度、沿在直径上相反的两条线切开，以获得两个分离的部分(薄片)。
通过与模制两个分开挤出的薄片(其厚度是恒定的)相比较，这种方法使之有可能使用厚度变化的型坯(也就是说其中厚度沿它们的长度不是恒定的)，使用一个适当的挤出装置(总体上装备有一个模口以及一个冲头的一个挤出机，其位置是可调整的)而获得。这样一个型坯考虑到由于在模具中材料的非恒定的变形率而在模制过程中在该型坯的某些点上发生的厚度的减少。
不论是哪种用于模制该型坯的方法，按其定义它肯定包括使用模具，该模具通常包括两个空腔，这些空腔旨在与该型坯的外表面接触，该型坯的热压成形或吹气模制是通过使该型坯压靠在这些空腔上发生的，这是通过从这些空腔后面施加一个真空或通过使用注入型坯之中的增压气体。
根据本发明的一个有利的变体，该模具还包括一个内芯，该内芯结合了该紧固工具(模制铆接)的至少一个部分。术语“内芯”应理解为是指具有适合形状和尺寸的一个部分，该部分能够被插在这些模具空腔之间并且具体是当该型坯被模制时可以将该部分引入型坯之中。例如，像这样的一个部件在专利GB1410215中说明(为此目的，其内容结合到本申请中作为参看)。有利的是，这个内芯可以用于同时将几个附件紧固到型坯上，这是替代的装置(如机械手臂)通常不能完成的事情。在这个变体中，该附件被紧固到储箱的内壁上并且该凹形起伏是指向这个储箱的内部。
该内芯还可以用于引入吹气模制该型坯所需要的加压气体。此外，当有待被吹制的型坯包括两个部分时，至少在该过程的某些步骤(总体上：在将两个部分焊接在一起以生产储箱之前的这些步骤)的过程中，该内芯还可以用于保持这两个部分的边缘是热的。两部分的型坯非常适用于这个变体，因为在打开该模具时它们可以分离并因此使之更容易紧固加注管。
最后，该内芯还可以至少部分地用于过程控制。为此目的，例如，有可能将一个摄影机结合到该内芯之中以便于显示并且检查如此前说明的紧固该附件的质量。这个摄影机还可以检查紧固(连接)该加注管(以及储箱的所有其他可能的部件)的质量。总体上，通过图像分析来进行这些检查。用于测量一个或多个量值(如力、行程、压力、温度)的一个或多个传感器也可以安装到该芯件上，以便更好地监测该附件的紧固。
根据本发明，该附件通过使用一个适合工具的模制铆接被紧固到储箱的壁上，该工具优选地至少部分地整合到此前说明的一个内芯之中。为此目的，这个工具具有一个突出部分(凸形起伏)，该突出部分牢固地附接该内芯上并且能够与在该附件(的紧固接片)上存在的凹形起伏相配合。这个工具总体上是由一个调节致动器(即总体上调节力、冲程和/压力的一个液压冲头)来致动，并且它总体上包括一种相反的形状或空心形状，旨在用于模制铆钉的上部的部分(卡扣铆钉)。当存在几个模制铆接的孔口、并且因此有几个凹形起伏时，这些对应的突出部分可以成为一个单个的模制铆接工具或几个分离的工具的一部分。优选地，它是一个单个的工具或是由一个单个的致动器致动的几个工具。
应该指出，为了进行该模制铆接，有可能仅使用上述的内芯(带有其相反的形状)的突出部分来模制该卡扣铆钉。可替代地，并且根据在如以上提及的申请WO2006/008308中详细说明的一个优选的变体，该模具包括一个对应形状(一种凸峰)，其作用是帮助迫使熔融的塑料经过该模制铆接的孔口。
在本发明的这个变体中，根据该变体模制铆接工具至少部分地被一个内芯支承，该内芯上存在一个突出部分(该突出部分与有待被紧固的附件的凹形起伏相配合)使之有可能协助装载内芯并且使该模制铆接过程中施加这些应力自动定中心。
确切地说，将该附件定位为使其一个或多个凹形起伏固定到这个或这些模制铆接的工具这个或这些突出部分上即足够了，从而在将这些空腔密封在内芯上之前确保附件在内芯上的正确定位和定中心(在这些空腔之间可见到该型坯，以便能够在一个良好的位置处将所述附件紧固到这个型坯的内壁上)，。
因此，在本发明的背景中一个特别有利的方法包括以下步骤：
-如上说明将该附件定位在该内芯上；
-第一次闭合该模具(将空腔围绕内芯合在一起，将型坯插入它们中间)；
-将型坯牢固地压靠在这些模具空腔上(通过经内芯吹气和/或在这些空腔之后施加真空)；
-通过模制铆接将附件紧固到型坯上；
-打开该模具，移出该内芯，再次闭合该模具并且最终模制该储箱。
最后，重要的是要注意虽然已经在将多个内部附件紧固到储箱上的背景中得到开发了本发明，它也可以应用将多个外部附件紧固到储箱上，为此目的，这些附件将会预先定位在这些模具空腔中。在这个变体中，这些模具空腔将装备有模制铆接工具，该模制铆接工具包括能够与该凹形起伏(这次是指向该储箱的外部)相配合的一个突出部分。例如，这用夹子给出了良好的结果，这些夹子进而将使之有可能在该储箱的外部表面冷却之后将这些附件紧固(通过夹紧)到该储箱的外表面上。
本发明展示在图1至图3中，而不带有任何隐含的限制。
图1展示了适用于本发明的一个有利的变体的一个附件。
图2包括在该附件的紧固区域之一中该附件的一个部分的一个放大图。
图3示意性地展示一个紧固接片与对应的模制铆接工具的互补的几何形状(在左侧的一个空的模具中、并且在右侧用该型坯/储箱壁的一部分，以更好地展示该模制铆接的原理)。
图1和图2所展示的附件1事实上包括一个多附件的支架，该支架装备有多个紧固接片2，这些接片是柔性的并且具有旨在由它接受这些附件的多个不同的锚定起伏。
在图2中，附件1的这些紧固接片2的几何形状更加清楚地显现：这些接片的弯曲的末端3配备有一个中心孔口4，并且有几个缝隙5被定位在围绕这个孔口4的一个圆周上。这个弯曲的末端3由一个杯子形状的圆柱形的壁6延伸，该壁配备有两个凹陷7，这两个凹陷给予该接片的末端一定的活动性(在该储箱的冷却过程中伴随该材料的收缩所必需的)，以及一个较宽的窗口8，一旦该附件被紧固到一个储箱壁上，该窗口允许对该模制铆接进行视觉检查。这个壁6还包括一个舌形件9，该舌形件用于将该部件夹紧到该模制铆接工具上。
在图3中，可以看到牢固地附接到一个内芯(它未被表示)上的一个模制铆接工具10(仅示意性地展示了它的一部分并且它包括一个相反的形状10’)如何与该模具11中的一个形状(突出部分)11’相配合，以模制该卡扣铆钉。为了做到这一点，工具10使其相反的形状10’放置到紧固接片2中孔口4的右侧，然后它压入杯的底部之中，从而迫使熔融的塑料穿过孔口4以及这些缝隙5。材料的溢出得到该形状(凸峰)11’帮助的并且相反的形状10’使已经溢出的材料具有一个铆钉的形状。

Claims (10)

1.用于将一个附件紧固到一个塑料燃料储箱的一个壁上的方法，这种紧固是在通过模制来制造所述储箱的同时通过使用一种工具的模制铆接而发生，为此目的该附件配备有至少一个孔口，通过该孔口来进行该模制铆接，其中术语“模制铆接”是指在原位模制一个铆钉，其特征在于，该模制铆接的孔口至少部分地由一个凹形起伏围绕，该工具的一个凸形的起伏压入该凹形起伏之中，以便进行该模制铆接。
2.根据权利要求1所述的方法，其特征在于，该模制铆接的孔口是由一个紧固接片制成的，该紧固接片是作为该附件的一个部分被模制或者被附接到其上。
3.根据权利要求1所述的方法，其特征在于，该附件装备有几个均等分布的紧固接片，每个紧固接片包括几个模制铆接的孔口。
4.根据权利要求1至3之一所述的方法，其中，该凹形起伏由一个基本上圆柱形的壁构成，该壁基本上垂直于装备有多个开口的储箱的壁。
5.根据权利要求2或3的方法，其中，所述紧固接片是柔性的舌形件，所述舌形件的厚度、形状和/或构成材料给予所述附件相对于所述附件在所述储箱上的紧固点的相对的活动性。
6.根据权利要求5所述的方法，其特征在于，每个紧固接片具有一个弯曲的末端，该末端配备有一个圆形的孔口，该孔口被几个缝隙环绕，这些缝隙被均等地分布在环绕这个孔口的一个圆周上。
7.根据权利要求1至3之一所述的方法，其特征在于，该储箱是由一个型坯吹气模制的，该型坯由两个分离的部分制成，这两个分离的部分是通过挤出单个型坯、然后沿径向上相反的两条线在整个长度上切开该单个型坯而获得的。
8.根据权利要求1至3之一所述的方法，其特征在于，该模制是通过使用一个模具进行的，该模具包括两个空腔以及一个内芯，该内芯至少部分地与该模制铆接的工具相结合，并且其特征在于，该附件被紧固到该储箱的内壁上，其凹形起伏指向这个储箱的内部。
9.根据权利要求8所述的方法，其中，该内芯装备有一个摄影机，该摄影机允许进行该模制铆接质量的视觉控制。
10.根据权利要求1至3之一所述的方法，其特征在于，该模制铆接的工具是由一个调节致动器来致动。
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