CN102883871A - 用于制造热塑性塑料空心体的方法 - Google Patents

用于制造热塑性塑料空心体的方法 Download PDF

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CN102883871A
CN102883871A CN201180020951XA CN201180020951A CN102883871A CN 102883871 A CN102883871 A CN 102883871A CN 201180020951X A CN201180020951X A CN 201180020951XA CN 201180020951 A CN201180020951 A CN 201180020951A CN 102883871 A CN102883871 A CN 102883871A
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preformed member
mentioned
wall thickness
finished product
semi
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H-G·奈策特
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Kautex Textron GmbH and Co KG
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Kautex Textron GmbH and Co KG
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)

Abstract

本发明涉及一种用于制造由热塑性塑料构成的空心体的方法，包含下面的方法步骤：由塑化的塑料制造带状或薄层状的预成型件（1）；其中，给各预成型件（1）分别赋予一个特定的壁厚曲线；在保持所述壁厚曲线的情况下将预成型件（1）冷却成形状稳定的半成品（11）；加热半成品（11）并且将被加热的半成品成形为空心体的部分；并且将各半成品（11）焊接成一个基本上闭合的空心体。

Description

用于制造热塑性塑料空心体的方法
技术领域
本发明涉及一种用于制造热塑性塑料空心体的方法。
本发明特别是涉及一种用于制造由热塑性塑料构成的燃料容器的方法。这样的容器通常具有多层的由高密度聚乙烯（HDPE）制成的壁结构，其具有乙烯-乙烯醇共聚物（EVOH）作为相对于含有碳氢化合物的流体的阻隔层。
背景技术
传统的用于这样的由聚乙烯构成的燃料箱体的制造方法是挤出吹塑成型。在此软管状的塑料预成型件被挤出并且在熔化的状态下在多件式的挤出吹塑成型工具的内部在使用差压的情况下变形，例如借助于吹塑芯体进行吹气从而形成最终制成的容器，其中软管状的挤出物在处于工具内部的变形期间贴靠在吹塑工具的轮廓上。在吹塑成型的箱体中经由事后在箱体壁中切出的开口安装汽油泵、充填液位指示器、传感器和必要时阀门。这些开口在安装了这样元件之后或者重新被焊接封闭或者在服务开口的情况下设有密封的螺旋盖。事后将各元件安装到燃料容器中的过程是花费大的并导致液体的和/或气体的碳氢化合物的可能的泄漏。
因此已知各种不同的途径，在制造容器时业已将各元件一起安装到容器中。从而例如已知的是，将软管状的塑料预成型件在挤出期间或在挤出之后沿着长度切开并且摊开成带状的或者说平面的半成品/预成型件。这样的方法例如由EP 1 184 157 A1已知。该方法包括：在吹塑成型或共挤出吹塑成型设备中制造软管状的塑料预成型件；将挤出的或共挤出的塑料预成型件切开成至少一个平面的半成品；将获得的平面的半成品热变形成至少一个薄层状的半成品；将获得的平面的半成品热变形成半壳体；并且将热变形的半壳体焊接成一个空心体。热变形的半壳体的焊接根据EP 1 184 157 A1的方法由深冲热量实现。
该制造方法的优点在于，在焊接深冲的半成品之前，必要时可以将嵌件例如塑料系统元件无问题地安装在半壳体的内侧上。该方法的另外一个优点在于，通过经由吹塑成型设备制造薄层状的半成品可以实现对预成型件的有针对性的和可重复的壁厚控制。在挤出软管状的预成型件时的壁厚控制然而仅仅用于确保箱体半壳体中的均匀的且可复制的壁厚曲线。这样的壁厚控制在挤出吹塑设备中通常经由在挤出过程中调节喷嘴间隙实现，其中在所谓的轴向壁厚控制（即在挤出物的纵向方向上）和径向的壁厚控制（即在挤出物的圆周上）之间进行区分。由挤出头推出的材料流在被挤出的软管的圆周上分布，从而必然出现两个半壳体的材料分布彼此之间的一定的相关性。
在另外一个在现有技术中已知的制造方法、即所谓的热成型方法中，首先通过相应的板半成品的深冲而制造两个半壳并且将这两个半壳体在第二方法步骤中彼此焊接。该方法的一个基本的缺点然而尤其在于箱体半壳体中的仅仅有条件受控的壁厚控制，例如经由在加热时的温度曲线。壁厚曲线和因此阻隔层壁厚曲线仅仅可被非充分地控制，因为板半成品具有均匀的壁厚度，从而根据在深冲时的拉伸比，壁厚或阻隔层壁厚可能局部显著变薄。
发明内容
本发明的任务在于提供一种制造热塑性塑料空心体的方法，特别是制造大容器例如燃料容器，该方法比至今已知的方法更多地考虑在制成的产品上的壁厚曲线问题。特别是应当可能的是，得到这样的预成型件或者说半成品，其壁厚具有正规的“地貌（topography）”。
一个特别是潜在的考虑是：制成的产品上的有利的材料分布也有助于节省材料消耗并且因此可以实现成本特别的制造。此外也考虑到了对于轻量化的需要。
上述任务通过一种用于制造由热塑性的塑料制成的空心体的方法解决，包含下面的步骤：
由塑化的塑料制造带状或薄层状的预成型件，
其中给各预成型件分别赋予一个特定的壁厚曲线；
在保持所述壁厚曲线的情况下将预成型件冷却成形状稳定的半成品；
加热半成品并且将被加热的半成品成形为空心体的部分；并且将各半成品焊接成一个空心体。
本发明原则上违背这样的原理，即在制造空心体时使用其最初热量、即使用被挤出的预成型件的熔体热量。相反，在第一步骤中制造预加工的半成品，其在重新加热和变形成相应构成的半成品的情况下焊接成空心体。
根据本发明的方法的一个基本优点在于，在制造制成的空心体时，例如在制造燃料容器时，制造商无需提供任何挤出装置。特别是对于在制造大容器时需要的挤出装置由于待制造的预成型件的尺寸而需要很大的空间。
根据本发明在预成型件冷却成形状稳定的半成品之后优选实现半成品的裁剪/预加工。
该方法的一个特别的优点在于，在制造燃料容器或在制造箱体时，在两个箱体半部彼此焊接之前，箱体元件可以可选地放置在箱体内部。此外该方法特别是具有这样的优点，即半成品可以制造成具有预定的壁厚分布或者说壁厚曲线/地貌。
优选在挤出期间和/或之后所述壁厚曲线被赋予预成型件。
在一个特别优选的方案中，预成型件的挤出借助于挤出工具实现，其具有至少一个宽口喷嘴。特别是在使用宽口喷嘴以挤出薄层状的或带状的预成型件时具有这样的优点，即在预成型件的整个宽度上可以实现针对性的壁厚控制。
替代地，预成型件的挤出可以借助于传统的挤出吹塑成型设备或共挤出吹塑成型设备的传统的挤出头实现，其中首先将软管状的预成型件挤出，其直接在从挤出头排出后或在从挤出头排出期间在径向对置的位置上沿着长度被切开。被切开的软管可以摊开为两个带状的或者说平面的预成型件。在制造首先作为软管状的挤出物的预成型件时，壁厚曲线可以借助于已知的轴向和/或径向的壁厚控制装置被赋予预成型件。
原则上，预成型件的壁厚曲线至少部分通过在挤出过程中的喷嘴间隙调节产生。在使用具有宽口喷嘴或者说具有笔直延伸的喷嘴间隙的挤出装置时，喷嘴间隙可以例如至少在单侧直接被若干数量的彼此独立地横向于挤出方向可调节的分段限定，这些分段可以实现喷嘴间隙的幅度和/或宽度的阶梯型或楼梯型的调节。各分段可以分别设计成滑动件，其可经由各单个调节装置或致动器横向于熔体流动方向调节。通过在挤出期间动态调节各分段，预成型件在长度和/或宽度上被赋予一个壁厚曲线或壁厚轮廓。
根据本发明壁厚曲线通过预成型件的冷却被“冻结”，从而得到薄层状的半成品，其在重新加热后例如通过热变形和/或深冲被变形成燃料容器的相应的半壳体（half-shell）。各半壳体的焊接可以利用深冲热量或也在已知的加热元件的辅助下实现，其加热半壳体的环绕的法兰区域以便进行焊接。
预成型件的之前的冷却和地貌的冻结可以主动地在冷却介质的辅助下实现或被动地在环境温度下实现。优选预成型件的壁厚曲线通过在挤出后仍然处于熔体状态的预成型件的变形形成。如果预成型件在挤出后被赋予壁厚轮廓，例如可以在变形期间实现预成型件的冷却。
有利地，预成型件被多层地共挤出。特别是在制造作为空心体的燃料容器时，特别有利地共挤出HDPE和EVOH，EVOH作为嵌入到HDPE层中的阻隔层。该由EVOH构成的阻隔层或者阻挡层用于阻挡流体的或气体的碳氢化合物的弥散。例如一种典型的多层的壁构造是六层的，其中相应的外部的各层由HDPE构成，阻隔层嵌入两个增附层中并且在一个增附层和所述外部的HDPE层之间嵌入所谓的研磨物料层或再生材料层。在燃料容器的情况下，容器的壁的外层可以由利用碳黑染色的HDPE构成。从外向内相邻的是研磨材料层、增附层、EVOH层、增附层和HDPE层。最后提到的内部的HDPE层通常由非染色的原始聚乙烯制成。研磨材料层包含所有之前提及的层的成分并且通常由回收的在制造半壳体时产生的废料/有用材料制成。例如在预加工半壳体时产生的裁剪材料是适合的。
预成型件的壁厚曲线可以替代地或附加地也通过在多层的预成型件的共挤出时加设附加的层被影响。例如可以在挤出时叠加多个附加的加厚层。
在根据本发明的一个有利的变体中规定，预成型件的变形借助于型材轧辊实现。在此，首先借助于一个或多个宽口喷嘴实现例如带状的或条状的平面预成型件的挤出，其中预成型件业已被赋予一个壁厚曲线。预成型件可以例如利用在挤出头下方的拉伸装置转向并且被水平地在型材轧辊之间转移并且被定长切断。在被引导穿过构成一个辊隙的型材轧辊时，预成型件附加于在挤出时业已产生的地貌还经由型材轧辊被赋予一个地貌。该附加的方法步骤的优点在于，获得预成型件的精确定义的壁厚和材料分布，其中同时在借助于型材轧辊变形的情况下业已产生预成型件的冷却。当型材轧辊不被冷却的情况下，这样的冷却业已达到，然而也在本发明的范围内的是主动冷却型材轧辊。
替代预成型件的变形或压印/形成凹凸轮廓，根据本发明借助于至少一个压印挤压机实现预成型件的变形。
使用型材轧辊/碾压辊和/或压印挤压机使得可以将所谓的壁厚度图案或者在预成型件/板的上侧上或者在下侧上或者在两侧上获得。即使在使用压模或压印挤压机的情况下也可以主动冷却成型工具的部件。
该冷却例如可以在变形之后或期间也通过冷却的气流、浸入水池或转移到冷却的金属板传送带上实现。
在该方法的一个特别优选的方案中规定，制成的半成品在变形成半壳体之前在加热时被赋予一个温度曲线。该温度曲线例如如此实现，即在半成品的厚部位上实现强烈的加热，以便将例如在一个深冲工具中变形的半成品均匀拉伸。特别是在具有提高的壁厚的部位上可以为了支持变形，使用机械的拉伸辅助以提供对应期望的变形而言所需要的力。作为机械的拉伸辅助例如可以考虑压模或滑动件。
在另外一个有利的根据本发明的方法变体中规定，分多个阶段对半成品加热，其中在一个第一阶段在一个较低的第一温度下加热和可选地保持在该温度上并且在第二阶段加热到一个较高的第二温度。
特别是在使用多层的具有嵌入的阻隔层的半成品的情况下，预处理或预调温形式的加热是有利的，以便在半成品的整个厚度上在每个部位上达到尽可能一致的温度，从而确保半成品在其变形成半壳体时所有层、特别是EVOH层的均匀的拉伸。
如上业已提及，预成型件的冷却可以借助于至少一个设置在挤出过程下游的冷却装置实现。考虑使用空调腔、被冷却的输送装置、被冷却的拉出装置等等。
在根据本发明的优选方案中规定，在重力方向上挤出预成型件并且借助于至少一个拉出装置在水平方向上输送预成型件。
根据本发明的方法，首先制造用于极其不同的各空心体或燃料容器的半成品，其中用于容器上侧和容器下侧的半成品是不同的。因此根据本发明规定，在半成品上设置识别标记，其在应用在热成型机器或热成型工具中时可以实现半成品的单义配设。作为识别标记例如考虑标签、成型标记、射频识别标记或类似物。例如也可以在半成品边缘上设置机械的可探测的缺口编码作为成型标记。
为了可以在半成品变形成半壳体之前针对性地加热半成品的厚部位，半成品相对于深冲工具或者说变形工具的空腔以及相对于其加热装置的精确定向是有利的。为此在半成品上附加设置定向装置或定向辅助，其例如可以是光学可探测的标记、色标、光学图案。也可以规定识别各单个半成品的“壁厚山脉”的地貌。最后，成型标记、孔、缺口或突出部或类似物形式的可机械探测的标记也是有利的。
附图说明
根据本发明的方法接下来借助于一个实施例详细阐述。附图示出:
图1用于应用在根据本发明的方法中的用于制造预成型件的挤出装置的示意图；
图2和3在根据本发明的方法中应用的宽口喷嘴的横截面的高度简化的视图，其具有可调节的喷嘴间隙；
图4示出宽口喷嘴的第二方案的与图2和3相对应的视图；
图5示出由宽口喷嘴排出的预成型件的非常夸张的视图；
图6a至7示出预成型件的可能的横截面轮廓；
图8示出根据本发明的制造方法的一个第一变体的示意图，其中未示出半壳体的重新加热、热变形和焊接方法步骤；
图9高度示意示出根据本发明的制造方法的第二变体；
图10根据本发明的制造方法的第三变体。
具体实施方式
在附图中示意示出本发明的制造方法的多个变体。在图1中仅仅示意和高度简化地示出具有两个螺旋挤出机的挤出设备的挤出头4，所述螺旋挤出机按照已知的方式设计成用于塑化和输送塑料颗粒。螺旋挤出机在径向上连接在挤出头4上，在挤出头内部塑化的热塑性材料经由熔体通道被输送给挤出喷嘴2，所述挤出喷嘴在当前情况下设计成所谓的宽口喷嘴。连接在挤出头1上的螺旋挤出机3的数量对于本发明而言不是关键的并且取决于利用1表示的带状或条状的预成型件的待挤出的层的数量。
物品或空心体（在当前情况下是由热塑性的塑料制造的燃料容器）的制造首先包括制造带状的平面的或者说条状的预成型件1（其被挤出成具有规定的“地貌”的单层的挤出体或者多层的挤出体）、将预成型件制造和冷却成薄层状的半成品11并且将半成品11进一步加工成制成的空心体或燃料容器。在附图中未示出对半成品的所述进一步加工。半成品11为此在工业已知的用于热变形/深冲的装置被重新加热和变形成半壳体，其在必要时配备嵌件的情况下在法兰状构成的边缘上焊接成制成的空心体。在容器中待装入的嵌件可以以简单的方式焊接和/或铆接在半壳体的可利用的内侧上。深冲热量可用于半壳体焊接成制成的空心体以及嵌件的焊接和铆接，为此然而也可以借助于红外加热装置将附加的加热能量引入半成品中。
在根据本发明的方法中，针对性的壁厚分布或者说壁厚地貌可以首先仅仅在制造预成型件时产生。壁厚曲线可以而后在冷却预成型件1时被冻结。如接下来还要详细阐述，可以在该方法中附加地在预成型件1的冷却之前或期间通过机械的作用优选通过压印和/或挤压赋予精确定义的“校准的”壁厚分布。
首先在挤出喷嘴2中实现壁厚控制，如借助于附图2至7进行阐述。尽管预成型件1也通过在径向对置的位置上待切开的软管的挤出而可制造有针对性的壁厚分布（WDS和PWDS），在上述的方法中挤出优选借助于宽口喷嘴实现。
为此首先规定，挤出喷嘴2的喷嘴间隙6不仅在其宽度上而且在其幅度上是可调节的。如特别是在图2至4可以看出，喷嘴间隙6设计在横截面上矩形的狭槽，其宽度（Breite）是其幅度（Weite）的多倍。
在图2和3中示出的实施例中，喷嘴间隙6一方由喷嘴体8的刚性的壁部段7并且另外一方面由多个形式为滑动件9的分段界定。壁部段7和滑动件9相应限定喷嘴间隙6的纵向侧。滑动件9分别经由调节装置10可横向于挤出方向调节并且彼此之间独立，从而相应的预成型件可以被赋予一个大致楼梯形或台阶形的轮廓。
尽管喷嘴间隙的横截面因此是台阶形的，然而令人意想不到地发现，塑化的材料具有这样的流动特性，使得预成型件上的台阶或非连续的壁厚改变不作为尖锐的过渡部位出现。
如上业已提到，滑动件9的位置经由调节装置在挤出期间即动态地被影响，从而预成型件1可以在宽度上被赋予一个在预成型件的长度上改变的轮廓（厚度控制）。
滑动件9例如在图2中在完全打开的中间位置示出，相反例如在图3中限定喷嘴间隙的最外部的窄侧的滑动件位于其完全闭合的终端位置。通过这种方式，喷嘴间隙6的宽度同样能够被影响，从而例如如在图5中夸大示出，预成型件可以被如此制造，使得其是束腰的或者具有收缩的部段（B）。
在图5中示出的预成型件1沿着长度具有三个依次相继的部段A、B、C，而部段B相对于部段A、C具有较小的宽度或是收缩的。在此描述的挤出喷嘴不具有任何重叠的或单独的基础间隙调节，其在喷嘴间隙6的整个宽度上作用。然而同样可以设置这种重叠的基础间隙调节。滑动件9全部可以彼此独立地被操作。
在图4中示出挤出喷嘴的一个变体，其中滑动件直接限定喷嘴间隙的两个纵向侧，从而预成型件可以被这样赋予一个壁厚轮廓（壁厚曲线），使得其具有两个凹凸不平的外侧，其例如在剖视图图7中示出。通过这种方式可以特别简单有利地制成一种预成型件，其在其两个大的外表面上具有在长度上和宽度上改变的复杂的地貌。此外如在图4中示出，喷嘴间隙的宽度是可被调节的。滑动件9可以分段地从外向内相互移动，从而即使在根据图4的装置中可以制造如在图5中示出的预成型件。
如上业已提及，如此制造的地貌不具有尖锐的过渡部位，它们也不总是期望的。
通过以上述的方式制造预成型件1，主要达到一种材料分布，其形状可以被冻结，如例如在图8中示出。在那儿在挤出头4的下方设置传送带12的形式的拉出装置，利用所述拉出装置预成型件1（其首先是悬垂地即在重力方向上被挤出）在传送带12的输送方向上水平地从挤出头4抽出。传送带12例如设计成金属板传送带并且利用在传送带12的各分支之间设置的热交换器13冷却。传送带12的上分支或负载分支穿过冷却盒子14，其被冷却的空气或冷却气体冲刷。在从冷却盒子4出来后，预成型件1借助于切割装置15被分割。由切割装置15待分离的位置可以在之前在挤出时通过针对性的喷嘴间隙调节而业已设计成薄部位。切割装置15可以例如具有热刀具或热金属丝或类似件。
在图9中示出根据本发明的方法的另外一个变体。在那儿同样预成型件1借助于传送带12从挤出头9抽出，其中预成型件然而而后被输送给压印挤压机16。在具有上压模16a和下压模16b的压印挤压机16中，预成型件1被赋予规定的和校准的地貌。这可以在挤出时无显著的厚度控制的情况下实现，然而也可以附加于在挤出时的壁厚控制和壁厚分布实现。在此预成型件可以在单侧并且也可以在两侧被压印。上压模16a在所述的实施例中设有热交换器13，从而冷却和压印在此在一个方法步骤中顺利进行。当然冷却和压印可以彼此分离。
根据本发明的另外一个实施例在图10中示出。在那儿设置一个为两个型材轧辊17a、17b形式的压印装置，这两个型材轧辊限定一个辊隙，预成型件1被引导穿过所述辊隙。在所述的实施例中两个辊子设计成型材轧辊17a、17b，对于专业人员来说，也可以仅仅其中一个辊子设计成型材轧辊。在离开辊隙之后，被变形的预成型件1经由传送带12被抽出，紧接着预成型件1冷却和被切割成可存放的半成品11。
在存放半成品11之前半成品也可以进行修剪形式的加工。
被预加工的半成品紧接着被重新加热、塑化和变形/成形。而后它们被焊接成制成的燃料容器，其中在塑形/成形过程之间必要时将嵌件安装在半成品的待彼此面对的内侧上。
附图标记清单
1 预成型件
2 挤出喷嘴
3 螺旋挤出机
4 挤出头
6 喷嘴间隙
7 壁部段
8 喷嘴体
9 滑动件
10 调节装置
11 半成品
12 传送带
13 热交换器
14 冷却盒子
15 切割装置
16 压印挤压机
16a 上压模
16b 下压模
17a、b 型材轧辊

Claims (15)

1.一种用于制造由热塑性塑料构成的空心体的方法，包含下面的方法步骤：
由塑化的塑料制造平面的预成型件；
其中，给各预成型件分别赋予一个特定的壁厚曲线；
在保持所述壁厚曲线的情况下将预成型件冷却成形状稳定的半成品；
加热半成品并且将被加热的半成品成形为空心体的部分；并且
将各半成品焊接成一个基本上闭合的空心体。
2.如权利要求1所述的方法，其特征在于，通过挤出塑化的塑料制造所述预成型件。
3.如权利要求1或2所述的方法，其特征在于，在挤出期间和/或之后赋予预成型件所述壁厚曲线。
4.如上述权利要求1至3之一项所述的方法，其特征在于，预成型件的挤出借助于至少一个具有至少一个宽口喷嘴的挤出工具实现。
5.如上述权利要求1至4之一项所述的方法，其特征在于，预成型件的壁厚曲线至少部分通过在挤出期间的喷嘴间隙调节产生。
6.如上述权利要求1至5之一项所述的方法，其特征在于，预成型件的壁厚曲线至少部分通过在挤出后仍然为熔体的预成型件的变形产生。
7.如权利要求6所述的方法，其特征在于，预成型件的冷却在变形期间实现。
8.如上述权利要求1至7之一项所述的方法，其特征在于，预成型件多层地共挤出。
9.如上述权利要求1至8之一项所述的方法，其特征在于，预成型件的壁厚分布通过在挤出时加设附加的层来影响。
10.如上述权利要求6至9之一项所述的方法，其特征在于，借助于至少一个型材轧辊实现预成型件的变形。
11.如上述权利要求6至9之一项所述的方法，其特征在于，借助于至少一个压印挤压机实现预成型件的变形。
12.如上述权利要求1至11之一项所述的方法，其特征在于，半成品在加热时被赋予一个温度曲线。
13.如上述权利要求1至11之一项所述的方法，其特征在于，半成品被多阶段加热，其中在一个第一阶段在一个较低的第一温度下加热和可选地保持在该第一温度，并且在第二阶段加热到一个较高的第二温度。
14.如上述权利要求1至13之一项所述的方法，其特征在于，预成型件的冷却借助于至少一个设置在挤出过程下游的冷却装置实现。
15.如上述权利要求1至14之一项所述的方法，其特征在于，在重力方向上挤出预成型件并且借助于至少一个拉出装置在水平方向上输送预成型件。
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