CN102917857A - 基于两个片材制造塑料空心体的工艺和设备 - Google Patents
基于两个片材制造塑料空心体的工艺和设备 Download PDFInfo
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- CN102917857A CN102917857A CN2011800132804A CN201180013280A CN102917857A CN 102917857 A CN102917857 A CN 102917857A CN 2011800132804 A CN2011800132804 A CN 2011800132804A CN 201180013280 A CN201180013280 A CN 201180013280A CN 102917857 A CN102917857 A CN 102917857A
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- sheet material
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Abstract
一种工艺,用于在包括两个型腔的模具中对两个熔融塑料片材进行模制来制造塑料空心体,所述工艺包括以下步骤:a)挤压出至少一个熔融塑料流并对其进行横向切割,以制造两个熔融塑料片材;b)将这些片材送入所述模具的型腔之间;c)闭合所述模具,使这两个片材按照所述模具的型腔成型来制造所述空心体;d)将所制成的空心体从所述模具取下;e)基于两个新片材重复a)到d)的所有操作以制造另一空心体,其特征在于:在所述横向切割的操作之前、之中或之后,采用专门的装置来冷却所述两个新片材的下部,所述装置能够在所述下部中对所述片材进行局部冷却。
Description
本发明涉及制造塑料空心体、尤其是基于两个片材制造塑料燃料箱的工艺。其还涉及适用于所述工艺的设备。
各种类型车辆上的燃料系统一般包括给箱内包含的碳氢化合物进行通风的装置。其还可包括向发动机供应燃料的装置。这些装置构成了包含在燃料箱内的部件(阀、燃料泵等)与置于燃料箱外的部件(炭罐、加油管等)之间的连接。箱壁的渗透必须考虑现行环保标准(例如LEV II和PZEV)所制定的密封要求。鉴于此,降低箱壁上的开孔数量和尺寸对减少蒸发损失是有利的。然而,这样就增大了将部件插入箱内并就位的难度。
以本申请人名义的申请EP 1110697介绍了一种燃料箱模制工艺,其使用由多个部分组成的型坯,以能够在模制的同时将附属件插入箱内。为此,挤压出一个筒状型坯;然后,在型坯离开阴模时在其中沿两条相对的母线进行两个纵向切割。该文献推荐使用对所获得的型坯的两个部分进行引导和分离的装置,以能够在模制的同时将附属件插入箱内。
理想地,该装置还应该能够将型坯的两个部分基本上弄平,使其无褶皱,以能将其正确地施放在型腔之间。这可采用按要求间隔布置的直圆柱形滚筒或滚轴来实现。然而,这种简单(在理论上适合)的技术毕竟具有离开滚轮时获得的片材保持弯曲、其相对位置无法很好地加以控制的这样的缺点。这是因为,塑料一旦离开阴模就开始凝固(固化),从而趋向于维持阴模赋予其的形状。
并且,在模具闭合以模制燃料箱之前,这些片材自由地悬垂在模具型腔之间;所以,在这个阶段也可能再次产生褶皱。在片材厚度不均和在片材较长时,这种现象就更加明显。当有意地使片材的厚度有控制地变化时,这种现象就尤为明显。因为这种现象导致相当比例的浪费(废料),所以对工艺的利润率有不利影响。
以本申请人名义的申请WO 2008/040766针对该问题提出了解决办法:通过夹子或夹钳(其优选地例如由冷却或PTFE-覆层的金属制成)对片材的自由端(在模具型腔之间因重力而悬垂)进行引导,使其被平整地挤压出,从而避免形成褶皱。不过,在每次循环中,当片材被插入模具型腔之间时都必须启动这样的装置。为此,可使用自动(机器人)装置,但这些通常较复杂和昂贵。
同样以本申请人名义的申请WO 2009/007384介绍了一种工艺,其采用在模具闭合时自动启动的抹平装置来解决上述问题。在该工艺中,当模具闭合时,附接到该模具的一个装置自动地侧向拉伸和/或抹平片材(即张紧并抚平片材)。该工艺的不足之处在于,一方面其需要提供额外的相当长的型坯长度,另一方面每个模具(专用于给定燃料箱/给定车系)都必须装配这种装置,从而在车系变化时产生损失。
本发明的目的在于提供一种工艺,其旨在减少甚至消除这些不足,同时还更有效地消除片材底部的褶皱。
为此,本发明涉及一种用于在包括两个型腔的模具中对两个熔融塑料片材进行模制来制造塑料空心体的工艺,所述工艺包含以下步骤:
a)挤出至少一个熔融塑料流并对其进行横向切割,以制造两个熔融塑料片材;
b)将这些片材送入模具型腔之间;
c)闭合模具,使两个片材按照所述模具的型腔成型来制造空心体;
d)将所制成的空心体从模具取下;
e)基于两个新片材重复a)到d)的所有操作以制造另一空心体,
其特征在于:在横向切割操作之前、之中或之后,采用专门的装置来冷却两个新片材的下部,该装置能够在所述下部中对所述片材进行局部冷却。
根据本发明的工艺适合于任何空心体,尤其适合于需要在其内部引入至少一个附属件的空心体。有利地,其可应用于制造燃料箱(FT)。术语“燃料箱”应理解为指能够在不同的和变化的环境和使用条件下存储燃料的不渗透的箱。这种箱的一个例子就是车辆上装配的燃料箱。在后文中,术语“空心体”和“箱”可互用。
通过根据本发明的工艺获得的空心体由塑料壁制成,一般在其凹形部份有内表面,而在其凸形部份有外表面。
术语“塑料”应理解为指包含至少一种合成树脂聚合物的任何材料。
各种类型的塑料都可能合适。热塑性塑料类的塑料尤其合适。
术语“热塑性塑料”应理解为指任何热塑性聚合物,包括热塑性弹性体及其混合物。术语“聚合物”应理解为既指均聚物,又指共聚物(尤其是二元或三元共聚物)。这类共聚物的例子有(非穷举):无规共聚物、线性嵌段共聚物、非线性嵌段共聚物和接枝共聚物。
任何类型的热塑性聚合物或共聚物,只要其熔点低于分解温度,都是合适的。熔点范围分布在至少10摄氏度上的合成热塑性塑料尤其合适。这类材料的例子包括那些分子量呈现多分散性的材料。
具体而言,聚烯烃、热塑性聚酯、聚酮、聚酰胺及其共聚物都可以使用。还可以使用聚合物或共聚物的混合物;同样,也可以使用聚合物材料与以下物质的混合物:无机物、有机物和/或天然填料,比如(非穷举)碳、盐和其它无机衍生物、天然纤维或聚合物纤维。也可使用由结合在一起的叠层组成的多层结构,其包含上述至少一种聚合物或共聚物。
燃料箱常用的一种聚合物是聚乙烯。采用高密度聚乙烯(HDPE)获得了很好的结果。
优选地,准备采用根据本发明的工艺制造的空心体具有多层结构,其包含至少一个热塑性塑料层和至少一个另外的层,有利地,该至少一个另外的层可由能够阻隔液体和/或气体的材料制成。
优选地,阻隔层的性质和厚度被选择得使与空心体的壁接触的液体和气体的渗透性最小化。在燃料箱的情况下,该层优选地基于阻隔材料,即燃料无法渗透的树脂,比如EVOH(一种部分水解的乙烯/醋酸乙烯共聚物)。或者,还可对箱体进行表面处理(氟化或磺化),使其不渗透燃料。
本发明很好地适用于具有EVOH阻隔层的HDPE燃料箱的情况。
根据本发明,箱体采用两个熔融塑料片材模制而成。可通过经由两个扁平阴模的挤压来获得这些片材,优选地其后紧接着进行空心体的模制(以避免必须再次加热/使其熔化)。然而,更优选地,通过对型坯进行纵向切割来获得这些片材,该型坯优选地厚度可变。
术语“型坯”应理解为指各种形状的挤压制成的预型件,通常成大致圆柱形或筒形,其旨在在模制后形成箱壁。
根据本发明的该变型,必须将筒形型坯转变成为两个片材,即必须至少经过一次横向切割操作和通常沿两条相对的母线(相互成180度)的两次纵向切割操作。
通常而言,纵向切割操作或者利用两个刀片(这两个刀片与不与阴模附接(或者说固不固定在阴模上)均可)来进行,或者在阴模自身内部来进行。后一变型较为优选,因为其能够最大程度地使工艺自动化,并便于生产进程的启停。在该变型中,优选地,首先用阴模中集成的分流器切割型坯,然后,由于一个或多个型坯塑料流流过的阴模内部通道的逐渐变化,所以型坯切割得到的两个部份被逐渐整平。该变型即上述申请WO 2008/040766的主题,因此通过引用将其整体内容合并于本申请当中。
优选地,型坯的厚度可调节(即厚度能够有控制地纵向(沿母线)和/或横向(在同一截面上)地变化),该调节可采用集成在阴模中的至少一个已知的装置,比如WDS(竖直可置换的型芯)、PWDS(可变形环)、SFDR(剖面可变的机器加工型芯或形状可变的销栓)或者“模滑条”(局部插入阴模的部件:参见以本申请人名义的专利US 5057267)。在模制厚度恒定的型坯方面,这种处理方法能够考虑到在模制(尤其是吹模法)过程中因模具内材料的变形程度不恒定所导致的型坯中的某些部位产生的厚度减小。
当在阴模出口获得片材(经过纵向切割和部分整平后的型坯)时,其处理和至模具的转移明显更为容易。因此可以降低阴模出口与模具型腔之间所需的高度。这样可减小被挤压的材料在环境空气中的停留时间,从而提高片材的温度,这有利于后续的模制工序,尤其当该工序包括在空心体的最终模制前将部件(附属件)紧固于型坯内部、其内表面之上这一步骤时。
根据本发明,片材是用合适的切割工具(刀片)横向(垂直于挤压方向)切割的。优选地,这种切割操作的完成要尽可能地快(通常短于1秒),并采用可移动的钝器(刀片),该钝器的致动器(一般是气缸致动器)优选地远离片材(片材是热的,会释放热量,如果距离太近,所述致动器就需要隔热和/或冷却)。特别优选地,该横向切割操作采用切割表面结束于基本成水平的末端(即从而具有水平线的形状)的这样的刀片来进行;每个片材一般有两个刀片,其宽度优选地约等于片材的宽度,其尺寸、位置和运动使得切割表面的末端基本上会合于熔融塑料流的中心。
可以采用任何已知的方式将片材(被纵向和横向切割的材料流)转移到模具。不过,根据一种优选的变型,模具型腔位于阴模之下,并在模具型腔之间连续挤出型坯(片材),随后模具在所述片材上闭合,紧接着横向切割和模制所述片材。
在根据本发明的工艺中,在对熔融塑料流的横向切割之前、之中或之后,用冷却装置专门冷却从该熔融塑料获得的片材的下部(片材其余部分的温度不受所述装置的显著影响)。表达方式“下部”应理解为指高度在厘米范围内的条状区域(实际上,该高度要尽可能小,以避免浪费过多材料,但该高度要足以产生足够的加劲作用;一般3到5cm的条状区域就能获得良好的结果),并且其基本上位于片材的下边缘附近。优选地,该条状区域整个位于下边缘附近,但是实际上该变型只有在冷却发生在切割操作之后时才可行,详见下文解释。
本发明所用的局部冷却装置可以是任何已知类型,一般是采用冷却剂、与不与型坯直接接触均可的这样的局部冷却装置。第二类型的装置可例如包括棒状物(一般是两根,用来冷却片材的两个外表面),该冷却棒上有小孔,冷却气体(比如空气)通过该孔被吹到型坯上。第一类型的装置(优选的)可以包含空心棒或者任何其它类型的空心装置,其中优选地流过冷却剂(一般是水),其表面优选地经过处理,能够与片材直接接触而不产生粘连。含氟聚合物(PTFE型)覆层的效果就很好。
冷却时间和温度一般使得片材(在挤压机出口处的温度通常约为160到190°C)在硬化条状区域中的温度达到60到90°C左右。温度介于5和20°C之间(通常介于10和15°C之间)的水能够轻松达到这个目标,即使在刀片的运动与冷却棒的运动被相关联的情况下也是如此(参见下文)。
考虑到挤压机排出材料流的速度,如果冷却棒固定不动,则冷却棒和片材之间的直接接触应该在时间上有限。所以,根据本发明的一种优选变型,在冷却过程中冷却棒可以作旋转运动(即冷却棒自转但实际上在空间上没有绝对运动),也可以随熔融塑料流作线性运动。应理解,刀片和冷却棒还可以在垂直于挤压的方向上运动,以便处于“活动”位置(用于切割和冷却)或者“待命”位置(以允许挤压出后续片材)。
本发明所用冷却装置优选地位于刀片上方,其运动或者与刀片的运动相联动(即这两个装置的运动由同一致动器控制),或者由专门的致动器(单独的致动器,即控制冷却装置的运动的致动器不同于控制刀片的运动的致动器)控制。后一变型更为优选。特别地,其使得在切割后也可以进行冷却,这样的好处在于:由于材料的弹性,切割后材料一般会向着阴模回缩上升,于是有利地,在冷却新片材和跟随其运动的同时,可利用冷却装置夹住新片材的下边缘,从而避免损失过多的材料。
在根据本发明的工艺中,优选地,一般通过在闭合模具时沿片材周长将片材焊接起来,来将箱模制成单个部件(用单个步骤即获得了一体式箱,而无需再进行额外的组装单独壳体的步骤)。特别而言,有利地通过以下方式来模制箱:
■吹模法,即展开切割后的型坯,并利用加压流体将其压向模具型腔(参见申请EP 1110697,为此通过引用将其内容合并在本申请当中);
■对型坯进行热成型,即例如通过在模具型腔后提供吸力(制造真空)来将型坯压向所述型腔。
优选地采用吹模法来模制箱。这是因为,热成型通常涉及将模具加热到高温,以能够达到深度变形(例如,在箱体角落这样的位置型坯被高度拉伸)。这导致其周期时间比吹模法长,而吹模法中就不存在该约束。
根据本发明的工艺还涉及对型芯的使用,其被用于在模具的第一次闭合中将附属件紧固到片材的内表面上。在该变型中,优选地具有防止在模具的第一次闭合中(当型坯被压向型腔以将附属件紧固在型坯上时)将片材的边缘焊接在一起的这样的装置。有利地,该装置被集成于型芯之中。因此,该型芯优选地是形状和尺寸适合于部分地(一般沿其周长的至少一部分)插入待焊接片材之间的这样的插入件。为便于焊接,模具型腔有利地配备有热控制装置,该热控制装置可以在与模具第一次闭合有关的步骤中适当地对焊接区域进行加热(以便附接一个或多个部件到该区域)。
型芯还可以在与型坯相接触的区域、尤其是上述焊接区域中集成上述(热控制)装置。该变型能进一步提高箱的焊接质量(通过减少内部焊珠,从而提高箱的抗冲击能力)。例如,以本申请人名义的申请FR 0413407中描述了这样的装置,因此通过引用将该申请的内容合并于本申请当中。
在根据本发明的工艺的该变型中,在模具第一次闭合的过程中,片材首先被压向模具型腔(这借助于通过型芯吹气以及/或者在型腔后施加吸力来实现),然后型芯上的装置(例如气缸致动器、液压油缸(hydraulic rams)等)将附属件紧固到被按压的片材。接下来,重新打开模具,取下型芯,再次封闭模具以对预模制好的片材进行焊接,并通过最后一次吹模操作来制成箱体。
本发明还涉及用于实施上述工艺的设备。该设备包含两个可移动的刀片和两个同样可移动的冷却棒;刀片和冷却棒的几何形状分别适用于横向切割熔融塑料流和在切割之前、之中和之后对片材的下部进行冷却。
通常而言,该设备还包括挤压机和模具。优选地,上述刀片和冷却棒被固定到挤压机(优选地固定到挤压机的挤出头(或阴模))或者模具,其中前者较为优选。
在本说明书涉及工艺的部分中所描述的所有优选特征都可应用于该设备。
图1到图4旨在图示本发明的某些具体方面,并无意在任何方面限制本发明的范围。它们分别图示了以下示意性视图:
-图1:根据现有技术的工艺和设备(无抹平),正视图;
-图2:根据本发明的工艺和设备,同样为正视图;
-图3:沿与图2中示出的片材之一相垂直的竖直面的截面图,
以及根据本发明一种优选变型的切割和冷却步骤;
-图4:沿与图2中示出的片材之一相垂直的竖直面的截面图,
以及根据本发明另一优选变型的切割和冷却步骤。
在这些图中,相同的附图标记表示相同的部件,即:
1.挤压阴模;
2.用于横向切割片材的刀片;
3.片材;
4.模具的型腔;
5.型坯中的褶皱;
6.冷却棒;以及
7.待模制片材下部中的硬化材料条状区域,其在模具型腔之间因重力而悬垂。
图1和图2图示了如何在片材(3)的底部获得硬化材料的条状区域(7),从而防止该区域中出现褶皱(5)。
图3图示了一种变型,根据该变型,分别采用刀片(2)和固定的棒(6)在水平条状区域(7)上同时切割和冷却从挤压机出来的片材,刀片(2)与片材在片材中部相遇(一般短于一秒),棒(6)与后续片材底部的接触时间是有限的,以防止上游形成水平褶皱(如果挤压机排出的材料堆积过多,就会形成这种水平褶皱)。
图3中图示了棒的两种不同的几何形状,其中右下角的优选于其上方图示的,因为其交换面积更大,且刚度设计更大。
图4图示了另一变型,其中棒(6)是可转动的,以便跟随挤压的速度。
在图3和图4中,运动的方向用箭头表示,并绘出了以下三个阶段:在左边,刀片(2)和棒(6)被定位在切割位置和冷却位置的两边;在中间,当刀片(2)来到一起进行切割时,这时棒(6)通过接触来冷却一部分上游材料流;在右边,收回刀片(2)和棒,以允许挤压出布置有硬化材料条状区域(7)的后续片材。
Claims (10)
1.一种工艺,用于在包括两个型腔的模具中对两个熔融塑料片材进行模制来制造塑料空心体,所述工艺包括以下步骤:
a)挤压出至少一个熔融塑料流并对其进行横向切割,以制造两个熔融塑料片材;
b)将这些片材送入所述模具的型腔之间;
c)闭合所述模具,使这两个片材按照所述模具的型腔成型来制造所述空心体;
d)将所制成的空心体从所述模具取下;
e)基于两个新片材重复a)到d)的所有操作以制造另一空心体,
其特征在于:在所述横向切割的操作之前、之中或之后,采用专门的冷却装置来冷却所述两个新片材的下部,所述冷却装置能够在所述下部中对所述片材进行局部冷却。
2.如前一权利要求所述的工艺,其特征在于,所述片材是通过纵向切割厚度可变的型坯获得的。
3.如前述权利要求之一所述的工艺,其特征在于,所述横向切割的操作是使用切割表面结束于基本水平的末端的刀片来进行的,设置为每个片材使用两个刀片,所述刀片的宽度基本等于所述片材的宽度,所述刀片的尺寸、位置和运动使得其切割表面的末端基本上会合于所述熔融塑料流的中心。
4.如前述权利要求之一所述的工艺,其特征在于,所述冷却通过与所述冷却装置直接接触来进行,所述冷却装置具有处理过的表面。
5.如前一权利要求所述的工艺,其特征在于,所述冷却装置被牢固地附接到进行所述横向切割的操作的刀片。
6.如权利要求1至4之一所述的工艺,其特征在于,所述冷却装置由致动器移动,所述冷却装置的活动与所述刀片的活动由不同的致动器控制。
7.如前述权利要求之一所述的工艺,其特征在于,所述冷却装置包括每个片材两个棒。
8.如前一权利要求所述的工艺,其特征在于,所述棒能够通过旋转或者跟随所述熔融塑料流的线性活动来移动。
9.如前一权利要求所述的工艺,其特征在于:所述冷却在所述切割之后进行;以及,所述冷却装置被用来在冷却所述新片材和跟随所述新片材的活动的同时夹住所述新片材的下部。
10.一种通过对两个熔融塑料片材进行模制来制造塑料空心体的设备,其包括具有两个型腔的模具,并且还包括两个可移动的刀片和两个同样可移动的冷却棒,所述刀片和所述棒的几何形状分别适合于横向切割熔融塑料流和在所述横向切割的操作之前、之中和之后对所述片材的下部进行冷却。
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FR1051669 | 2010-03-08 | ||
FR1051669A FR2957018B1 (fr) | 2010-03-08 | 2010-03-08 | Procede et appareillage pour la fabrication d'un corps creux en matiere plastique a partir de deux feuilles |
PCT/EP2011/053254 WO2011110480A1 (en) | 2010-03-08 | 2011-03-04 | Process and equipment for manufacturing a plastic hollow body from two sheets |
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CN102917857B CN102917857B (zh) | 2016-03-16 |
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US (1) | US9527225B2 (zh) |
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JP (1) | JP5851427B2 (zh) |
KR (1) | KR101779633B1 (zh) |
CN (1) | CN102917857B (zh) |
BR (1) | BR112012022476A2 (zh) |
FR (1) | FR2957018B1 (zh) |
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WO (1) | WO2011110480A1 (zh) |
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CN103935003B (zh) * | 2013-01-22 | 2016-06-08 | 亚普汽车部件股份有限公司 | 一种挤出两片型坯的平面口模装置以及成型方法 |
EP3000583A1 (en) | 2014-09-29 | 2016-03-30 | Inergy Automotive Systems Research (Société Anonyme) | Vehicle component with heat shield and method for manufacturing the same |
WO2018167741A1 (en) * | 2017-03-13 | 2018-09-20 | Davies Robert Michael | Molding assembly for high temperature composite articles using low temperature inflatable mandrels |
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- 2011-03-04 BR BR112012022476A patent/BR112012022476A2/pt not_active IP Right Cessation
- 2011-03-04 CN CN201180013280.4A patent/CN102917857B/zh not_active Expired - Fee Related
- 2011-03-04 JP JP2012556454A patent/JP5851427B2/ja not_active Expired - Fee Related
- 2011-03-04 RU RU2012142652/05A patent/RU2562489C2/ru not_active IP Right Cessation
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BR112012022476A2 (pt) | 2016-07-19 |
KR20130004325A (ko) | 2013-01-09 |
JP2013521165A (ja) | 2013-06-10 |
WO2011110480A1 (en) | 2011-09-15 |
JP5851427B2 (ja) | 2016-02-03 |
US20130140730A1 (en) | 2013-06-06 |
EP2544873B1 (en) | 2014-09-10 |
EP2544873A1 (en) | 2013-01-16 |
FR2957018B1 (fr) | 2012-10-12 |
KR101779633B1 (ko) | 2017-09-18 |
FR2957018A1 (fr) | 2011-09-09 |
US9527225B2 (en) | 2016-12-27 |
RU2562489C2 (ru) | 2015-09-10 |
CN102917857B (zh) | 2016-03-16 |
RU2012142652A (ru) | 2014-04-20 |
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