CN102958731A - 塑料燃料箱及其制造方法 - Google Patents

塑料燃料箱及其制造方法 Download PDF

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CN102958731A
CN102958731A CN2011800284205A CN201180028420A CN102958731A CN 102958731 A CN102958731 A CN 102958731A CN 2011800284205 A CN2011800284205 A CN 2011800284205A CN 201180028420 A CN201180028420 A CN 201180028420A CN 102958731 A CN102958731 A CN 102958731A
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fuel tank
fuel
layer
internal layer
instrument
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CN102958731B (zh
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U·卡尔施
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Kautex Textron GmbH and Co KG
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
    • B65D1/40—Details of walls
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0017—Combinations of extrusion moulding with other shaping operations combined with blow-moulding or thermoforming
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0022—Combinations of extrusion moulding with other shaping operations combined with cutting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
    • B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
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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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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
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    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/0081—Shaping techniques involving a cutting or machining operation before shaping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/22—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor using multilayered preforms or parisons
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
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Abstract

本发明涉及一种塑料燃料箱，其具有多层燃料箱壁，所述多层燃料箱壁包括热塑性材料的至少一个内层和纤维复合材料的至少一个外层。内层和外层通过材料粘接剂而彼此连接。

Description

塑料燃料箱及其制造方法
技术领域
本发明涉及一种塑料燃料箱及其制造方法。
背景技术
已知的用于机动车辆的塑料燃料箱形成为基于聚乙烯（HDPE）的燃料箱。这些燃料箱通常具有带有碳氢化合物阻隔层的多层壁结构或者通过化学处理（氟化/磺化）做成防碳氢化合物。基于HDPE的塑料燃料箱的优点是它们能制成空间上相对复杂的设计并且具有足够的形状保持性和稳定性。这种燃料箱也是足以抵抗冲击的，因此，在碰撞的情况下，它们能经受相应的碰撞力。在碰撞情况下燃料箱短期的变形一般不会导致轮廓上任何永久的改变。最后，已知的塑料燃料箱在内部压力短时间增加时还保持它们的形状，至少使得当压力减小时它们回到它们最初的形状。
为了防止燃料箱在覆盖大面积容器壁对区域中外壳形状发生变化，在燃料箱内部设置各种支撑元件是已知的。在相对小的塑料燃料箱的情况下，甚至设置在燃料箱中的内部结构（例如内挡板、供给单元等的形式）都具有稳定燃料箱的作用。
随着混合动力汽车的引入，塑料燃料箱的稳定措施变得越来越重要了。在柴油或汽油车辆中，燃料箱通常通过具有变化尺寸的燃料气体过滤器基本无压地连通。当机动车辆的内燃机处于操作中时，燃料气体过滤器被反冲，因为在发动机操作过程中经由燃料气体过滤器吸取发动机所需的空气。相应地设计了燃料气体过滤器的吸收能力。
但是在现代混合动力车辆的情况下，另一方面大大减少了内燃机操作循环的数量和操作时间。因此，同样限制了燃料气体过滤器的可能的反冲循环的数量和持续时间。这需要对燃料气体过滤器进行相应的尺寸设计，这通常由于安装空间而收到限制。由于该原因，混合动力车辆的燃料箱通常相对于大气密封，使得能在燃料箱内产生相对于大气大约+400巴至-150巴的压力波动。希望这种相对于大气的压力差能尽可能地保持相对长的时间。
对于基于聚乙烯的燃料箱稳定性尤其重要。这是因为聚乙烯具有如果承受支撑压力和/或张力，其甚至会在室温下流动的特性，因此，已知的采取燃料箱内部支撑元件的形式的稳定措施在所有情况下不会产生令人满意的结果。
发明内容
因此本发明是基于提供一种解决上述问题的塑料燃料箱的目的。
该目的首先是通过具有多层燃料箱壁的塑料燃料箱达到的，多层燃料箱壁至少包括热塑性材料内层和纤维复合材料外层。这种“夹层构造”意味着燃料箱具有相对刚性的重量轻的外层，而内层具有一定的柔顺性，尤其是确保整个燃料箱系统的不渗透性。根据本发明的燃料箱将高强度刚性结构（同时还具有一定的脆性）的优点与在一定极限内屈服并对碳氢化合物不渗透的壳体优点结合起来，其在碰撞的情况下，能吸收相应的冲击载荷。为此目的，如果内外层在材料上不彼此粘接是有利的。在燃料箱的有利变型的情况下，这些层在材料上彼此粘接。
在根据本发明的燃料箱的一个特别优选的实施方式的情况下，基于HDPE的多层挤压件作为内层被提供。该内层能以传统方式通过挤压工艺生产。
燃料箱的内层和外层有利地通过粘接剂彼此连接。
外层例如可由在热固性聚合物基体中的纤维材料构成。原理上，热塑性塑料也能被考虑作为基体材料。
玻璃纤维/芳纶或者碳纤维，最好是连续纤维，被考虑作为纤维材料。
如果将室温固化材料（temperature-curable plastic）作为热固性塑料是尤其有利的；这样，内层和外层尤其有利地能在单个生产过程中彼此粘接。
内层例如可包括带有碳氢化合物阻隔层的共挤压件。
尤其优选地，内层形成为四层共挤压件，例如对于共挤压件的外层粘接剂层能同时生产与外层粘接的材料。
先前已知的多层燃料箱一般是由六层共挤压件组成的，该层结构从内部到外部包括无颜色的纯HDPE、粘接剂层、EVOH阻隔层、另一粘接剂层（例如基于LDPE）、回收或再研磨材料层和炭黑色HDPE的HDPE层。
在根据本发明的燃料箱的情况下，燃料箱壁的两个外层然后优选地由纤维复合材料替代，外层的厚度能选择成使得外层的质量小于或等于共挤压件的其他所需的外层的质量。位于EVOH层上的粘接剂层在该种情形中用于产生与外层粘接的材料。
本发明所基于的目的还通过一种用于生产燃料箱的方法实现，尤其是用于生产上述类型燃料箱的方法，包括在多部件工具中由热塑性材料形成两个壳状半成品、形成模具腔、连接壳体以形成基本封闭的中空体，其中在壳体形成之前将纤维复合材料元件放置在工具中，所述元件被放置在由模具腔界定的轮廓上，以便于在形成壳体期间纤维复合材料与壳状半成品形成材料粘接。
在根据本发明的方法的有利变型的情况下，将未固化的热固性材料板状元件放置在工具中。这里元件例如能是所谓的“半固化”件（半固化纤维），也就是说，半成品由未固化的热固性聚合物基体中的连续纤维构成。连续纤维可采取纯单向层、织物结构或铺放结构。例如，它们可作为织物板放置在工具中并且固定在那里。
在根据本发明的方法的一个特别有利的变型的情况下，设置成：板状元件由经过热熔的壳状半成品的接触热传递固化，热熔的壳状半成品在工具中形成过程中被放置成抵靠在工具中固定的板状元件，从而将热量传递到板状元件。（热固性）基体材料的固化特性的合适设定获得这样的效果，即，在冷却过程中板状元件本身适应基于聚乙烯的内层的收缩。
根据本发明的方法优选地包括管状预成型件的挤压，管状预成型件被切开以形成片状板并展开并且通过使用挤压的热量形成壳体。
替代性地，板状式的片状预成型件可直接被挤压并通过使用挤压热量将其形成壳体。
使用挤压的热量表示热量基本来自于在挤压机中塑炼的聚合物的第一热量。
本身公知的、也能用在挤压吹塑中的挤压头或共挤压头可用在预成型件的挤压中。
根据本发明的方法优选地作为挤压吹塑方法被实现，其中预成型件基本在吹塑工具中基本处于第一热量中而形成壳体并且彼此连接或彼此熔接。纤维复合材料元件形式的板状元件放置到吹塑工具中，以便它们包覆纤维复合材料壳体形式的成品中空体。
更有利地，预成型件以多层状态挤压，具有至少一个碳水化合物和/或氧气阻隔层，至少一个粘接剂层，与纤维复合材料的板状元件接触以便在内层与外层之间产生材料粘接的粘接剂层。
在根据本发明的有利变型的情况下，首先将板状式的热塑性材料的预成型件带到三个部件的吹塑工具的打开部件（两个外模具）之间，两个外模具形成限定成品轮廓的模腔。在第一方法步骤中，将纤维复合材料的未固化或仅部分固化的元件放置在吹塑模具半体的腔室中并且固定在那里。在另一个步骤，将板状式的基于聚乙烯的热塑性材料的片状预成型件带到吹塑工具内的打开的外模具与布置在它们之间的中央模具/中央工具之间。在进一步的方法步骤中，吹塑模具半体闭合抵靠中央工具，热塑性材料壳体形成为抵靠设置在腔室中的纤维复合材料的板状元件。就在壳体形成之后，使用中央工具将燃料箱的内部部件连接到壳体的面对模具腔室的侧面上。在进一步的方法步骤中，移除中央工具并且将吹塑模具半体彼此闭合抵靠，以便在形成夹断焊缝的同时将壳体彼此熔接。夹断焊缝基本产生在燃料箱的内层的区域中。不必要将形成燃料箱外层的纤维复合材料的元件连接在夹断焊缝的区域中，因为它们通过与内层材料的粘接而形成紧密粘接。
附图说明
下面基于在附图中示出的示例性实施方式来说明本发明，其中：
图1示出了采取两个纤维复合材料元件形式的塑料燃料箱的内层的示意性透视图，
图2示出了在将板状元件引入到吹塑模具半体的腔室内时用于生产根据本发明的燃料箱的吹塑工具的示意图，
图3示出了对应于图2的视图，图示了挤压热塑性材料的预成型件的方法步骤，
图4示出了相应的视图，图示了壳体在抵靠纤维复合材料元件的工具中形成，
图5示出了在燃料箱壳体熔接期间闭合的吹塑工具的视图，
图6示出了根据本发明的燃料箱的壁结构的放大视图。
具体实施方式
在附图中（图5）以高度示意性放大的形式示出了热塑性材料的燃料箱1。其包括热塑性材料的内层2和纤维复合材料的外层3。外层3包括在热固性的室温固化（temperature-curable material）材料基体中的连续纤维，例如玻璃纤维或碳纤维。它（室温固化材料）例如可以是具有室温可激活的硬化剂的环氧树脂。外层3完全包覆燃料箱并且在所有表面区域上与内层形成材料粘接。内层2是基于HDPE的四层共挤压件，包括内HDPE层4、基于LDPE的第一粘接剂层5、EVOH阻隔层6和第二外粘接剂层7，第二外粘接剂层7与纤维复合材料外层3形成材料粘接。
根据本发明的燃料箱1在图2中示出的总共三个部件的吹塑工具8中进行生产，吹塑工具8包括两个外模具9a，9b和中央工具10。中央工具10主要用于密封由外模具9a，9b（其用于形成壳体的目的）形成的腔室，中央工具10其次用于将插入件和纤维复合材料的元件引入到外模具9a，9b的腔室11中。
图1示出了两个元件12a，12b，它们已经具有半壳体的形式并且以这种形式被带入到完全固化状态的外模具9a，9b的腔室11中，如图2中表明的。本发明应该在原理上理解为表示：在元件12a，12b是基本未固定轮廓（contourless）状态下的板或条的形式时，元件12a，12b初始地被带到外模具9a，9b的打开的部件之间，并且通过压差（例如通过真空）抵靠外模具9a，9b的腔室11。但是，元件12a，12b还可以被相应的操作人员/操纵装置放置成抵靠腔室并且固定在那里。附图中示出的是一种变型，其中元件12a，12b已经具有半壳体的形式，但是它们不能完全保持它们的形状。
在图2中示出的方法步骤中，中央工具10布置在外模具9a，9b之间，在附图的平面内可彼此远离和彼此靠近地移动，中央工具10能相对于外模具9a，9b的位移运动横向移动，即进出附图的平面。中央工具10包括构件承载器14，构件承载器14能制成为借助汽缸15沿外模具的方向相对于由中央工具10构成的框架移动进入和移动出来。在图2中示出的方法步骤的情况下，构件承载器14承载有元件12a，12b，元件12a，12b首先被带入到外模具9a，9b中并且放置在腔室11中。例如通过真空，这些元件可以固定在那里。在进一步的方法步骤（图3）中，板或条形式的片状预成型件17以悬垂的方式（即沿重力方向）从挤压头连续地被挤压。如上面提到的，预成型件17形成为基于HDPE的具有EVOH阻隔层的四层共挤压件。在进一步的方法步骤中，外模具9a，9b闭合抵靠中央工具10，外模具9a，9b在所有情况下都将预成型件17夹紧抵靠中央工具10。
吹塑工具8放置成远离挤压头16，以便不妨碍连续挤压的预成型件17露出。
然后，通过施加压差（例如通过排空腔室11或通过向腔室11的内壁吹气）预成型件17（图4）被放置成抵靠元件12a，12b。如开始提到的，元件12a，12b包括热固性材料的室温固化基体。借助来自于热熔（molten-hot）的预成型件17的接触热传递，在由腔室限定的轮廓中的这些元件与内层2的热塑性材料一起发生固化以形成半壳体18。在进一步的方法步骤中，中央工具10能用于将内部部件引入到仍然热熔的半壳体中。为此，例如同样可以使用之前提到的构件承载器14。最后，从外模具9a，9b之间移除中央工具10，并且将它们彼此闭合抵靠，通过在周边夹断边缘19的区域中熔接内层2，半壳体开始形成最终的燃料箱1。
附图标记列表
1             燃料箱
2             内层
3             外层
4             内HDPE层
5             第一粘接剂层
6             阻隔层
7             外粘接剂层
8             吹塑工具
9a，9b        外模具
10            中央工具
11            腔室
12a，12b      元件
14            构件承载器
15            汽缸
16            挤压头
17            预成型件
18            半壳体
19            夹断边缘

Claims (15)

1.一种塑料燃料箱（1），其具有多层燃料箱壁，所述多层燃料箱壁包括热塑性材料的至少一个内层（2）和纤维复合材料的至少一个外层（3）。
2.根据权利要求1所述的燃料箱，其特征在于，内层（2）和外层（3）彼此材料地结合。
3.根据权利要求1或2所述的燃料箱，其特征在于，基于聚乙烯，优选地基于HDPE的多层挤压件作为内层被提供。
4.根据权利要求1-3中任一项所述的燃料箱，其特征在于，所述内层（2）和所述外层（3）通过粘接剂彼此连接。
5.根据权利要求1-4中任一项所述的燃料箱，其特征在于，所述外层（3）由热固性聚合物基体中的纤维材料构成。
6.根据权利要求1-5中任一项所述的燃料箱，其特征在于，优选作为连续纤维的玻璃纤维或碳纤维作为纤维材料被提供。
7.根据权利要求5所述的燃料箱，其特征在于，优选地基于环氧树脂的室温固化材料作为热固性塑料被提供。
8.根据权利要求1-7中任一项所述的燃料箱，其特征在于，所述内层（2）包括至少一个阻隔碳氢化合物的层（6）。
9.根据权利要求1-8中任一项所述的燃料箱，其特征在于，所述内层（2）形成为四层共挤压件。
10.一种用于生产燃料箱的方法，包括：在多部件的工具中由热塑性材料形成两个壳状半成品；形成模具腔；和连接壳体以形成基本封闭的中空体，其中在形成壳体之前将纤维复合材料的元件放置在所述工具中或者适配在所述工具中，所述元件被放置在由模具腔界定的轮廓上，以便在形成壳体的过程中所述纤维复合材料与所述壳状半成品优选地形成材料粘接。
11.根据权利要求10所述的方法，其特征在于，将未固化的热固性材料的板状元件放置在所述工具中。
12.根据权利要求10或11所述的方法，其特征在于，借助热熔的壳状半成品的接触热传递将所述板状元件固化。
13.根据权利要求10-12中任一项所述的方法，其特征在于，挤压管状预成型件，该管状预成型件被切开以形成片状板并被展开并且通过使用挤压的热量形成壳体。
14.根据权利要求10-12中任一项所述的方法，其特征在于，挤压板状的片状预成型件，该片状预成型件通过利用挤压的热量而形成壳体。
15.根据权利要求13或14所述的方法，其特征在于，以多层状态将预成型件挤压成具有至少一个阻隔碳氢化合物的层和至少一个粘接剂层，粘接剂层与纤维复合材料的板状元件接触。
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