CN103442921A - 用于机动车辆的热塑性聚合物的燃料箱以及生产燃料箱的方法 - Google Patents

用于机动车辆的热塑性聚合物的燃料箱以及生产燃料箱的方法 Download PDF

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Publication number
CN103442921A
CN103442921A CN2012800147819A CN201280014781A CN103442921A CN 103442921 A CN103442921 A CN 103442921A CN 2012800147819 A CN2012800147819 A CN 2012800147819A CN 201280014781 A CN201280014781 A CN 201280014781A CN 103442921 A CN103442921 A CN 103442921A
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fuel tank
reinforcing element
wall
closing device
tank
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CN2012800147819A
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CN103442921B (zh
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D·奥伊利茨
U·卡尔施
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Kautex Textron GmbH and Co KG
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Kautex Textron GmbH and Co KG
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    • 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
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • 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
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
    • B29C49/04—Extrusion blow-moulding
    • 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
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/20—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/022—Particular heating or welding methods not otherwise provided for
    • B29C65/028—Particular heating or welding methods not otherwise provided for making use of inherent heat, i.e. the heat for the joining comes from the moulding process of one of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; 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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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/532—Joining single elements to the wall of tubular articles, hollow articles or bars
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/61—Joining from or joining on the inside
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/63—Internally supporting the article during joining
    • B29C66/636—Internally supporting the article during joining using a support which remains in the joined object
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
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    • B29C66/73771—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being amorphous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
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Abstract

本发明涉及一种用于机动车辆的热塑性聚合物的燃料箱，所述燃料箱内具有至少一个加强元件，所述加强元件在所述燃料箱内在两个相对的箱壁（15）之间延伸，所述加强元件的一部分穿过箱壁并且所述加强元件的一部分从外侧接合在所述箱壁后方，根据本发明的燃料箱的区别在于，所述加强元件（8）设置有至少一个多部分的紧固头部（11），所述紧固头部包括第一闭合装置和第二闭合装置，所述第一闭合装置通过所述箱壁（15）从内侧进行接合，所述第二闭合装置通过所述箱壁（15）从外侧进行接合，所述第一闭合装置和所述第二闭合装置为互补的构造。

Description

用于机动车辆的热塑性聚合物的燃料箱以及生产燃料箱的方法
技术领域
本发明涉及用于机动车辆的热塑性聚合物的燃料箱，其在燃料箱内具有至少一个加强元件，燃料箱内的加强元件在两个相对的箱壁之间延伸，加强元件的一部分穿过箱壁，并且加强元件的一部分从外侧接合在箱壁后方。
背景技术
这样的燃料箱可见于例如DE102008009829A1。
热塑性聚合物的燃料箱无一例外地几乎都是基于HDPE（高密度聚乙烯）制成。在这里使用多层挤出物，其具有用于碳氢化合物的阻挡层，该阻挡层考虑了聚乙烯对碳氢化合物的不完全抵抗。在这点上应当提及的是，不采用具有用于碳氢化合物的阻挡层的、基于HDPE的共同挤出物，还可以采用单层挤出物，其已经通过化学处理而具有抗性，例如通过在箱的内侧上进行磺化或氟化，以抵抗碳氢化合物通过材料的扩散。
根据可加工性和稳定性，已经证明HDPE是用于生产燃料箱的特别合适的材料。HDPE在尺寸上足够稳定并且具有足够的抗性，尤其在冲击的情况下，例如在碰撞的情况下在机动车辆中可能发生的冲击。
然而，使用HDPE作为用于生产热塑性聚合物箱的材料所具有的缺陷在于，HDPE在暴露于长期压力时具有产生蠕变的某种趋势。与取决于绝对压力相比，聚合物产生蠕变的趋势更加取决于时间。
燃料箱在常规上主要以无压的方式操作。本文中的无压应当理解为指的是相对于大气压为大致-30到+100mbar的系统压力。燃料箱中的压力条件可能例如由于填充和清空、温度波动、燃料在燃料箱中运动等而改变。为了确保无压燃料箱，可以借助于通风阀和通风管线来均衡压力改变。在常规上经由活性碳过滤器通风到大气。这样的活性碳过滤器通常在内燃机的操作期间定期回洗，这是通过经由活性碳过滤器吸入用于内燃机的燃烧空气而实现的。
在混合动力车辆中，冲洗活性碳过滤器的可能性受到限制，原因是燃烧发动机仅仅在某些驱动状况下开启。这意味着在混合动力车辆中，燃料箱有利地关闭的操作状况有可能是占据主导的。在这种情况下，在燃料箱内可能出现稍稍升高的内部压力，甚至超过延长的时间段。因此，对于这样的车辆，需要使得燃料箱相应地具有耐压性。进一步参考现有技术，在上述DE102008009829A1中已经描述了这个问题。
为了解决这个问题，例如在DE102008009829A1中建议提供一种用于机动车辆的热塑性聚合物的燃料箱，其在燃料箱中具有至少一个加强元件，加强元件在两个相对的箱壁之间延伸，以使其抵消由燃料箱中的内部压力引起的变形。在这种情况下，具体地，布置在燃料箱中的加强元件的两个端部从外侧接合到箱壁后方。这具有的优点在于，加强元件和箱壁之间的连接部仅仅暴露于压力，由此，聚合物产生蠕变的趋势在加强元件和箱壁之间的连接部的区域中被抵消。
根据DE102008009829A1的加强元件被构造成多部分传送单元，该传送单元在箱壁中的相对的、对准的、较大的开口之间延伸，并且该传送单元在每种情况下利用凸缘状紧固卡圈靠着箱外壁支撑在箱壁的相对侧上。
这种布置需要箱内较大量的结构空间，尽管由于流过的燃料流而不会占据任何显著的箱体积，但是这种布置确实需要提供较大的开口，较大的开口总体上对箱壁而言存在失稳效应。根据DE102008009829A1的燃料箱整体上被构造成使得在生产箱或箱腔体之后无论如何必须引入为传送单元形式的加强元件。此外，加强元件使得在单个燃料箱的情况下仅仅设置一个加强元件，而在具有两个或更多个大箱空间的鞍形箱中，如果需要的话，可以在箱中设置两个这样的加强元件。
原理上还已知的是，在燃料箱生产期间将为单个支柱元件形式的加强元件引入到燃料箱中。被称为“支杆（stand off）”的这些支柱元件可以例如在由多个幅材或带形预成型件生产燃料箱的过程中通过挤出吹塑模制而被引入到燃料箱中。这样的方法例如可见于DE102006031902A1。该方法涉及由热塑性聚合物生产燃料箱，其中增塑聚合物的幅材或带形预成型件在形成腔体的多部分模具中通过预成型件靠着腔体的内部轮廓膨胀和施加而成形，其中该方法首先包括形成为外壳形式的两个互补中间产品，插入件在安装位置中紧固到外壳的面向彼此的内侧中的每个内侧，并且其中互补外壳的插入件中的至少一些在每种情况下都为互补的构造，使得它们可以连接以形成组装的部件或功能单元，此外，外壳连接在一起，使得互补的插入件彼此接合或者彼此进行主动连接。在DE102006031902A1的情况下，对于本文参考的全部内容，也为了公开的目的，具体地参照燃料箱的生产方法，稳定中空本体的互补支柱构件设置成插入件，所述构件在外壳连接时闩锁在一起。
DE102006031902A1中所述的燃料箱不具有上述缺陷。然而已经发现的是，这种燃料箱的耐压性仍然存在某些限制。在根据DE102006031902A1的方法中，设置为插入件的支柱元件焊接或铆接到外壳的仍然热的且塑性的内壁。对于这样的燃料箱的测试表明，这样的连接在某些环境下也会受到热塑性聚合物在长时间暴露于压力的情况下产生蠕变的影响。
发明内容
因此，本发明的目的在于改进上述类型的燃料箱，使其生产尤其简单，并且具有耐久的耐压性。此外，本发明的目的还在于提供用于生产这样的燃料箱的方法。
本发明的目的首先通过用于机动车辆的热塑性聚合物的燃料箱来实现，该燃料箱内具有至少一个加强元件，该加强元件在燃料箱内在两个相对的箱壁之间延伸，加强元件的一部分穿过箱壁并且加强元件的一部分从外侧接合在箱壁后方，根据本发明的燃料箱的区别在于，加强元件设置有至少一个多部分的紧固头部，所述紧固头部包括第一闭合装置和第二闭合装置，所述第一闭合装置通过所述箱壁从内侧进行接合，所述第二闭合装置通过所述箱壁从外侧进行接合，所述第一闭合装置和所述第二闭合装置为互补的构造。这样的燃料箱具有的特别优点在于，在燃料箱的相对壁区域中不需要大面积的相互对准的圆形切口或开口。此外，根据本发明的燃料箱结合了以下的优点：在箱的内侧上引入的“支杆”的优点，例如如DE102006031902A1所述；DE102008009829A1的燃料箱的优点，其中连接元件靠着箱的外壁支撑在两侧上。
根据本发明，这还实现为，设有通过箱壁从外侧进行接合的第二闭合装置，该第二闭合装置与第一闭合装置以型面配合和/或粘合的方式相互作用，使得闭合装置优选地将箱壁夹在它们之间。
在根据本发明的燃料箱的特别优选的变型中，闭合装置螺纹连接在一起。
或者，闭合装置可以设置成闩锁在一起，在这种情况下，例如通过箱壁从外侧进行接合的闭合装置可以以按钮的方式闩锁到第一闭合装置。
通过箱壁从外侧进行接合的第二闭合装置可以另外地或作为另外一种选择地焊接或粘结到第一闭合装置。此外，第二闭合装置可以以型面配合的方式与第一闭合装置相互作用，或另一方面，可以通过接合在箱外壁上的卡圈而焊接到箱的外壁。
最后，第二闭合装置可以焊接到箱外壁，并且通过销接合在第一闭合装置的对应凹部中，其中在闭合装置的穿透区域中不必提供闩锁连接、粘合或焊接。
在根据本发明的燃料箱的便利变型中，加强元件的紧固头部焊接到燃料箱的内壁。
为此，紧固头部包括至少一个焊接卡圈，其周围在通过箱壁的直通部（feed through）的区域中焊接到燃料箱的内壁，使得直通部可靠地密封。
为了实现充分不扩散/不透气体的密封，可以在直通部区域中设置额外的密封手段。例如，还可以在直通部中设置与紧固头部粘合的接头。
在根据本发明的燃料箱的特别便利的变型中，第一闭合装置采用所述紧固头部的套筒式延伸部的形式，所述套筒式延伸部通过所述箱壁进行接合，从外侧接合在所述箱壁后方的闭合构件作为第二闭合装置插入到所述套筒式延伸部中。在这种情况下，该连接便利地形成为使得箱壁通过直通部区域中的焊接进行密封，而在箱壁由于压力而变形的情况下，第二闭合装置从外侧支撑箱壁，其中至少一部分力作为拉伸力被引入到加强元件中。在任何情况下，加强元件和箱壁之间的连接部仅仅暴露于压力，由此，聚合物产生蠕变的趋势在加强元件和箱壁之间的连接部的区域中被极大地阻止。
在根据本发明的燃料箱的特别便利的构造中，套筒式延伸部设置有螺纹衬套，闭合构件利用互补构造的螺纹销接合到螺纹衬套中。另外，闭合构件可以焊接到箱外壁，或者对于螺纹销而言粘结到和/或焊接到螺纹衬套。在根据本发明的燃料箱的特别便利的变型中，加强元件形成为至少两种不同热塑性聚合物的多部件式元件，其至少一个部件是在可焊接方面与所述箱壁相容的热塑性聚合物。
例如，紧固头部的形成螺纹的部分和闭合构件可以由尺寸特别稳定的抗蠕变的聚合物构成，例如聚酰胺。这还具体涉及紧固头部的螺纹衬套。另一方面，焊接卡圈可以由聚乙烯构成。根据本发明的燃料箱的箱壁同样至少主要由聚乙烯构成，其优选地采用基于HDPE（高密度聚乙烯）的多层共同挤出物的形式。
加强元件便利地采用多部分壁对壁的支柱元件的形式，并且由至少两个支柱部分构成。便利地，根据本发明的加强元件在燃料箱的大面积壁区域之间延伸，与燃料箱的较小面积壁区域相比，这些大面积壁区域在常规上更严格地暴露于压力相关的变形。
加强元件或支柱部分还可以采用中空管状元件的形式，其形成用于容纳管线或者用于对箱进行通风的通道。或者，这样的通道还可以容纳液压或电气出口。另外，具有一体的泡状截面的实施例也是可行的。
支柱部分便利地通过螺纹、卡口、插入、卡扣或闩锁连接而连接在一起。
本发明的目的还通过生产燃料箱的方法来实现，该方法包括以下方法步骤：
-由热塑性聚合物挤出幅材形预成型件，
-在多部分模具中模制该预成型件，以形成外壳，
-在将所述外壳连接在一起以形成闭合的箱之前或期间，将至少一个加强元件的至少一部分引入到所述外壳中，加强元件的一部分穿过至少一个外壳的壁并且焊接到该壁，以及
-利用至少一个闭合装置完成加强元件，在所述外壳连接在一起期间或之后，所述至少一个闭合装置通过壁从外侧进行接合。
在优选的变型中，根据本发明的方法提供两个待挤出的幅材形预成型件，幅材形预成型件在多部分模具中成形，该模具包括实现相对于彼此的打开和闭合运动的至少两个外部模具和至少一个中间模具，每个外部模具形成部分腔体的轮廓，该轮廓确定外壳的轮廓，中间模具设置有至少一个部件保持器，在外壳模制之后，至少一个加强元件或支柱部分放置或紧固在外壳的内侧上。
在外壳的内侧上放置例如两个支柱部分之后，移除外部模具之间的中间模具，然后外部模具能够靠着彼此闭合，使得外壳和放置在外壳内侧上的支柱部分彼此主动连接。
在方法的特别优选的变型中，在将加强元件或支柱部分引入到外壳的壁中的情况下，该壁在仍然热的且塑性的同时被加强元件或支柱部分的一部分穿孔，例如进入模具中的对应凹部，同时加强元件焊接到该壁。
优选地，在每种情况下，将多部分的加强元件的支柱部分引入到由两个外壳组装成的箱的外壳中，并且在所述外壳连接在一起的情况下，优选地为互补构造的支柱部分彼此主动连接，也就是彼此进行型面配合接合，使得加强元件可以总体传递拉伸力。
优选地，借助于至少一个切割头部进行外壳的壁的穿孔，所述至少一个切割头部能够从加强元件移除或者是能够消耗的。
如上已经提及的，利用压差并且利用挤出热在挤出吹塑模具中便利地进行预成型件的模制。
附图说明
以下将参考附图中示出的示例性实施例解释本发明，其中：
图1、2和6示意性地示出了根据本发明的用于生产燃料箱的基础吹塑模制方法，
图3a和3b示意性地示出了借助于为此提供的工具而在外壳的壁上进行的穿孔，
图4a和4b示意性地示出了支柱部分放置或引入到外壳中，以及
图5a和5b示意性地示出了支柱部分组装以在最终的箱中形成加强元件以及闭合本体插入到加强元件中。
具体实施方式
图1示出了根据本发明的挤出吹塑模具1的部分横截面，其包括中心框架3和两个外部模具2，其中外部模具2能够朝向和远离中心框架3移动而进行打开和闭合运动。另一方面，中心框架3可以与外部模具2的这种打开和闭合运动成横向地移动，也就是进入和离开附图的平面。每个外部模具2都形成部分腔体4，该部分腔体限定了最终产品的轮廓，或者限定了在燃料箱6生产过程中生产为中间产品5的外壳的轮廓。
附图标记7表示幅材形预成型件，其被引入到挤出吹塑模具1的打开部分之间。
在这点上，应当指出的是，根据本发明的燃料箱6不必通过挤出吹塑模制来生产，相反，外壳5可以例如通过注射模制或热成形来生产，可以在引入插入件之后进行外壳5的连接以形成最终的燃料箱6，同时还进行外壳的部分再加热，即局部再加热。在本文所述的生产方法中，当预成型件7的整个长度在外部模具2和中心框架3之间延伸时，外部模具2靠着中心框架3闭合。挤出吹塑模具1的闭合，即外部模具2靠着中心框架3闭合，使得部分腔体4密封，从而通过施加压差可以进行预成型件7模制到外壳5中。“通过施加压差”指的是通过施加真空和/或通过施加内部过压。
没有较为详细描述的部件保持器布置在中心框架3中，在图2所示的结构中，借助于该部件保持器，插入件可以施加或连接到部分模制的外壳5的内部。待生产的燃料箱6的功能部件，例如泵、换能器、阀或类似物，或者实际的支柱元件、加强元件等，是可以想到的插入件。
在本文所述的示例性实施例的情况下，支柱部分8a、8b作为插入件放置在外壳5的内侧上，所述插入件在最终的燃料箱6中连接在一起以形成连续的加强元件8。该加强元件也可以称为“支杆”或“系结杆”。当支柱部分8a、8b已经连接到外壳5的内侧时，挤出吹塑模具1打开，中心框架3在外部模具2之间移入或移出附图的平面，并且外部模具靠着彼此闭合，其中外壳5最终在其边缘处进行吹塑，以通过向外部模具施加合适的压力并且通过向闭合的箱施加合适的压差来形成闭合的燃料箱6。在生产燃料箱6并且将该燃料箱从挤出吹塑模具移除之后，在这种状态下组装以形成连续加强元件8的支柱部分8a、8b从外侧利用闭合装置而完成生产，该闭合装置通过箱壁接合，为闭合构件10的形式，设置有螺纹销9。具体地，从图4a和4b可以清楚地看到，每个支柱部分8a、8b都设置有紧固头部11，该紧固头部包括具有螺纹衬套13的套筒形延伸部12。在延伸部12的面向箱内侧的一侧上，设有周边卡圈14，该卡圈用于焊接到箱壁15或焊接到外壳5的壁。在所示的示例性实施例中，紧固头部11采用“2个部件的元件”的形式，也就是其包括两个部件，其中具有包括延伸部12和卡圈14的一体式紧固头部11的支柱部分8a由HDPE构成，而螺纹衬套13采用聚酰胺的插入件的形式。螺纹衬套13以型面配合的方式插入到紧固头部11中。紧固头部11的两个部件的相互连接没有详细示出。原理上，支柱部分8a、8b可以完全由聚酰胺构成，并且设置有HDPE的卡圈14。
延伸部12的从其前端到例如卡圈14的高度大致对应于箱壁15的厚度。
紧接着模制外壳5之后，支柱部分8a、8b在合适的部位处插入到每个外壳5中，其中延伸部12接合或穿过箱壁15中的开口16，使得卡圈14抵靠着箱壁15。在这种情况下，紧固头部11经由卡圈14焊接且密封到箱壁15。
然后，箱壁15中的开口16可以借助于设置在紧固头部11上的切割头部来提供，该切割头部可以在箱壁穿孔之后失去或移除，或者箱壁15中的开口16可以借助于具有切割头部17的单独工具17a而形成。这在图3a和3b中示出。
如果箱壁15被延伸部12自身刺穿，那么应当确保通过刺穿而从箱壁15移除的材料不会进入螺纹衬套13，使得螺纹衬套最终能够自由地从燃料箱6外侧触及，例如如图5a和5b所示。
如图3a和3b所示，可以利用合适的例如中心框架3中的能够气动地或液压地移动的致动元件/部件保持器来进行借助于支柱部分8a、8b和借助于单独工具的箱壁15的穿孔。
在支柱部分8a、8b在箱壁15的相互面对的且（在最终的箱中）相互对准的通道/开口处插入之后，外部模具2之间的中心框架被移除，且外部模具2靠着彼此闭合，使得外壳5在每种情况下在周边凸缘状边缘处连接且焊接在一起，以形成最终的燃料箱6。同时，支柱部分8a、8b在相互面对的紧固端部18处连接在一起以形成加强元件8。在所示的示例性实施例中，紧固端部18一方面采用联接套筒19的形式，另一方面采用销20的形式。联接套筒19设置有闩锁突起21，而销20设置有对应的闩锁凹部22。支柱部分8a设置有联接套筒19，另一方面，支柱部分8b设置有销20。联接套筒19上的闩锁突起21与销20上的闩锁凹部22互补。
当外壳5和支柱部分8a、8b已经连接在一起时，闭合构件10从外侧利用其螺纹销9拧入到支柱部分8a、8b的螺纹衬套13中，如图5a和5b所示。闭合构件10同样便利地由聚酰胺构成。
每个闭合构件10形成卡圈23或盘式闭合盖，该卡圈或盘式闭合盖从外侧接合在箱壁15后方，使得箱壁15被夹在卡圈23和延伸部12的卡圈14之间。闭合构件10的卡圈23接合在箱壁15后方，使得箱壁仅仅暴露于压力，合力被引入到加强元件8中。通过卡圈14在箱内侧上的周边焊接进行穿过箱壁15的开口16或直通部的可靠密封。
附图标记列表
1 挤出吹塑模具
2 外部模具
3 中心框架
4 部分腔体
5 外壳
6 燃料箱
7 预成型件
8 加强元件
8a、8b 支柱部分
9 螺纹销
10 闭合构件
11 紧固头部
12 延伸部
13 螺纹衬套
14 卡圈
15 箱壁
16 开口
17 切割头部
17a 工具
18 紧固端部
19 联接套筒
20 销
21 闩锁突起
22 闩锁凹部
23 卡圈、闭合构件

Claims (17)

1.一种用于机动车辆的热塑性聚合物的燃料箱（6），所述燃料箱（6）内具有至少一个加强元件（8），所述加强元件（8）在所述燃料箱（6）内在两个相对的箱壁（15）之间延伸，所述加强元件（8）的一部分穿过箱壁（15）并且所述加强元件（8）的一部分从外侧接合在所述箱壁（15）后方，其特征在于，所述加强元件（8）设置有至少一个多部分的紧固头部（11），所述紧固头部包括第一闭合装置和第二闭合装置，所述第一闭合装置通过所述箱壁（15）从内侧进行接合，所述第二闭合装置通过所述箱壁（15）从外侧进行接合，所述第一闭合装置和所述第二闭合装置为互补的构造。
2.根据权利要求1所述的燃料箱，其特征在于，所述第一闭合装置和所述第二闭合装置将所述箱壁（15）夹在它们之间。
3.根据权利要求1和2中任一项所述的燃料箱，其特征在于，所述第一闭合装置和所述第二闭合装置螺纹连接在一起。
4.根据权利要求1和2中任一项所述的燃料箱，其特征在于，所述第一闭合装置和所述第二闭合装置闩锁在一起。
5.根据权利要求1至4中任一项所述的燃料箱，其特征在于，通过所述箱壁从外侧进行接合的所述第二闭合装置焊接到所述燃料箱的外壁。
6.根据权利要求1至5中任一项所述的燃料箱，其特征在于，所述加强元件（8）的所述紧固头部（11）焊接到所述燃料箱的内壁。
7.根据权利要求6所述的燃料箱，其特征在于，所述紧固头部（11）包括至少一个焊接卡圈，所述至少一个焊接卡圈的周围在通过所述箱壁（15）的直通部的区域中焊接到所述燃料箱的内壁。
8.根据权利要求1至7中任一项所述的燃料箱，其特征在于，所述第一闭合装置采用所述紧固头部（11）的套筒式延伸部（12）的形式，所述套筒式延伸部通过所述箱壁（15）进行接合，从外侧接合在所述箱壁（15）后方的闭合构件（10）作为第二闭合装置插入到所述套筒式延伸部中。
9.根据权利要求8所述的燃料箱，其特征在于，所述套筒式延伸部（12）设置有螺纹衬套（13），所述闭合构件利用互补构造的销（9）与所述螺纹衬套接合。
10.根据权利要求1至9中任一项所述的燃料箱，其特征在于，所述加强元件（8）形成为至少两种不同热塑性聚合物的多部件式元件，其至少一个部件是在可焊接性方面与所述箱壁（15）相容的热塑性聚合物。
11.根据权利要求1至10中任一项所述的燃料箱，其特征在于，所述加强元件（8）采用多部分壁对壁式支柱元件的形式，并且由至少两个支柱部分（8a、8b）构成。
12.根据权利要求11所述的燃料箱，其特征在于，所述支柱部分（8a、8b）通过螺纹、卡口、插入、卡扣或闩锁连接而连接在一起。
13.一种生产根据权利要求1至12中任一项所述的燃料箱的方法，包括以下步骤：
-由热塑性聚合物挤出幅材形预成型件，
-在多部分模具中模制该预成型件，以形成外壳，
-在将所述外壳连接在一起以形成闭合的箱之前或期间，将至少一个加强元件的至少一部分引入到所述外壳中，加强元件的一部分穿过至少一个外壳的壁并且焊接到该壁，以及
-利用至少一个闭合装置完成加强元件，在所述外壳连接在一起期间或之后，所述至少一个闭合装置通过壁从外侧进行接合。
14.根据权利要求13所述的方法，其特征在于，在将加强元件引入到外壳的壁中的情况下，该壁在仍然是热的且有塑性的同时被加强元件的一部分穿孔，同时加强元件焊接到该壁。
15.根据权利要求13和14中任一项所述的方法，其特征在于，在每种情况下，将多部分的加强元件的支柱部分引入到由两个外壳组装成的箱的外壳中，并且在所述外壳连接在一起的情况下，支柱部分彼此主动连接。
16.根据权利要求13至15中任一项所述的方法，其特征在于，借助于至少一个切割头部进行外壳的壁的穿孔，所述至少一个切割头部能够从加强元件移除或者是能被消耗的。
17.根据权利要求13至17中任一项所述的方法，其特征在于，利用压差并且利用挤出热在挤出吹塑模具中进行预成型件的模制。
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WO2012126569A2 (en) 2012-09-27
US10086687B2 (en) 2018-10-02
KR20130124577A (ko) 2013-11-14
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