CN105121127B - 用于生产容器的方法和穿孔装置 - Google Patents

用于生产容器的方法和穿孔装置 Download PDF

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Publication number
CN105121127B
CN105121127B CN201480021622.0A CN201480021622A CN105121127B CN 105121127 B CN105121127 B CN 105121127B CN 201480021622 A CN201480021622 A CN 201480021622A CN 105121127 B CN105121127 B CN 105121127B
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China
Prior art keywords
prefabricated component
connecting element
mould
mandrel
opening
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CN201480021622.0A
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CN105121127A (zh
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D·杜卡伊
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Kautex Textron GmbH and Co KG
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Kautex Textron GmbH and Co KG
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Abstract

本发明涉及一种由具有热塑性材料制备容器的方法，所述容器具有穿过其壁的连接元件(5)。该方法包括：使得能够获得由增塑的热塑性材料制备的至少一个板形或壳形或管形预制件(3)；将预制件(3)引入具有腔的多部件式模制工具(1)内，所述腔限定至少一个模制凹部；利用压差在模制工具(1)中模制和最终成形预制件(3)；借助于芯轴(9)从工具侧穿刺仍然温塑性的预制件(3)，以便于在预制件(3)中形成开口(6)；从模制凹部侧将连接元件(5)插入至由芯轴(9)形成的开口(6)中；以及将连接元件(5)连接至预制件(3)。

Description

用于生产容器的方法和穿孔装置
技术领域
本发明涉及一种由热塑性材料制备容器的方法，所述方法包括下列方法步骤：
-使得能够获得由增塑的热塑性材料制成的至少一个板形或壳形或管形的预制件，
-将至少一个预制件引入至多部件式的模制工具中，所述模制工具优选具有限定模制凹部的至少两个腔，
-利用压差在模制工具中模制和最终成形预制件。
背景技术
根据本发明的这种方法例如可以实施作为挤压吹塑法。作为替代性的方案，该方法还可以实施作为深拉法。
例如通过挤压腹板形、壳形或管形的预制件，能够获得根据本发明由增塑的热塑性材料制成的板形或壳形的预制件，其中，管形预制件优选在一侧上至少纵向分裂，并且随后被引入模制工具中，从而使得内部配件可以结合至模制工具中的仍然温塑性的预制件。在完成容器之后，这些构件布置在容器中，并且确定地连接和/或通过材料连接至容器壁。
预制件首先放置在模制工具内的模制工具腔上，并且在模制工具的腔内被模制和赋予最终形状，以形成壳形中间体。在另一方法步骤中，随后例如通过闭合模制工具的各部件而将中间体结合在一起以形成闭合的中空体，其中，壳形中间体彼此焊接在一起。
根据本发明的方法优选是制备用于机动车辆的油箱的方法，例如用于制备燃料箱、或者用于制备洗涤-除去箱、或者用于制备液体添加剂箱。
该方法主要包括利用预制件的增塑热塑性材料的挤压热而最终形成容器。然而，在本发明的范围内，还可以设想使用在被引入模制工具中之前或期间再增塑的板形或壳形半成品。
根据本发明使用压差指的是：由模制工具形成的至少暂时闭合的模制凹部经受气体压力、和/或排空模制工具的腔。
根据本发明的方法特别地指的是由热塑性材料制备容器，所述容器具有穿过其壁的至少一个连接元件。
例如在DE 10 2007 024 667 A中已知这类方法。这种方法包括通过挤压吹塑由热塑性材料制备容器，其中，在多部件式工具内进行最终成形期间，容器设置有穿过其壁的至少一个连接元件，其中，在容器壁仍然处于增塑的状态下通过连接元件的一部分而穿刺容器壁，使得连接元件进入材料中，从而连接元件至少在部分区域中与容器壁结合在一起，其中，连接元件设置有穿刺尖部，并且在穿刺容器壁期间，将连接元件插入至硬模中，所述硬模设置在工具中并且布置在容器壁背离连接元件的一侧上。在该方法中，连接元件被推动穿过容器壁或穿过模制凹部侧上的预制件。该连接元件主要用于使得布置在完工容器的内侧处的内部配件(特别是通风装置等)借助于软管而连接至外侧。在制备容器期间穿刺预制件的壁所具有的优点在于避免随后在容器中进行环形切割或钻孔。特别地，由热塑性材料制成的燃料箱是通过与针对碳氢化合物的屏障层进行多层共挤压而制成的。由于在容器壁中形成开口而对屏障层造成的后续损伤从根本上而言是不期望的，这是因为防止碳氢化合物扩散的屏障层的屏障作用在这些区域被折损。
例如，根据EP 1 211 196 A1已知一种由热塑性材料制备燃料箱的方法并且已知具有用于软管等的连接元件的这种燃料箱。EP 1 211 196A1描述了一种由热塑性材料制成的双壳燃料箱，所述双壳燃料箱具有嵌入在燃料箱壁中的碳氢化合物屏障层，并且被连接在一起以形成燃料箱的壳是通过热成型而获得的。为了在维持针对碳氢化合物的高抗渗透性的同时确保简单地附接连接元件，在EP 1 211 196 A1中提供了一种包括至少一个外部部件和至少一个内部部件的两部件式连接元件或两部件式配件，其中，外部部件被焊接至燃料箱的外壁，而内部部件通过移动和夹住燃料箱壁而至少部分地穿透外部部件。这种布置方案的优点在于燃料箱壁在各构件之间移动且被包封，其结果是被移动的材料作为通道的密封件。然而，在EP 1 211 196 A1中描述的方法中进行的材料移动使得必须在制备燃料箱之后通过适当地修整燃料箱而移除内部部件和外部部件之间的材料，所述材料阻挡通过构件的通道，而这个移除处理是相当复杂。
相比而言，根据DE 10 2007 042 667已知的方法的缺点在于：由连接部件或安装在连接部件上的切割套筒冲压离开预制件壁的材料会阻塞连接部件的开口。至少必须移除在形成连接之后冲压离开预制件的材料坯料。而且，需要将相对大的冲压单元容纳在工具内。为了实现在工具中可靠地穿刺预制件，必须以相对大的力和相对高的进给速度操作冲压单元，而这是相对昂贵的。
此外，就冲压单元相对于设置在工具内的硬模的布置而言，需要维持相对较窄的公差范围。
例如在DE 30 42 926 C2中公开了一种由热塑性材料制备容器的方法，所述容器具有穿过容器壁的连接元件，所述方法包括下列方法步骤：-使得能够获得由热塑性材料制成的至少一个板形、壳形或管形的预制件；-将至少一个预制件引入多部件式的模制工具中，所述模制工具具有限定模制凹部的腔；-利用压差在模制工具中模制和最终成形预制件，以提供壳形中间体；-结合壳形中间体以提供闭合的中空体，其中，壳形中间体被焊接至彼此；-通过芯轴从模制工具侧穿刺仍然温塑性的预制件，从而在预制件中形成开口；-从模制凹部侧处将连接元件插入至先前由芯轴形成的开口中，以及将连接元件(5)连接至预制件。例如在US 2011/0140314 A1中公开了将构件连接至模制物品的方法。
发明内容
因而，本发明的根本目的是提供一种在文章开头处所述的由热塑性材料制备容器的方法，该容器具有穿过其壁的连接元件，该方法不具有前述缺点。
该目的通过这样的方法而得以实现，所述方法是一种由热塑性材料制备容器的方法，所述容器具有穿过容器壁的连接元件，所述方法包括下列方法步骤：-使得能够获得由热塑性材料制成的至少一个板形、壳形或管形的预制件；-将至少一个预制件引入多部件式的模制工具中，所述模制工具具有限定模制凹部的腔；-利用压差在模制工具中模制和最终成形预制件，以提供壳形中间体；-结合壳形中间体以提供闭合的中空体，其中，壳形中间体被焊接至彼此；-通过芯轴从模制工具侧穿刺仍然温塑性的预制件，从而在预制件中形成开口；-从模制凹部侧处将连接元件插入至先前由芯轴形成的开口中，以及将连接元件连接至预制件，其特征在于，由芯轴形成的开口在插入连接元件之前或期间定尺寸，以及借助于从模制工具侧插入开口中的至少一个定尺寸套筒而进行定尺寸。各从属权利要求涵盖了根据本发明的方法的其它有利实施例。
本方法的效果概述如下：在工具侧处(即在预制件朝向腔壁的一侧处)，在仍然温塑性的预制件中形成开口；和从模制凹部侧处(即从内侧处或从预制件背离工具腔的一侧处)插入连接元件。连接元件被引入至该开口中，并且在这个过程期间，连接元件确定地连接和/或通过材料连接至容器的后续内壁。
一方面，根据本发明的方法的优点是位于工具内部的大型冲压单元是多余的；而另一方面，本方法允许开口和连接元件相对于彼此以较大的公差布置。由芯轴形成的开口可能尺寸略大，而开口的密封是通过从内侧将连接元件插入由芯轴形成的开口而实现的。在这个处理过程期间，预制件的仍然温塑性的材料通过与连接元件结合而移动，从而确保对由芯轴形成的开口进行可靠的密封。
如果使用具有芯或中央框架的三部件式模制工具实施本方法，则在芯或中央框架上需要相对较少的空间来操作连接元件。
在根据本发明的方法中，优选规定在将连接元件插入开口之前，例如借助于红外加热装置、焊镜、加热板等预加热连接元件。
根据本发明，规定在插入连接元件之前或期间对由芯轴形成的开口进行定尺寸。
例如，可以借助于从工具侧插入开口中的至少一个定尺寸套筒而进行定尺寸。借助于这种定尺寸套筒，有关的开口可以以精确的方式扩张，其尺寸略大。这种类型的尺寸过大可以是几十毫米的数量级。
借助于连接短轴，容易地将连接元件插入至位于开口中的定尺寸套筒中，接着从开口中撤回定尺寸套筒，在这个处理期间或随后，借助于设置在所述连接元件上的轴环而将连接元件焊接至预制件。
优选仅在焊接处理已经实施之后将定尺寸套筒撤入腔内。在焊接连接元件期间，连接短轴中的通道由预制件密封。
作为示例，连接元件可以设计作为具有焊接轴环的“2构件式部件”，其就可焊性而言与预制件相适应，然而连接部件的其它构件可以由不能焊接至预制件的材料构成。例如，焊接轴环可以由聚乙烯制成，这在预制件具有基于聚乙烯(HDPE)的多层壁结构时尤为有利。例如，连接元件自身可以设计为聚酰胺接管。作为替代方案，连接元件可以由能够焊接至预制件材料的单一热塑性材料制成。
在本方法的可取且有利的变型方案中，规定连接元件在模制凹部侧处连接至布置于容器中的通风装置。
根据本发明的方法包括首先将预制件放置在工具腔上，随后可能通过闭合工具而抵靠具有用于内部配件的支承件的芯或中心框架，将连接元件插入预制件的之前不久形成的开口中，并且将至少一个内部配件在模制凹部侧处结合至预制件壁。此后，可以再次打开模制工具，从具有腔的各模制工具部件之间移除中心框架或用于内部配件的芯或支承框架，并且再次闭合模制工具以便于将预制件结合至闭合容器中。在本方法的这个阶段中，模制凹部经受气压，例如5至7巴的数量级。
为了在对模制凹部进行的这种加压期间保护设置在容器内的容积免受这些压力峰值的影响，根据本发明规定在对模制凹部进行的加压期间经由连接元件建立通风装置的容积的压力平衡。
例如，这种压力平衡可以借助于芯轴而实现。
恰当的是在定尺寸套筒处于预制件的开口中时实施压力平衡。定尺寸套筒确保对预制件的开口进行一定的密封，并且芯轴可以连接至模制工具的吹塑压力管路。
根据本发明的另一有利变型方案的不同之处在于使用设置在工具侧的至少一个芯轴，所述至少一个芯轴与定尺寸套筒共轴地布置在模制工具的腔内，所述定尺寸套筒可以相对于芯轴进行调整。
作为示例，芯轴可以设计作为具有至少一个开口的中空针，介质可以流动通过所述中空针，并且所述芯轴可以连接至压力介质源以用于对模制凹部加压。
附图说明
下文通过附图中所示的示意性实施例解释本发明，在各附图中：
图1示出了在穿刺预制件之前的模制工具的一部分的简化示意图，其中模制工具具有已插入其中的预制件和根据本发明的穿孔装置，
图2示出了在穿刺预制件期间的对应于图1的视图，
图3示出了在对开口定尺寸期间的对应于图1的视图，
图4示出了对应于图3的视图，其中芯轴缩回，
图5示出了对应于图4的视图，其示出了将连接元件插入开口中，
图6示出了将连接元件焊接至预制件之后的对应于前述附图的视图。
具体实施方式
在附图中，模制工具1和穿孔装置2的尺寸比未按比例示出。图示仅用于说明本方法，并且在其它方面高度简化。
图1中仅示出了模制工具1的部分壁2。为简化起见，未示出完整的模制工具以及若存在时的一个或多个相关联挤压装置，所述挤压装置包括挤压机和至少一个挤压头、移除装置等。
模制工具1可以设计为吹塑工具，例如所述吹塑工具包括中心模具和至少两个外部模具，其中吹塑工具的各个部件以常规方式安装在模具夹板上，所述模具夹板被布置成能够在闭合框架中移动。外部模具可以远离彼此或朝向彼此地移动，以形成吹塑工具的打开和闭合运动。中心模具可以横向于打开和闭合运动而移动。中心模具包括可气动地调节或可移动的构件保持器，例如通过所述构件保持器可以将内部配件定位在待制备的容器中。根据本发明的容器可取地设计为由基于HDPE的热塑性材料而多层挤压的塑料容器。
下文中参考所示实施例说明的方法包括从至少一个挤压头排出腹板形预制件3，其中预制件3切割成长度介于模制工具的上述外部模具和中心模具之间。
在第一方法步骤中，外部模具抵抗中心模具或工具分隔器而闭合，通过施加气体压力和/或借助于从外部施加的真空而拉动或推动预制件3进入模制工具1的局部腔4内，所述局部腔由外部模具形成。虽然在此处提到了多个局部腔4，但是在附图中仅示出在模制工具1的一侧处具有一个局部腔4。
在局部腔4中，在初始模制之后，预制件3首先呈模制工具1的由局部腔4预确定的轮廓。在另一方法步骤中，规定在模具凹部侧处(即，预制件3背离局部腔4的一侧处)将内部配件结合至预制件3。例如这种结合可以通过焊接和/或“原位”铆接而实现。根据本方法，例如规定向容器引入内部通风装置，所述内部通风装置包括通风管路、至少一个气泡部分以及互通的通风管路。
借助于下文将描述的连接元件5，包括阀和至少一个气泡部分的通风管路装置设置有穿过后续容器壁的连接部，即所述连接部呈连接元件5的形式(例如，参见图5)。为此，连接元件5被插入至在预制件3中先前形成的开口6中。
为此，首先参考图1，其示出了模制工具1的部分壁2，预制件3插入至所述模制工具中。在这种状态下，预制件3处于熔融温度下并且是温塑性的。在预制件3的待穿孔的位置处，在模制工具1的壁2中设置孔7，在所述孔的后方，在模制工具侧提供根据本发明的穿孔装置8。
穿孔装置8包括芯轴9和定尺寸套筒10，所述芯轴被设计作为中空针，所述定尺寸套筒与芯轴9同心且共轴地布置。芯轴9和定尺寸套筒10设置有第一进给装置11和第二进给装置12，借助于所述第一进给装置和第二进给装置，芯轴9和定尺寸套筒10被设置成能够共同地移动以及相对于彼此移动。例如，进给装置11、12可以具有气压缸和相应的驱动机构。作为替代方案，例如，这些进给装置可以设计为电力驱动，例如呈步进马达的形式。进给装置11、12同样可以液压驱动。
芯轴9和定尺寸套筒10可以移动通过模制工具1中的壁2内的孔7而进入局部腔4。
在根据本发明的方法中，至少在一个预制件3的情况下，可以设想的是在模制工具1的局部腔4内再成形或放置预制件3之后，借助于穿孔装置8形成开口6，以容纳连接元件5。在这个处理过程中，芯轴9首先被驱动或推动穿过孔7而进入局部腔4，穿刺预制件3。芯轴9被设计为中空针，其针尖端13具有例如呈孔形的多个介质通道。
在图2中示出了推进芯轴9的过程。这并不包括任何将材料冲压离开预制件3，而仅仅是穿刺预制件3。这具有优点，特别是没有材料与预制件3分离开，而在一些情况下材料将杂散地位于完工的容器内。
在推进芯轴9之后，还借助于进给装置12而推动定尺寸套筒10进入由此形成的开口6内，其中，定尺寸套筒10的直径大于芯轴9，并且在定尺寸套筒的前端处设置有包绕且向外倾斜的边缘15。定尺寸套筒10移动预制件3的材料，以便于形成外径限定的开口6(参见图3)。
在对预制件3中的开口6进行定尺寸之后，相对于定尺寸套筒10拉回芯轴9，而定尺寸套筒10仍然处于预制件3的开口6内(参见图4)。
随后借助于构件保持器(未示出)，通过连接短轴16而将连接元件5插入的预制件3的开口6内，所述构件保持器布置在模制凹部侧，即位于预制件的背离模制工具1的壁2的一侧(参见图5)。
连接元件5被设计为接管形的“2构件式部件”，其在模制凹部侧呈冷杉状轮廓17，并且在相对侧包括从随后的容器突出的连接短轴16。在附图中，连接短轴16形成为光滑的短轴，但是其同样可以具有冷杉状轮廓。连接短轴16和连接元件8的冷杉状轮廓17被设计作为允许通流的管状聚酰胺主体。连接元件5还包括包绕的轴环18，所述轴环设置有焊接凸缘19。焊接凸缘19优选由与预制件13的HDPE兼容的HDPE构成，以允许进行焊接。
在模制凹部侧处，通风阀装置的通风管路安装在连接元件5的冷杉状轮廓17上。利用预装配的通风管路，连接元件5被推入预制件3的开口6内，直至焊接凸缘19在模制凹部侧处接触预制件3为止。在这个处理过程中，连接元件5被焊接至预制件，在焊接凸缘19的区域中所述预制件仍然处于熔融温度下。
当定尺寸套筒10仍然处于预制件3的开孔6中时(在图5中插入连接元件5之后以及在图6中缩回穿孔装置8之前)，从各外部模具之间移除中心模具，外部模具抵靠彼此而闭合，以便通过施加约4至7巴的吹塑压力而完成吹塑模制待形成的容器。为此，驱动一个或多个吹塑芯轴进入预制件3中。这些吹塑芯轴未示出。
以常规方式向吹塑芯轴提供气态压力介质，例如空气。芯轴9被设计作为介质可以流动通过其中的中空针，所述芯轴与用于提供吹塑压力的压力介质管路相连通，从而经由芯轴9将一部分压力介质引入至连接元件5内并且进入连接至所述连接元件的通风装置的容积，由此与通风装置建立压力平衡，从而最终施加的吹塑压力不会引起通风装置的容积或局部容积塌缩。
在最终吹塑之后，穿孔装置完全从模制工具1内的容器或者预制件3中撤回，如图6中所示。
附图标记
1 模制工具
2 模制工具的壁
3 预制件
4 局部腔
5 连接元件
6 开口
7 孔
8 穿孔装置
9 芯轴
10 定尺寸套筒
11 进给装置
12 进给装置
13 针尖端
14 介质通道
15 边缘
16 连接短轴
17 冷杉状轮廓
18 轴环
19 焊接凸缘

Claims (9)

1.一种由热塑性材料制备容器的方法，所述容器具有穿过容器壁的连接元件(5)，所述方法包括下列方法步骤：
-使得能够获得由热塑性材料制成的至少一个板形、壳形或管形的预制件(3)，
-将至少一个预制件(3)引入多部件式的模制工具(1)中，所述模制工具具有限定模制凹部的腔，
-利用压差在模制工具(1)中模制和最终成形预制件(3)，以提供壳形中间体，
-结合壳形中间体以提供闭合的中空体，其中，壳形中间体被焊接至彼此，
-通过芯轴(9)从模制工具侧穿刺仍然温塑性的预制件(3)，从而在预制件(3)中形成开口(6)，
-从模制凹部侧处将连接元件(5)插入至先前由芯轴(9)形成的开口(6)中，以及
-将连接元件(5)连接至预制件(3)，
其特征在于，
由芯轴(9)形成的开口(6)在插入连接元件(5)之前或期间定尺寸，以及
借助于从模制工具侧插入开口(6)中的至少一个定尺寸套筒(10)而进行定尺寸。
2.根据权利要求1所述的方法，其特征在于，借助于连接短轴(16)而将连接元件(5)插入至位于开口(6)中的定尺寸套筒(10)中，接着从开口(6)中撤回定尺寸套筒(10)，并且在这个过程中或者随后借助于设置在所述连接元件上的轴环(18)而将连接元件(5)焊接至预制件(3)。
3.根据权利要求2所述的方法，其特征在于，在模制凹部侧处连接元件(5)被连接至待布置在容器中的通风装置。
4.根据权利要求3所述的方法，其特征在于，在对模制凹部进行加压期间，经由连接元件(5)建立通风装置的容积的压力平衡。
5.根据权利要求4所述的方法，其特征在于，借助于芯轴(9)实现所述压力平衡。
6.根据权利要求5所述的方法，其特征在于，当定尺寸套筒(10)位于预制件(3)的开口(6)中时实施所述压力平衡。
7.根据权利要求1至6中的任意一项所述的方法，其特征在于，使用设置在模制工具侧的至少一个芯轴(9)，所述至少一个芯轴与定尺寸套筒(10)共轴地布置在模制工具(1)的腔内，所述定尺寸套筒能够相对于芯轴(9)进行调整。
8.根据权利要求7所述的方法，其特征在于，芯轴(9)被设计作为具有至少一个开口的中空针，介质能够流动通过所述中空针，并且所述芯轴被连接至用于对模制凹部进行加压的压力介质源。
9.根据权利要求1所述的方法，其特征在于，在壳形中间体被结合以形成闭合的中空体之前，通过连接所述连接元件而实现对仍然温塑性的预制件进行模制工具侧穿刺和从模制凹部侧插入连接元件。
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