CN107438506A - 制造包括抗摇晃装置的由塑料材料制成的储箱的方法 - Google Patents
制造包括抗摇晃装置的由塑料材料制成的储箱的方法 Download PDFInfo
- Publication number
- CN107438506A CN107438506A CN201680020144.0A CN201680020144A CN107438506A CN 107438506 A CN107438506 A CN 107438506A CN 201680020144 A CN201680020144 A CN 201680020144A CN 107438506 A CN107438506 A CN 107438506A
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- CN
- China
- Prior art keywords
- layer
- mould
- foam
- injection
- storage tank
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
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- 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
- B60K15/077—Fuel tanks with means modifying or controlling distribution or motion of fuel, e.g. to prevent noise, surge, splash or fuel starvation
- B60K2015/0777—Fuel tanks with means modifying or controlling distribution or motion of fuel, e.g. to prevent noise, surge, splash or fuel starvation in-tank reservoirs or baffles integrally manufactured with the fuel Tank
Abstract
提出一种用于制造根据本发明的储箱的至少一个壁的方法,所述至少一个壁至少包括第一层和第二层,所述第一层由热塑性材料制成,所述第二层基于泡沫,基于泡沫的所述第二层形成抗摇晃装置的至少一部分,所述方法的特征在于所述第一层和所述第二层在同一个模具中被模制。
Description
技术领域
本发明涉及制造由塑料材料制成的储箱的方法。更具体地,本发明涉及配备有抗摇晃装置的储箱的制造。本发明尤其地应用于制造用来储存液体(例如碳氢燃料或者尿素)的机动车辆用储箱。
背景技术
在车辆储箱的情况下,车辆的连续的刹车或重启的操作引起储箱中液体质量的平移,该平移以带有碰撞效果的噪音(也被称为晃动噪音,英语为slosh noise)的形式被驾驶者感知。此外,该质量的转移可能影响车辆在路上的表现。
为了减缓这些缺陷,提出了配备有包括刚性或半刚性隔板的抗摇晃装置(或者减摇装置)(或者挡板,英文为baffle)的储箱。
已知用于制造这类储箱的多种技术。
第一种已知技术在于在模制储箱之后将抗摇晃装置安装在储箱中。该第一种已知技术在例如文献WO 2010/029103中有描述。
第二种已知技术在于在模制储箱期间将抗摇晃装置安装在储箱中。该第二种已知技术在例如文献WO 2008/138869中有描述。
这些安装操作是精细的并且耗费时间。此外,液体撞击在这些刚性或半刚性的抗摇晃装置上产生的震动可能在储箱中导致固体噪音(bruit solidien)。
发明内容
因此,本发明的目的之一在于提供一种用于制造配备有抗摇晃装置的储箱的现有技术的替代技术。
所谓“储箱”,指的是用于储存碳氢燃料、碳氢燃料用添加剂(比如要求的用于降低在例如柴油马达的粒子过滤器上滞留的粒子的燃烧温度的碳氢燃料用添加剂)、排放气体用添加剂(比如SCR系统中的尿素或者其它氨前驱物)或者其它任何的车(轿车、卡车……)载流体的密封腔体。
于是,提出一种用于制造储箱的至少一个壁的方法,所述至少一个壁至少包括第一层和第二层,所述第一层由热塑性材料制成,所述第二层基于泡沫,基于泡沫的所述第二层形成抗摇晃装置的至少一部分,所述方法的特征在于所述第一层和所述第二层在同一个模具中被模制。
因此,根据本发明的方法制造的储箱能够配备有基于热固性或热塑性泡沫(具有开孔的或闭合的单元)的抗摇晃装置。这种抗摇晃装置是在预成型件的注射或吹制时获得(即成型)的。由于本发明,因此能够通过注射或吹制操作来制造装配有抗摇晃装置的储箱。
本发明因此带来节省设施和人力的优势,并且显著地提高抗摇晃装置的效率。
在本发明的第一具体实施方式中,提出一种用于通过挤压吹制来制造配备有抗摇晃装置的储箱的方法。
根据本发明的第一具体实施方式的方法包括以下步骤:
-在打开的所述同一个模具中插入至少包括所述第一层和所述第二层的由热塑性材料制成的预成型件;
-闭合所述同一个模具;以及
-当所述同一个模具被闭合后,就借助于加压流体对所述预成型件进行吹制以使其与所述同一个模具贴抵。
所谓“预成型件”,是指管状型胚或者由热塑性材料制成的两个板片状件的组件。管状型胚或者两个板片状件的组件本身可以由(例如通过共挤制得到的)不同材料的多个层组成。
有利地,为了得到至少包括所述第一层和所述第二层的由热塑性材料制成的预成型件,可同时挤制所述第一层和所述第二层。
有利地,所述第二层是由热塑性聚合物与化学起泡剂的混合物形成的层。所述第二层(或者混合物层)在吹制后形成抗摇晃装置。
术语“聚合物”可以指均聚物也可以指共聚物(尤其是二元或三元的共聚物)。不局限性地,这样的共聚物例如是:无规共聚物、序列共聚物(les copolymères séquencés)、崁段共聚物和接枝共聚物。特别地,可以使用聚烯烃、热塑性聚酯、聚酮、聚酰胺和它们的聚氨酯共聚物(copolymères PU)。也可以使用聚合物或者共聚物的混合物,同样地可以使用具有无机、有机和/或天然的添加物(非限制性地举例如下:碳、盐类和其它无机衍生物、天然纤维或聚合纤维)的聚合材料的混合物。使用高密度聚乙烯(PEHD)或6-6聚酰胺得到了非常好的结果。
在一个具体的实施方式中,预成型件包括内层(即所述第二层)、一个或多个至少包括一种粘合剂的层以及基于热塑性聚合物的外层(即所述第一层),其中所述内层包括所述混合物层。
在另一个具体的实施方式中,预成型件包括内层和基于热塑性聚合物的外层,其中所述内层包括所述混合物层。在这个具体的例子中,没有使用任何粘合剂层。
有利地,当所述同一个模具被闭合之后,就在闭合的模具中注射包含例如基于氮或二氧化碳(CO2)的反应剂的气体,以便引发所述第二层的起泡剂的起泡反应。如常规的吹塑挤制方法中一样,加压气体会将型胚贴抵在模具的壁上。
优选地,将反应剂引入模具内是通过在吹塑阶段引进包含反应剂的气体来实现的。于是,当储箱模具在型胚上重新闭合之后,就在储箱的吹塑阶段引发起泡反应。
当型胚由两个板片状件制成(这属于已知技术,例如在文献EP1110697中有描述)时,可以通过使用安装在吹塑模具的模芯上的反型形状(contres-formes)来控制泡沫的膨胀。这里“反型形状”指的是模具的可移动或不可移动的部分,这些部分允许在必要时通过阻挡的方式来机械地控制泡沫的膨胀。
有利地,预成型件还包括中间层,所述中间层至少包括一种粘合剂。
有利地,预成型件还包括位于所述内层(即所述第二层)和所述外层(即所述第一层)之间的针对碳氢化合物的屏障层和/或包括回收塑料材料的层。
因此,本发明的方法很适合制造多层塑料储箱。
所谓“屏障层”,是指液体和气体不可渗透的层。屏障层通常包括屏障树脂。可以使用任何已知的屏障树脂,只要其对于与储箱接触的流体(尤其是碳氢化合物)是有效的、并且与成型储箱时使用的模制技术兼容即可。在可使用的树脂中,可以非限制性地举出聚酰胺或共聚酰胺或乙烯醇与乙烯的统计共聚物等例子。还可以使用多种屏障树脂的混合物。使用乙烯醇与乙烯的统计共聚物得到了很好的结果。
所谓“回收塑料材料”,指的是通过将在制造储箱(尤其是根据本发明的多层储箱)的各个阶段得到的边角料粉碎或者将到了使用期限的用过的储箱粉碎获得的塑料材料。
可以使用的化学起泡剂优选地是偶氮二甲酰胺、异丁烷/n-丁烷的混合物、氯氟化碳或具有相同性质的任何其它起泡剂。
在本发明的第二具体实施方式中,提出一种用于通过注射来制造配备有抗摇晃装置的储箱的方法。
根据本发明的第二具体实施方式的方法包括以下步骤:
-将所述同一个模具置于第一闭合位置,以形成第一注射腔;
-注射所述第一层;
-将所述同一个模具置于第二闭合位置,以形成第二注射腔;
-注射所述第二层。
因此,通过该第二实施方式,能够控制所述第二层的尺寸,从而控制抗摇晃装置的尺寸。更具体地,可以通过调整第二注射腔的开口来控制所述第二层的尺寸。因此,使用同一个模具能够制造包括不同形状和尺寸的抗摇晃装置的储箱。
优选地,在闭合的所述同一个模具中注射例如氮气的气体,以便触发泡沫的膨胀反应。这还允许优化泡沫的孔隙尺寸。
有利地,注射的所述第一层至少包括一个衔接腔(cavitéd’accrochage),在所述第二注射腔中注射所述第二层时所述第二层能够进入所述衔接腔。
有利地,所述同一个模具包括注射所述第二层的多个注射点。
有利地,所述第二层是由聚氨酯泡沫制成的层。
有利地,所述第二层是由聚合物泡沫制成的层。
附图说明
附图1a至1c的目的在于示例性而非限制性地示出根据本发明的第一具体实施方式的通过挤压吹制来制造的方法的原理。
附图2a至2d的目的在于示例性而非限制性地示出根据本发明的第二具体实施方式的通过注射来制造的方法的原理。
具体实施方式
根据本发明的第一实施方式,如图1a所示,由塑料材料制成的型胚1被引入在打开位置上的模具2的两个半模之间。型胚1在被引入模具2中的同时被维持成打开的/分开的。模具2包括半模3、4。模具的半模3、4具有对应待模制储箱的外表面的内表面3’、4’。
在该实施例中,型胚1包括多层结构。它因此包括内层、中间层和外层,其中该内层由第一PEHD(高密度聚乙烯)层和第二化学起泡剂层组成,该中间层包括粘合剂,该外层基于PEHD。要注意的是该粘合剂的中间层是可选的。
型胚的内层在型胚1的成型温度下处于黏稠状态,其在被引入模具中时的黏度与在储箱成型的传统工艺中使用的高密度聚乙烯的黏度相仿。
此外,在将第二起泡剂层引入模具2中时(即在吹塑操作前),该(可以起反应但还没起泡的)第二起泡剂层与第一PEHD层相连结。因此,该起泡剂层优选地与第一PEHD层同时地被挤压制成。
在图1a至1c示出的第一实施方式中,当储箱模具在型胚1上再次闭合之后,就在储箱的吹塑阶段引入允许引发起泡反应(或者激活起泡剂)的反应剂。优选地,将反应剂引入模具2中是通过在吹塑阶段引入包括反应剂的特定气体来实现的。
有利地,起泡剂的浓度和内层的厚度应该允许在起泡反应之后制成主要由开孔单元构成的层。在最终状态下的所述层的厚度有利地介于5mm到200mm之间。
图1b示出型胚的吹塑步骤。在该步骤中模具完全地闭合。可以看见模具的半模通过其轮廓而对接在一起。在该吹塑步骤中,将形成储箱的外壁5和基于泡沫的内抗摇晃装置6。
事实上,在该吹塑步骤中,在模具2中引入包括允许触发起泡反应的反应剂的气体,以完全地或部分地取代在吹塑方法中通常使用的空气或重氮(diazote)。通过变化温度、压强、吹塑气体中的反应剂的浓度和储箱内层暴露在反应剂下的时间来控制泡沫的膨胀。优选地,包括反应剂的气体为氮气,反应剂基于氮或二氧化碳(CO2)。
当储箱由型胚制造时,储箱的接合面(plan de joint)仅在预充气阶段暴露在反应剂下。该预充气阶段可以借助不包括反应剂的吹塑气体来实现,反应剂在预充气阶段结束后被引入。
当储箱由两个板片状件制造时,接合面不暴露在反应剂下。
此外,还是在储箱由两个板片状件制造的情况下,泡沫的膨胀能够通过模具2的模芯所支撑的元件(例如安装在吹塑模具模芯上的反型形状)来机械地制约。这些反型形状是模具2的可移动或不可移动的部分,这些部分允许在必要时通过阻挡的方式来机械地控制泡沫的膨胀。
要注意的是起泡剂的激活阶段只很小地影响传统储箱的吹塑时间。不过,可能需要在吹塑程序结束前净化该包括反应剂的气体。
当整体被冷却后,打开模具(即使半模彼此分离),储箱可以退模了。这被图1c示出。因此得到在摇晃区域具有由开孔单元泡沫制成的覆层的储箱,该覆层的存在允许限制储箱中的固体噪音或带有撞击效果的噪音(晃动噪音)。由此制造的储箱从而有利地包括安装在其内轮廓上的抗摇晃装置。
根据本发明的第二个实施方式,储箱通过注射来制造。
在图2a中,能够看见在第一闭合位置的模具10。模具与注射螺杆20相连接。在该第一闭合位置,在模具的半模11、12之间形成第一注射腔30。
然后,如在图2b中能看见的,注射螺杆20在第一注射腔中注射热塑性聚合物,以模制第一壁元件(即注射的所述第一层)40。
有利地,模具的半模12包括可移动部件120,该可移动部件120被配置成可相对于半模12移动。
在图2c中,能够看见在第二闭合位置的模具10。如图所示,模具通过沿着箭头50所指的方向来移动可移动部件120,而得以从第一闭合位置来到第二闭合位置。在该第二闭合位置,在模具的半模之间形成第二注射腔60。
如图2d示出的,模具10与注射嘴80连接,该注射嘴80被配置成用于在该第二注射腔60中注射聚合物泡沫。该聚合物泡沫可以示例性而非限制性地为聚氨酯泡沫。
该聚氨酯泡沫优选地来自于多个液体组分的混合物。这些组分例如在被加以选择的温度和压强的条件下被混合,以便借助于包括注射嘴80的高压混合机(本身是已知的)来形成可注射的液体。
优选地,为了触发泡沫的膨胀反应将例如氮气的气体加入上述混合物。因此,优选地直接在第二注射腔60中注射添加有这种气体的液体泡沫。这还允许优化泡沫的孔隙尺寸。要注意的是膨胀反应归功于产物的混合物和混合物与气体的注射条件。
通过该方式,在第一壁元件40上模制第二壁元件70(即注射的所述第二层)。
有利地,第二壁元件70能够形成储箱内部的抗摇晃装置的全部或部分。
图3a至3d的目的在于示例性而非限制性地示出根据本发明的第二具体实施方式的通过注射来制造的第二制造方法的原理。
图3a和3b示出了类似于图2a和2b所示的步骤,其中能够看见在第一闭合位置的模具110,接合模具的半模111、112的接合面P是闭合的。
在图3c中,能够看见在第二闭合位置的模具,接合面P是打开的。如图所示,模具通过例如沿着箭头150所指的方向来移动半模112或半模111或移动模具110的两个半模,而得以从第一闭合位置来到第二闭合位置。在第二闭合位置,在模具的半模之间形成第二注射腔160。有利地,半模112可以包括可移动部件220,该可移动部件220被配置成可相对于半模112移动并且因此更好地控制第二注射腔160的尺寸。
如图3d所示,模具与注射嘴180连接,该注射嘴180被配置成用于在第二注射腔160中注射聚合物泡沫。聚合物泡沫可以示例性而非限制性地为聚氨酯泡沫。
该聚氨酯泡沫优选地来自于多个液体组分的混合物。这些组分例如在被加以选择的温度和压强的条件下被混合,以便借助于包括注射嘴180的高压混合机(本身是已知的)来形成可注射的液体。
优选地,为了触发泡沫的膨胀反应将例如氮气的气体加入上述混合物。因此,优选地直接在第二注射腔60中注射添加有这种气体的液体泡沫。这还允许优化泡沫的孔隙尺寸。要注意的是膨胀反应归功于产物的混合物和混合物与气体的注射条件。
通过该方式,在第一壁元件140上模制第二壁元件70(即注射的所述第二层)。
由于接合面P的打开而在模具内产生的失压(dépressurisation)的原因,与打开的模具的接合面P一起实现的该泡沫注射步骤因此允许容易地控制所注射的模具的膨胀。该打开还允许获得对注射嘴180而言更简单的注射路径。
在注射泡沫之后,该泡沫借助于气体的添加来催化和优化其膨胀并且导致放热反应。设备腔体的空闲空间因此会逐渐地被泡沫完全填充。能够通过注射设备的调节系统来控制该膨胀。为此,注射周期的时间可进行适应性调节以得到灵活的泡沫。
在膨胀之后,高速地打开模具以便产生允许闭合泡沫的薄壁出现穿孔的降压。因此,在制造周期结束时得到在摇晃区域具有由开孔单元泡沫制成的覆层的储箱半壳,该覆层的存在允许限制储箱中的固体噪音或带有撞击效果的噪音(晃动噪音)。因此,有利地,第二壁元件170能够形成储箱内部的抗摇晃装置的全部或部分。
在一个有利的实施方式中,(由注射的第一层形成的)第一壁元件可以包括一个或多个衔接腔,聚合物泡沫能够在其注入第二注射腔时进入该衔接腔。以此方式,得到第一和第二壁元件之间的牢固的机械固定。衔接腔例如在第一壁元件140的与第二壁元件70相对的这部分上形成纹理网络(réseau de nervures)或者反脱离形状(contre-dépouille)。
在一个变型中,模具可以根据需求包括多个泡沫注射点和多种厚度。
本发明不局限于所介绍的实施方式和对于本领域技术人员而言显而易见的其它实施方式。尤其在上文参照图2和图3描述的注射方法的另一具体实施方式中,注射嘴可进行适应性调节以注射任何种类的聚合物泡沫。在一个具体的实施方式中,注射嘴适于在方法中的不同时刻注射至少两种不同的聚合物泡沫。
Claims (14)
1.一种用于制造储箱的至少一个壁的方法,所述至少一个壁至少包括第一层和第二层,所述第一层由热塑性材料制成,所述第二层基于泡沫,基于泡沫的所述第二层形成抗摇晃装置的至少一部分,所述方法的特征在于,所述第一层和所述第二层在同一个模具中被模制。
2.如权利要求1所述的方法,其特征在于,所述方法包括以下步骤:
-在打开的所述同一个模具中插入至少包括所述第一层和所述第二层的由热塑性材料制成的预成型件;
-闭合所述同一个模具;以及
-当所述同一个模具被闭合后,就借助于加压流体对所述预成型件进行吹制以使其与所述同一个模具贴抵。
3.如权利要求2所述的方法,其特征在于,为了得到至少包括所述第一层和所述第二层的由热塑性材料制成的所述预成型件,同时挤制所述第一层和所述第二层。
4.如权利要求2或3所述的方法,其特征在于,所述第二层是由热塑性聚合物与化学起泡剂的混合物形成的层。
5.如权利要求2和4的组合所述的方法,其特征在于,当所述同一个模具被闭合之后,就在闭合的所述模具中注射包含例如基于氮或二氧化碳的反应剂的气体或液体,以便触发所述第二层的所述起泡剂的起泡反应。
6.如权利要求2至5中的任一项所述的方法,其特征在于,所述预成型件还包括中间层,所述中间层至少包括一种粘合剂。
7.如权利要求2至6中的任一项所述的方法,其特征在于,所述预成型件还包括位于所述第一层和所述第二层之间的针对碳氢化合物的屏障层和/或包括回收塑料材料的层。
8.如权利要求1至7中的任一项所述的方法,其特征在于,所述化学起泡剂是偶氮二甲酰胺。
9.如权利要求1所述的方法,其特征在于,所述方法包括以下步骤:
-将所述同一个模具置于第一闭合位置,以形成第一注射腔;
-注射所述第一层;
-将所述同一个模具置于第二闭合位置,以形成第二注射腔;
-注射所述第二层。
10.如权利要求9所述的方法,其特征在于,在闭合的所述同一个模具中注射例如氮气的气体,以便触发所述泡沫的膨胀反应。
11.如权利要求9或10所述的方法,其特征在于,注射的所述第一层至少包括一个衔接腔,在所述第二注射腔中注射所述第二层时所述第二层能够进入所述衔接腔。
12.如权利要求9至11中的任一项所述的方法,其特征在于,所述同一个模具包括注射所述第二层的多个注射点。
13.如权利要求9至12中的任一项所述的方法,其特征在于,所述第二层是由聚氨酯泡沫制成的层。
14.如权利要求9至13中的任一项所述的方法,其特征在于,所述第二层是由聚合物泡沫制成的层。
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FR1552916A FR3034340A1 (fr) | 2015-04-03 | 2015-04-03 | Procede de fabrication d'un reservoir en matiere plastique avec dispositif anti-ballottement. |
FR1552916 | 2015-04-03 | ||
FR1560675 | 2015-11-06 | ||
FR1560675A FR3034341B1 (fr) | 2015-04-03 | 2015-11-06 | Procede de fabrication d'un reservoir en matiere plastique avec dispositif anti-ballottement. |
PCT/EP2016/057288 WO2016156608A2 (fr) | 2015-04-03 | 2016-04-01 | Procede de fabrication d'un reservoir en matiere plastique avec dispositif anti-ballottement |
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IT201700019746A1 (it) * | 2017-02-22 | 2018-08-22 | Sapa S R L | Metodo multifase di produzione di una componente composita per veicoli e prodotto così ottenuto. |
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US11155008B2 (en) | 2021-10-26 |
EP3277474B1 (fr) | 2020-07-15 |
FR3034341A1 (fr) | 2016-10-07 |
FR3034340A1 (fr) | 2016-10-07 |
US20180071963A1 (en) | 2018-03-15 |
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WO2016156608A3 (fr) | 2016-11-24 |
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