CN111941850A - 用于制造具有补强部的塑料箱的方法 - Google Patents

用于制造具有补强部的塑料箱的方法 Download PDF

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CN111941850A
CN111941850A CN202010406161.6A CN202010406161A CN111941850A CN 111941850 A CN111941850 A CN 111941850A CN 202010406161 A CN202010406161 A CN 202010406161A CN 111941850 A CN111941850 A CN 111941850A
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reinforced structural
fiber
semifinished sheet
structural component
thermoplastic
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R.普赫莱特纳
P.古特曼
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Magna Steyr Fuel Systems GmbH
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    • 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
    • B29C66/71—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 composition of the plastics material of the parts to be joined
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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
    • B60K15/03177—Fuel tanks made of non-metallic material, e.g. plastics, or of a combination of non-metallic and metallic material
    • 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
    • B29C51/14—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 using multilayered preforms or sheets
    • B29C51/145—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 using multilayered preforms or sheets having at least one layer of textile or fibrous material combined with at least one plastics layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/02—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers
    • B29C70/026—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers and with one or more layers of pure plastics material, e.g. foam layers
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
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    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
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Abstract

本发明涉及制造具有补强部的塑料箱的方法，包括提供由塑料构成的半成品板以形成塑料箱箱壁的至少一部分，其中半成品板具有至少一个由第一热塑性塑料构成的外层；提供至少一个纤维增强的结构构件作为用于塑料箱箱壁的补强部，其中纤维增强的结构构件含由第二热塑性塑料构成的基体，其中第二热塑性塑料可焊接至第一热塑性塑料；将纤维增强的结构构件施加在半成品板外层的预定区域上；使施加有纤维增强的结构构件的半成品板穿过连续式加热炉，其中将纤维增强的结构构件与半成品板外层熔接；将加热的具有与之熔接的纤维增强的结构构件的半成品板重塑成箱壁的至少一部分的最终形状；任选地与箱壁的至少一个另外的部分连接以形成塑料箱的完整箱壁。

Description

用于制造具有补强部的塑料箱的方法
技术领域
本发明涉及一种用于制造具有补强部的塑料箱的方法。
背景技术
在汽车制造中，一段时间以来，箱体(储箱)、尤其是燃料箱不仅由金属制成，而且越来越多地由塑料制成。这样的塑料箱(塑料储箱)能容易地并且成本低廉地制造，然而塑料箱的机械强度不足以应对所有应用。
尤其是在低排放车辆例如部分零排放车辆(PZEV)的运行时需要箱体系的运行策略，该运行策略预先规定最高达400豪巴的恒定压力以及-210豪巴和+560豪巴的压力峰值，其可导致箱体系的某些区域中的高度变形。在体系的某些运行状态中，压力和温度峰值的关联，尤其对于具有由塑料构成的壳体材料的箱，由于弹性和塑性变形而可导致箱壳体的高的相对运动，并且必须通过建设性措施来限制。
因此，塑料罐、尤其是压力箱必须部分地采用补强措施来实现。
已知的支撑方案大多使用固定于车身的抵靠点以限制箱囊部的变形。然而这样的措施对于压力下的箱体系是不够的，并且必须使用额外的措施以减少变形。通常提高箱囊部的壳体厚度或者使用加强的焊接的内部构件来限制变形。这些措施由于自身的原因导致箱体积的重大损失，并且因此限制体系的功能。
发明内容
本发明所要解决的技术问题是提供一种用于制造具有补强部的塑料箱的方法，以便有效地实现箱的补强并且在此能够简便地并且成本低廉地实施。
本发明所要解决的技术问题通过一种用于制造具有补强部的塑料箱的方法来解决，该方法包括以下步骤：提供由塑料构成的半成品板以形成塑料箱的箱壁的至少一部分，其中半成品板具有至少一个由第一热塑性塑料构成的外层；提供至少一个纤维增强的结构构件作为用于塑料箱的箱壁的补强部，其中纤维增强的结构构件包括由第二热塑性塑料构成的基体(基质)，其中第二热塑性塑料可焊接至第一热塑性塑料；将纤维增强的结构构件施加在半成品板的外层的预定区域上；使施加有纤维增强的结构构件的半成品板穿过连续式加热炉(Durchlaufofen)，其中将纤维增强的结构构件与半成品板的外层熔融(熔接)；将加热的具有与之熔接的纤维增强的结构构件的半成品板重塑成箱壁的至少一部分的最终形状；任选地与箱壁的至少一个另外的部分连接以形成塑料箱的完整的箱壁。
根据本发明，塑料箱至少部分地通过由塑料构成的半成品板制成，将半成品板引导穿过连续式加热炉以进行加热从而用于重塑工艺。为了进行补强并因此为了减少制造的塑料箱的变形，在穿过连续式加热炉前将至少一个、优选多个纤维增强的结构构件施加在半成品板上的待补强的区域中。对此，纤维增强的结构构件的面积小于半成品板的面积，使得纤维增强的结构构件形成“补丁(Fleck)”，也称为“补片(贴片)”，或者称为“纤维垫”。纤维增强的结构构件使用基体材料，该基体材料可焊接至半成品板至少在于其上施加纤维增强的结构构件的那侧上所具有的材料。这使得纤维垫的基体与壳体材料能够进行材料连接。第一热塑性塑料和第二热塑性塑料可为化学相似的。第一热塑性塑料优选是与第二热塑性塑料相同的材料。因此，在无论如何都必须穿过连续式加热炉或者隧道式炉(Tunnelofen)的情况下，纤维增强的结构构件熔接或焊接至半成品板。通过有针对性地施加一个或多个纤维增强的结构构件实现塑料箱的良好的补强。本方法使用连续式加热炉的热量并且可以成本有利的方式实施。
在重塑过程中要么直接产生完整的箱体，要么产生箱体的一部分例如塑料箱的半壳，从而通过连接一个或者多个另外的部分(例如另外的以这种方式产生的具有补强部的半壳)可完成整个箱体。
半成品板的外层的第一热塑性塑料和/或纤维增强的结构构件的基体的第二热塑性塑料优选是高密度聚乙烯(HDPE)、聚酰胺(PA)或者线性低密度聚乙烯(LLDPE)。
优选提供多个纤维增强的结构构件作为用于塑料箱的箱壁的补强部，其中纤维增强的结构构件各自包括由第二热塑性塑料构成的基体，其中将纤维增强的结构构件施加在半成品板的外层的预定区域上，其中施加有纤维增强的结构构件的半成品板穿过连续式加热炉，其中将纤维增强的结构构件与半成品板的外层熔接。然后，将具有与之熔接的纤维增强的结构构件的半成品板重塑成箱壁的至少一部分的最终形状。
半成品板的两个外层优选由第一热塑性塑料构成，并且优选将纤维增强的结构构件施加在半成品板的两个外层的预定区域上，即在半成品板的两侧上，使得在施加有纤维增强的结构构件的半成品板穿过贯穿炉时，纤维增强的结构构件与半成品板的相应的外层熔接。
优选将半成品板在传送带上移动至贯穿炉和/或穿过贯穿炉，并且将纤维增强的结构构件施加在半成品板上在传送带上进行。
特别优选地，首先将至少一个纤维增强的结构构件放置在传送带上，然后将半成品板被放置在所述至少一个纤维增强的结构构件上，并且之后将至少一个另外的纤维增强的结构构件放置在半成品板上。然后，由半成品板和纤维增强的结构构件组成的组合穿过连续式加热炉并且被重塑。
优选地，所述重塑优选通过深冲进行。
在重塑前并且在穿过连续式加热炉之后，将施加有纤维增强的结构构件的半成品板的一个或多个预定区域再次明确地加热，尤其借助于可调节的红外加热元件，以便实现良好的可重塑性。
将纤维增强的结构构件放置在传送带上和/或将半成品板放置在传送带上优选地借助于定位装置，尤其是机械臂或者机器人来进行。
附图说明
以下参照附图示例性地说明本发明。
图1示出了通过根据本发明的方法制造的具有补强部的塑料容器的示意图；
图2示出了在利用根据本发明的方法制造根据图1的塑料箱的过程中的中间状态的示意图；
图3示出了用于根据本发明的方法制造根据图1的塑料箱的装置的示意图。
具体实施方式
在图1中示出了利用根据本发明的方法制造的塑料容器。
塑料容器包括由半成品板1或者由多个半成品板1形成的箱壁，并且包括一个或者多个纤维增强的结构构件2作为补强部。在图1的实施例中，纤维增强的结构构件2被施加在箱壁的外侧上，并且另外的纤维增强的结构构件2被施加在箱壁的内侧上。
如图2所示，优选借助传送带4进行箱体的制造。
首先，至少一个纤维增强的结构构件2被放置在传送带4上，然后，半成品板1被放置在至少一个纤维增强的结构构件2上，并且之后，至少一个另外的纤维增强的结构构件2被放置在半成品1板上。
如在图3中可见，可借助定位装置5将纤维增强的结构构件2和/或半成品板1放置在传送带4上。
因此，根据本发明，通过附接纤维增强的结构构件2减少箱壳体的局部变形。这些补片的附接可在箱体之内或者之外进行，因此可在由其制造箱体的半成品板1的两个外侧的任一侧上进行。
所描述的方法基于基体材料(尤其是HDPE)、纤维补片或者纤维增强的结构构件2与箱壳体的外层材料HDPE的定位和熔接或焊接。这是在穿过隧道式炉3以加热半成品板1的过程在深冲工艺前被实现的。
在第一步中，通过合适的定位装置5将用于附接在箱内壁上的纤维补片2放置在传送带3上。在成功定位后，现在将半成品板1放置在纤维补片2上。在第三步中，通过定位装置5还将用于箱外壁的另外的纤维补片2放置在半成品板上。
现在将包括半成品板1的复合材料利用传送带4移动穿过连续式加热炉3，从而加热板1。在加热过程中，纤维补片2与半成品板1熔接。
在收取如此制造的复合板后，具有纤维补片2的区域通过可调节的红外加热元件被再次明确地加热，以提供良好的可重塑性。最后进行深冲工序。
附图标记清单
1 半成品板
2 纤维增强的结构构件
3 连续式加热炉
4 传送带
5 定位装置

Claims (9)

1.一种用于制造具有补强部的塑料箱的方法，包括以下步骤：
提供由塑料构成的半成品板(1)以形成塑料箱的箱壁的至少一部分，其中半成品板(1)具有至少一个由第一热塑性塑料构成的外层；
提供至少一个纤维增强的结构构件(2)作为用于塑料箱的箱壁的补强部，其中纤维增强的结构构件(2)包括由第二热塑性塑料构成的基体，其中所述第二热塑性塑料可焊接至所述第一热塑性塑料；
将纤维增强的结构构件(2)施加在半成品板(1)的外层的预定区域上；
使施加有纤维增强的结构构件(2)的半成品板(1)穿过连续式加热炉(3)，其中纤维增强的结构构件(2)与半成品板(1)的外层熔接；
将加热的具有与之熔接的纤维增强的结构构件(2)的半成品板(1)重塑成箱壁的至少一部分的最终形状；
任选地，与箱壁的至少一个另外的部分连接以形成塑料箱的完整箱壁。
2.根据权利要求1所述的方法，其特征在于，
半成品板(1)的外层的第一热塑性塑料和/或纤维增强的结构构件(2)的基体的第二热塑性塑料是高密度聚乙烯HDPE、或聚酰胺PA、或线性低密度聚乙烯LLDPE。
3.根据权利要求1所述的方法，其特征在于，
提供多个纤维增强的结构构件(2)作为用于塑料箱的箱壁的补强部，其中所述多个纤维增强的结构构件(2)各自包括由所述第二热塑性塑料构成的基体；
将所述多个纤维增强的结构构件(2)施加在半成品(1)的外层的预定区域上；
使施加有所述多个纤维增强的结构构件(2)的半成品(1)穿过贯穿炉(3)，其中所述多个纤维增强的结构构件(1)与半成品(2)的外层熔接；
将加热的具有与之熔接的多个纤维增强的结构构件(2)的半成品板(1)重塑成箱壁的至少一部分的最终形状。
4.根据权利要求1所述的方法，其特征在于，
所述半成品板(1)的两个外层由所述第一热塑性塑料构成，并且将纤维增强的结构构件(2)施加在半成品板(1)的两个外层的预定区域上，使得在施加有纤维增强的结构构件(2)的半成品板(1)穿过贯穿炉(3)的过程中，纤维增强的结构构件(2)与半成品板(1)的相应的外层熔接。
5.根据权利要求1所述的方法，其特征在于，
将半成品板(1)在传送带(4)上移动至贯穿炉(3)和/或移动穿过贯穿炉(3)，并且将纤维增强的结构构件(2)施加在半成品板(1)上在传送带(4)上进行。
6.根据权利要求4所述的方法，其特征在于，
首先将至少一个纤维增强的结构构件(2)放置在传送带(4)上，然后将半成品板(1)放置在所述至少一个纤维增强的结构构件(2)上，并且之后将至少一个另外的纤维增强的结构构件(2)放置在半成品板(1)上。
7.根据权利要求1所述的方法，其特征在于，
所述重塑通过深冲进行。
8.根据权利要求1所述的方法，其特征在于，
在重塑之前并且在穿过贯穿炉(3)之后，将施加有纤维增强的结构构件(2)的半成品板(1)的预定区域再次明确地加热。
9.根据权利要求1所述的方法，其特征在于，
将纤维增强的结构构件(2)和/或半成品板(1)放置在传送带(4)上借助于定位装置(5)进行。
CN202010406161.6A 2019-05-15 2020-05-14 用于制造具有补强部的塑料箱的方法 Pending CN111941850A (zh)

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