CN112810944A - 制造塑料箱的方法 - Google Patents
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Abstract
一种用于制造塑料箱的方法,其中塑料箱的箱壁(1)的至少一个外层由第一材料组成,其中至少部分地由第一材料组成的加强片(2)在至少一个区域中附接到塑料箱的箱壁(1)的外层,其特征在于,首先,箱壁(1)被准备为热半成品片(1’),其中加强片(2)在成形工具(3)外部被固定(特别是被焊接)在热的半成品片(1’)上,该半成品片(1’)随后和固定的加强片(2)一起被引入到成形工具(3)中,并在成形工具(3)中成形以形成塑料箱的箱壁(1),由此,加强片(2)被更牢固地固定在箱壁(1)上,特别是更牢固地焊接到箱壁(1)。
Description
技术领域
本发明涉及一种用于制造塑料箱的方法。
背景技术
已知塑料箱(其例如作为比如客车和重型货车的机动车辆的燃料箱)除了具有多种积极的特性之外,在燃料箱可能的变形方面是有问题的。在机动车辆箱系统的正常操作期间,在箱系统的特定区域内可能发生大的变形。箱的区域内的压力和温度峰值的结合可以导致箱外壳的大的相对运动,特别是在塑料箱的情况下,并且这些相对运动必须通过设计手段而限制。
现有技术中用于减少燃料箱不期望的变形的支持概念通常使用固定在箱体上的支持点以限制箱壁的变形。然而,特别地,对于加压的箱系统,这些措施还不足够,并且必须采用另外的措施以减少变形。通常,箱囊的外壳厚度是增加的,或者加强部件被固定到箱壁上以限制变形。然而,到目前为止,加强部件到箱壁的附接是耗时且昂贵的,并且相对于可行的加强部件几何结构缺乏灵活性。
发明内容
本发明的目的是详细说明一种用于制造塑料箱的方法,其中,该塑料箱被保护以免于变形。同时,应当可以以特别有效的方式实施本方法,并且本方法对于加强几何结构具有灵活性。
该目的由一种用于制造塑料箱的方法而达到,其中塑料箱的箱壁的至少一个外层由第一材料组成,其中至少部分地由第一材料组成的加强片在至少一个区域中附接到塑料箱的箱壁的外层,其中,首先,箱壁被准备为热的半成品片,其中加强片在成形工具外部被固定(特别是被焊接)在热的半成品片上,其中该半成品片随后和固定的加强片一起被引入到成形工具中,并在成形工具中成形以形成塑料箱的箱壁,由此,加强片被更牢固地固定在箱壁上,特别是更牢固地焊接到箱壁。
根据本发明,加强片作为加强元件被施加到箱壁,其中施加在两个阶段进行:首先,加强片在成形工具外部仅轻轻地固定。由于加强片至少部分地由与箱壁相同的材料组成,特别是由相同的塑料组成或者包括相同的塑料,特别地,对于加强片来说,被压到箱壁上是一件简单的事,因此加强片被熔化或焊接到热的箱壁上。附接有加强片(也被称作“贴片”)的相同的箱壁,随后在成形工具中成形为塑料箱的最终形状,其中,加强片被甚至更牢固地固定在箱壁上,或者焊接在其上,或者更牢固地熔接在其上。
通过根据本发明的在成形工具外部的贴片或加强片的引入,加强片的表面几何结构的可复现复杂性和成形的可实现的程度是非常高的。
术语“外层”指的是位于外部的箱壁层,并且在完整形成的塑料箱的情况下,可能在箱的内部或外部。
箱壁优选地是多层或复合结构,但也可以由单层组成。
本发明的发展在从属权利要求、说明书和附图中详细说明。
加强片优选地由纤维增强塑料组成,其中纤维增强材料被嵌入到基质中,并且其中该基质由第一材料组成。
第一材料优选是高密度聚乙烯(HDPE)。
作为特别偏好,加强片是玻璃织物纤维结构。
热的半成品片优选地通过保持装置而保持,特别是通过真空,同时加强片在成形工具外部被固定到半成品片上。
在成形工具外部,加强片优选地通过可延伸的压头被固定到半成品片上。
压头可以通过真空来保持加强片。该真空优选地在加强片被固定到热的半成品片上之后终止。随后压头再次从半成品片移开,特别是缩回。
压头的表面相对于半成品片的预期中立位置是倾斜的。通过这种方式,半成品片的下凹可以被补偿,并且加强片被平行于半成品片的相应部分施加。
压头优选地以力控制或路径控制的方式被压入热的半成品片中,以便将加强片在成形工具外部固定到热的半成品片上。
热的半成品片可以在切削工具中被修整,特别是在热的半成品片可用于固定加强片之前。
半成品片优选地通过在成形工具中深冲压成形以形成塑料箱的箱壁,特别是通过真空。
附图说明
在下文中,参考附图通过示例更详细地描述本发明。
图1是根据本发明制造的塑料箱的示意图。
图2是根据本发明的用于制造塑料箱的方法的示意图。
图3是根据本发明的如图2的方法中的加强片的附接的示意图。
图4是根据本发明的如图2的方法中的加强片的附接的初始步骤的详细示意图。
图5是根据本发明的如图2的方法中的加强片的附接的第二步骤的详细示意图。
具体实施方式
箱外壳的局部变形通过附接结构部件而减少,结构部件即加强片2,其特别是纤维增强结构部件。为此,这些加强片2、结构部件或贴片可以附接在箱的内部和/或外部。图1示出了此类塑料箱,其中塑料箱的箱壁1通过在不同区域附接加强片2或贴片而被部分地加强。至少塑料箱的箱壁1的外层是由HDPE组成的。至少部分地由相同材料HDPE组成的加强片2附接在塑料箱的箱壁1的外层的多个区域内。加强片2由纤维增强塑料组成,其中纤维增强材料被嵌入到基质中,并且其中该基质由高密度聚乙烯组成。
如在图2中示意性地示出的,为了制造此类塑料箱,箱壁1首先被准备为热的半成品片1’,其中半成品片1’最初可以是未修整的(例如连续的)多层片。
热的半成品片1’在切削工具6中被修整,随后可用于将加强片2固定在其上。
在成形工具3(箱外壳的形状随后在其中形成)外部,加强片2被固定在热的半成品片1’上,特别是熔化在其上-如图3至5中更详细的所示。
在图3至5中显而易见的是,热的半成品片1’通过保持装置4而保持,特别是通过真空,同时加强片2在成形工具3外部固定到半成品片1’上。从图4和图5中的细节图可见,半成品片1’可以从上方被保持,并允许其向下悬挂。
在成形工具3外部,加强片2通过可延伸的压头5被固定到半成品片1’上。
具有固定的加强片2的半成品片1’随后被引入成形工具3,并且在成形工具3中成形以形成塑料箱的箱壁1,由此,加强片2被更牢固地固定到箱壁1上,即更牢固地熔接或焊接到箱壁1。
半成品片1’通过在成形工具3中深冲压成形以形成塑料箱的箱壁,特别是通过真空,因此优选地通过真空深冲压。
因此,该描述的方法是基于纤维贴片或加强片2的基质材料HDPE到成形工具3外部的箱外壳的外层材料HDPE的定位和熔接。
该描述的熔接在两个阶段进行。在第一步中,贴片2被定位在半成品片1’上的限定位置,并通过使半成品1’和纤维贴片2接触而被固定。通过随后的深冲压工艺,两个材料被永久熔接,并且形成了永久的材料结合的连接。
在制造热的多层片之后,所述片被传送到切削和处理装置6中。在完成切削半成品片1’的过程之后,其被接收在保持装置4中,并且半成品片1’被引导到用于附接纤维贴片2的装置。在纤维贴片2附接后,现在,被纤维贴片2加强的半成品片1’被引导到模具3,并在成形过程中形成其最终形状。
图3示意性地示出了加强片2的附接。
具有热的半成品片1’的保持装置4被移动到压头5上方精确限定的位置。纤维贴片2被定位在压头5上,并通过将其施加到热片1’上与热片1’接触。这可以是被加热或处于室温的贴片或者加强片2。
图4示出了将加强片2固定到压头5上和将加强片2或纤维贴片定位到半成品1’上的详细图解。
纤维贴片2通过受到真空而被保持在压头5上的位置。该真空优选地通过环形槽或通过孔而实现。在应用压头5期间,保持真空直到定位结束。仍部分增塑的多层材料1’的自然下凹通过压头5相对于半成品1’的中立位置的适当倾斜而补偿。除了压头5的形状,该倾斜还可以通过压头5的关节接头或球接头安装而实施。
图5示出了将加强片2固定到半成品片1’上和初始附接过程的详细图解。
为了施加必要的接触压力,压头5通过力控制或路径控制的方式被压入部分增塑的半成品片1’中直到特定终止位置。为此,压头5的边缘区域可以设置有倒角。玻璃纤维贴片2在半成品片1’上的接触压力可以通过环形真空槽或环形真空孔而另外地加强。在此过程中,半成品片1’另外地通过真空槽或真空孔被吸附在压头5的表面上。
在接触压力的时间失效后,用于固定贴片2的真空被解除,不带有纤维贴片2的压头5移动回到初始位置。
现在,被纤维贴片或加强片2加强的半成品片1’被馈送到深冲压工艺,在其中,通过施加来自工具方向的真空,获得了已经形成的纤维贴片2和箱壁1之间的永久的材料结合的连接。
附图标记
1箱壁
1’半成品片
2加强片
3成形工具
4保持装置
5压头
6切削工具
Claims (9)
1.一种用于制造塑料箱的方法,其中,塑料箱的箱壁(1)的至少一个外层由第一材料组成,其中至少部分地由所述第一材料组成的加强片(2)在至少一个区域中附接到所述塑料箱的箱壁(1)的外层,其特征在于,首先,所述箱壁(1)被准备为热的半成品片(1’),其中所述加强片(2)在成形工具(3)外部被固定,特别是被焊接在热的半成品片(1’)上,所述半成品片(1’)随后和固定的所述加强片(2)一起被引入到所述成形工具(3)中,并在所述成形工具(3)中成形以形成所述塑料箱的箱壁(1),由此,所述加强片(2)被更牢固地固定在所述箱壁(1)上,特别是更牢固地焊接到所述箱壁(1)。
2.根据权利要求1所述的方法,其特征在于,加强片(2)由纤维增强塑料组成,其中纤维增强材料被嵌入到基质中,并且其中所述基质由所述第一材料组成,其中第一材料优选是高密度聚乙烯。
3.根据权利要求1所述的方法,其特征在于,所述热的半成品片(1’)通过保持装置(4)而保持,特别是通过真空,同时所述加强片(2)在所述成形工具(3)外部固定到所述半成品片(1’)上。
4.根据权利要求1所述的方法,其特征在于,在所述成形工具(3)外部,所述加强片(2)通过可延伸的压头(5)被固定到所述半成品片(1’)上。
5.根据权利要求4所述的方法,其特征在于,所述压头(5)通过真空保持所述加强片(2),其中真空优选地在所述加强片(2)已经被固定在热的半成品片(1’)上之后终止。
6.根据权利要求4所述的方法,其特征在于,所述压头(5)的表面相对于所述半成品片(1’)预期中立位置是倾斜的。
7.根据权利要求4所述的方法,其特征在于,所述压头(5)以力控制或路径控制的方式被压入所述热的半成品片(1’)中,以便在所述成形工具(3)外部将所述加强片(2)固定到所述热的半成品片(1’)上。
8.根据权利要求1所述的方法,其特征在于,在所述热的半成品片(1’)可用于固定所述加强片(2)之前,所述热的半成品片(1’)在切削工具(6)中被修整。
9.根据权利要求1所述的方法,其特征在于,所述半成品片(1’)通过在所述成形工具(3)中深冲压成形以形成所述塑料箱的箱壁(1),特别是通过真空。
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EP19209704.6A EP3822061B1 (de) | 2019-11-18 | 2019-11-18 | Verfahren zur herstellung eines kunststofftanks |
EP19209704.6 | 2019-11-18 |
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US20210078236A1 (en) | 2021-03-18 |
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CN112810944B (zh) | 2022-08-23 |
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