CN1608010A - 燃料罐和用于制造该燃料罐的方法 - Google Patents

燃料罐和用于制造该燃料罐的方法 Download PDF

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CN1608010A
CN1608010A CNA028260732A CN02826073A CN1608010A CN 1608010 A CN1608010 A CN 1608010A CN A028260732 A CNA028260732 A CN A028260732A CN 02826073 A CN02826073 A CN 02826073A CN 1608010 A CN1608010 A CN 1608010A
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jar
diaphragm
annex
fuel
infrared radiation
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CN100421980C (zh
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Y·热拉尔
S·莱奥纳尔
F·杜尼尔
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Nergy Automotive Systems Research SA
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Inergy Automotive Systems Research SA
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B29C66/5326—Joining single elements to the wall of tubular articles, hollow articles or bars said single elements being substantially flat
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
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Abstract

一种塑料罐和用于制造该塑料罐的方法，它包括通过一个多层结构的柔软膜片覆盖若干附件，该附件穿出罐的壁，该膜片包括一个燃料阻挡层，该膜片的周边被焊接到罐的壁上。

Description

燃料罐和用于制造该燃料罐的方法
技术领域
本发明涉及一种气体和液体不能透过的塑料燃料罐(或箱)。
背景技术
用于工业中特别是用于汽车工业中用于装备汽车的塑料燃料罐，通常包括一个或更多与塑料燃料罐相关联的附件，例如补气阀和通气阀、卷绕虹吸管、各种传感器和它们的各种连接件、计量仪器和泵送模块等等。
此外，燃料罐必需满足越来越严格的密封和渗透性标准，被允许的排出限制变得如此低，以致与泄露相关的损失以及与附件和燃料罐的接口的渗透性相关的损失在罐/附件系统的总损失中呈现为一个较高的相对比例。
从专利申请WO 01/21428已经知道，封闭一个多层塑料罐的孔口，该孔口被形成用来借助于一个多层结构的薄片将一个附件引入或装入罐中，该薄片与罐的结构相容，并被焊接到罐的外壁上。
然而，在该文献中披露了被使用的薄片具有接近于罐壁的刚性，由此得出结论，当附件的露出部分体积太大时或当附件的露出表面不规则时，这些薄片不能容易地使用。
另外，尽管为了局部地减小构成多层薄片的塑料层的厚度，能在薄片的边缘附近制造凸起，但在薄片焊接到罐的地方通过排出产生的燃料泄露水平通常仍是太高，并且有时甚至超过最新的环保标准规定的非常低的限制。
发明内容
本发明的一个目的是提供一种塑料罐，它更进一步地限制在附件与周围环境的接口处的燃料损失，特别是在附件与罐的接口处，如果这些附件穿过罐的壁的话。
本发明的另一个优点是它允许一个用于将附件固定到罐的系统，它独立于被强加在罐/附件组件上的高的不渗透性要求。
为了该目的，本发明涉及一种设有至少一个附件的塑料燃料罐，该附件至少部分地位于该罐的外侧，附件被一个提高罐/附件组件的不渗透性的保护装置覆盖，其中，该装置是一个多层结构的柔软膜片，该膜片包括至少一个燃料阻挡(或防渗)层，通过在膜片的整个周边上将膜片焊接到该罐的外表面上，该膜片被固定到罐上。
应当理解，术语“燃料罐”意指能在不同的温度和压力条件下存储液体和/或气体燃料的任何类型的罐，更具体地，是指在机动车辆中遇到的那些类型的罐。应当理解，术语“机动车辆”包括轿车、摩托车和卡车。
应当理解，术语“塑料”意指包括至少一种合成树脂聚合物的任何材料。
所有类型的塑料可能都是合适的，特别适合的塑料属于热塑性塑料的族群。
应当理解，术语“热塑性塑料”意指任何热塑性聚合物，包括多种热塑性合成橡胶和它们的混合物。应当理解，术语“聚合物”意指均聚物和共聚物(特别是二元或三元共聚物)，这些共聚物的例子非限制性地是无规共聚物，线性嵌段共聚物，其它嵌段共聚物，和接枝共聚物。
熔化点在分解温度之下的任何类型的热塑性聚合物或共聚物都是合适的，具有遍布在至少10摄氏度的熔化范围的合成热塑性塑料是特别合适的，这些材料的例子是在它们的分子质量中表现出多分散性的材料。
具体地，聚烯烃、乙烯基多卤化物、热塑性聚酯、聚酮、聚酰胺和它们的共聚物都可以使用，聚合物或共聚物的混合物也可以使用，它可以是具有无机、有机和/或天然填充物的若干聚合材料的混合物，例如碳、盐和其它无机衍生物、以及天然或聚合纤维，但不局限于这些材料。使用由若干被固定在一起的叠加层构成的多层结构也是可能的，它包括上述的聚合物或共聚物中的至少一种。
聚烯烃产生了好的效果，在聚烯烃中，高密度聚乙烯(HDPE)是优选的。
本发明应用于设有至少一个附件的罐，该附件至少部分地位于罐之外。应当理解，术语“附件”  通常意指液体或气体通过的任何元件，或一个接触液体或气体的元件，并且实现对于一个罐形成其一部分的燃料装置特定的一个特殊的作用，包括在两个其它元件之间输送液体和/或气体的作用。
这些附件的例子包括但不局限于下列各项：
一个容纳任何化学或物理合成物的容器，特别是一个吸附蒸汽容器；
一个流量计或气压计；
一个端接在流量计或气压计中的电连接件；
一个液泵或气泵；
一个用于罐在某些特定情况下的受控封闭的安全阀；
一个用于接收液体的可排放容器；
一个用于向液泵或气泵的马达电的电接头；
一个用于端接在任何装置的供应装置中的液体管路，特别是用于发动机的供应装置中的液体管路；
一个液体/蒸汽分离装置。
在存在的相同附件的几个例子中，可以随意地使用至少两个附件的任何组合。
根据本发明，附件至少部分地位于罐的外侧上。附件可以完全位于罐的外侧上，一个例子是一个安装在罐壁上并执行一个特定功能的模块，该特定功能涉及燃料的存在。附件也可以仅仅部分地位于罐之外，在这种情况下，附件穿过罐的壁并设有一个与该壁的接口，它确保关于气体和液体的相关密封。
根据本发明，附件用一个保护装置覆盖，该保护装置改善罐/附件组件的不渗透性，换句话说，保护装置的存在显著地减少了在附件表面的燃料损失，和/或如果附件穿过罐壁，也显著地减少了在附件与罐的接口处的燃料损失。
根据本发明，该装置是一个多层结构的柔软膜片，即一个由叠置的几个层所构成的分层结构，每层包括至少一种热塑性塑料。叠置的层的厚度和性质是这样的，即膜片的柔韧性基本上大于罐壁的柔韧性，优选地，通过简单的手动动作，柔软膜片就能容易地变形。
柔软膜片具有各种类型的表面，例如，它可以构成一个凸面，其形状由相对圆的或椭圆的曲线确定，或相反地具有尖角，例如矩形或多边形的形状。柔软膜片也可以具有一个非凸起表面，该非凸起表面包括至少一个位于膜片的表面的内侧上的凸面，在这些包括在膜片的非凸起表面中的每个凸面中，多层结构被中断以便为封闭在非凸起表面中的空穴留下空间。
根据本发明，柔软膜片包括至少一个燃料阻挡层。应当理解，术语“燃料阻挡层”意指一个气体和液体燃料不能透过的层。阻挡层通常包括一种阻挡树脂，任何已知的阻挡树脂都可以存在于阻挡层中，只要它能有效地防止容易接触罐和/或附件的流体燃料特别是碳氢化合物的渗透，和只要它与被用来制造多层柔软膜片结构的技术相容。
在可能的树脂中，可以非限制性地提及聚酰胺或共聚多酰胺的和乙二醇/乙烯醇的无规共聚物。各种阻挡树脂的混合物也是可能的，用包括一种阻挡树脂的阻挡层已经获得了非常好的效果，该阻挡树脂由乙二醇/乙烯醇的无规共聚物制成。
柔软膜片可以通过任何已知的能制造一个薄的柔软的多层结构的技术获得，一种可能的技术是通过一个压片模挤压一个多层膜片的技术，另一种可能的技术是压缩模塑一个多层薄片。
根据本发明的覆盖罐的附件的柔软膜片通过焊接固定到罐上，例如，柔软膜片可以形成一个将附件装在里面的袋子，该袋子被焊接到罐上。
在根据本发明的罐情况下，柔软膜片在膜片的整个周边上被局部地焊接到罐的外表面。
柔软膜片的焊接可以用各种方式来进行，与装配的塑料相容的所有类型的焊接都是合适的。优选地，焊接是激光或红外照射焊接类型，在这种情况下，膜片可以有利地在一个比用其它类型的焊接更宽的周边区域上焊接，例如用激光照射焊接，10到20毫米的宽度是可能的。
在根据本发明的罐的一个优选实施方式中，在膜片的周边附近，柔软膜片的至少一个没有设置阻挡功能件的层在一个至少等于焊接区域宽度的距离上被变薄，在该实施方式中，没有设置阻挡功能件的层的厚度在柔软膜片的周边附近以这样一种方式减小，即至少在罐的壁上的焊接区域中，燃料渗透通道的横截面被减小。特别优选地，没有设置阻挡功能件的一层或多层被变薄，该阻挡功能件位于罐和阻挡层之间。
根据与上述实施方式相容的另一个实施方式，柔软膜片的直接接触罐壁的层包括一种激光照射或红外照射不能穿透的合成物，有利地，该实施方式提供这样的罐，其中通过激光照射或红外照射进行的柔软膜片的焊接是质量较高的。应当理解，表达“激光照射或红外照射不能穿透的合成物”意指一种吸收和/或反射相当大一部分的激光照射或红外照射能量的合成物。这种合成物中具有良好效果的一个例子是炭黑填充剂，有利地，该合成物均匀分布到整个直接接触罐壁的层的聚合材料中。
根据本发明的罐的另一个也与一个或更多上述实施方式相容的实施方式是，其中柔软膜片包括至少一个包含聚烯烃的层，优选地，聚烯烃是高密度聚乙烯(HDPE)。特别优选地，包含聚乙烯的层还包括一种激光照射或红外照射不能穿透的合成物，一个包含碳黑的HDPE层产生了极好的效果。
柔软膜片可以完全覆盖附件以便消除在该附件和罐外部的大气之间的任何直接接触。
作为选择，柔软膜片也可以用这样一种方式放置，即附件包括一个通向罐外部大气的管子，和以这样一种方式放置，即膜片仅仅允许管子伸出到该大气中。在这种情况下，一个在管子与膜片的出口交界面处将膜片固定到管子的装置被结合。各种固定装置都是可能的，只要它们提供一个比管子的端部与罐或其附件的接口处更好的密封接触，其中该管子的端部位于膜片之下。产生良好效果的固定装置是一个扣接固定装置以及一个包括在管子上带螺纹的螺杆和一个拧在管子上的环的系统，该系统在环和管子上的螺纹之间将膜片限制在螺杆的螺纹中。
本发明还涉及一种用于制造一个塑料燃料罐的方法，塑料燃料罐设有至少一个附件，该附件通过该罐壁的至少一个孔口(或开口)连接到罐的内部空间，附件和/或孔口被一个不可渗透的保护装置覆盖，其中在附件上面放置了一个薄的多层结构的膜片，该膜片包括至少一个燃料阻挡层，然后通过使激光或红外照射扫描膜片的整个周边区域，膜片在其整个周边上被焊接到罐上。
在该方法中，共同的术语具有与上面在罐的说明中所给出的同样的含义。
按照一个实施根据本发明的方法的方法，在通过激光或红外照射将膜片焊接到燃料罐之前，膜片通过热成形独立于燃料罐获得和预成型。
通过热成形进行的柔软膜片的预成型包括赋予膜片一个形状，当膜片仍是柔软的并且因而在某种程度上可以在没有相当大的机械力的情况下改变时，膜片接近于将被保护的附件的外表面的形状。优选地，柔软膜片的预成型通过塑性变形来实现。
按照实施根据本发明的方法的另一个与上述实施方式相容的方法，在执行焊接之前，通过一股热空气，膜片被压靠着附件和在该附件附近的罐的壁上。
有利地，该股热空气可以通过一个管子输送，该管子具有一个接近附件的宽度的直径，该管子指向该附件。
后面的附图的目的是说明本发明，而不是用来限制其范围。
图1表示一个圆形几何形状的通气阀1，它包括一个由聚缩醛树脂制成的裙部2，通过将阀1夹在一个虹吸管3上，阀1被保持在适当的位置上，虹吸管3的嘴部被连接到一个用于多层燃料罐4的内部通气的管子，一个包括两个HDPE层的多层结构的薄片5通过加热板焊接被焊接到罐5的壁的外表面6上，该两个HDPE层把一个EVOH阻挡层夹在里面，凸起7和8被构造在薄片5和罐4的壁的表面6上，以便在将薄片5焊接到罐4和虹吸管3的过程中使多个阻挡层聚集。一个具有0.3毫米总厚度的三层的圆形多层膜片9包括一个夹置在两个HDPE层之间的EVOH阻挡层，面对罐4的HDPE层用0.25％重量百分比的炭黑填充，该圆形多层膜片9定位在薄片5的上方并通过用二极管激光照射在罐外壁的一个环形区域10、11上扫描而被焊接，二极管激光照射被用于脉冲模式中(FAP式的钇铝石榴石激光，具有809纳米的波长和35瓦的能量)，环形区域10、11具有16毫米的宽度并环绕阀1和虹吸管3。
图2表示一个环形螺母式止动件的覆盖件，它用来装配一个用于HDPE燃料罐103的泵流量计模块。一个支承板101已定位在一个形成于罐103的孔口102上，一个拧在端部安装件105上的环形螺母装置104使安装板101被固定到罐103上，端部安装件105确定孔口102的壁，一个柔软的密封件106提供第一级的密封。
一个穿过支承板101的虹吸管107使一个安装件108通过扣接固定方式安装在燃料流出管路上。
端部安装件105、环形螺母装置104和支承板101的组合被一个0.3毫米厚的膜片109覆盖，该膜片具有一个包括EVOH阻挡层的多层结构，EVOH阻挡层夹置在两个HDPE层之间，膜片的与罐接触的HDPE层用0.3％重量百分比的碳黑填充，膜片109设有一个孔口并被用激光照射的扫描技术焊接，该孔口允许虹吸管107通过，该激光照射与用来焊接图1中所述膜片的激光照射具有同样的类型和同样的能量。在罐103的外表面，焊接在一个15毫米宽的环形区域上进行，在扣接固定安装件108的内凹部分的过程中，一个密封件110在虹吸管107周围提供密封。

Claims (10)

1.一种设有至少一个附件的塑料燃料罐，该附件至少部分地位于所述罐的外侧，附件被提高罐/附件组件的不渗透性的保护装置覆盖，其特征在于，该装置是多层结构的柔软膜片，该膜片包括至少一个燃料阻挡层，通过在膜片的整个周边上将膜片焊接到所述罐的外表面上，该膜片被固定到所述罐上。
2.如权利要求1所述的罐，其特征在于，焊接是激光或红外照射焊接类型。
3.如前述权利要求中任一项所述的罐，其特征在于，在所述膜片的周边上，至少一个没有设置阻挡功能件的层在至少等于焊接区域的宽度的距离上被变薄。
4.如前述权利要求中任一项所述的罐，其特征在于，所述膜片的直接接触罐的壁的层包括激光照射或红外照射不能穿透的合成物。
5.如前述权利要求中任一项所述的罐，其特征在于，所述膜片包括至少一个包含聚烯烃的层。
6.如前述权利要求中任一项所述的罐，其特征在于，所述膜片完全覆盖所述附件以便消除在该附件和罐的外部的大气之间的任何直接接触
7.如权利要求1至5中的任一个所述的罐，其特征在于，所述附件包括通向罐的外部的大气的管子，和所述膜片仅仅允许所述管子伸出到外部大气中。
8.一种用于制造塑料燃料罐的方法，该塑料燃料罐设有至少一个附件，该附件通过该罐壁的至少一个孔口被连接到罐的内部空间，附件和/或孔口被一个不可渗透的保护装置覆盖，其特征在于，在附件上面放置有薄的多层结构的膜片，该膜片包括至少一个燃料阻挡层，然后通过使激光或红外照射扫描膜片的整个周边区域，膜片在其整个周边上被焊接到所述罐上。
9.如前述权利要求中任一项所述的方法，其特征在于，在通过激光照射或红外照射将所述膜片焊接到燃料罐之前，该膜片通过热成形独立于所述燃料罐地获得和预成型。
10.如权利要求8或9所述的方法，其特征在于，在执行所述焊接之前，通过一股热空气，所述膜片压靠所述附件和在该附件附近的罐壁。
CNB028260732A 2001-10-24 2002-10-22 燃料罐和用于制造该燃料罐的方法 Expired - Fee Related CN100421980C (zh)

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KR20040050923A (ko) 2004-06-17
FR2831112A1 (fr) 2003-04-25
US20050067415A1 (en) 2005-03-31
CN100421980C (zh) 2008-10-01
FR2831112B1 (fr) 2004-01-23
DE60208812T2 (de) 2006-11-02
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DE60208812D1 (de) 2006-04-06
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