CN1668452A - 从半壳体中生产空心塑料制品的多阶段工艺 - Google Patents
从半壳体中生产空心塑料制品的多阶段工艺 Download PDFInfo
- Publication number
- CN1668452A CN1668452A CNA038166224A CN03816622A CN1668452A CN 1668452 A CN1668452 A CN 1668452A CN A038166224 A CNA038166224 A CN A038166224A CN 03816622 A CN03816622 A CN 03816622A CN 1668452 A CN1668452 A CN 1668452A
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- Prior art keywords
- parison
- technology
- plastic
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Abstract
本发明涉及一种用于生产空心塑料制品的多阶段工艺,包括如下步骤:a)通过挤压或共挤压生产管状塑料型坯;b)切开塑料型坯形成两平面部件;c)在两半模中成型平面部件以形成半壳体,其中可移动的中间框体至少沿周围边缘将两半模彼此分开,因此半成型品/半壳体彼此不接触;d)打开所述半模并且移去中间框体;e)关闭所述半模,从而半壳体沿着周围轮缘与另一个接触;并且f)连结半壳体形成空心成品。
Description
本发明涉及一种从半壳体中生产空心塑料制品的多阶段工艺。本发明更涉及由上述工艺生产的空心塑料制品及其用途,例如作为机动车辆上的塑料油箱使用。
油箱形式的空心塑料制品已几乎完全代替至今在机动车辆结构中通常使用的由金属材料制成的油箱。而且,当前所有类型的便携式或可移动的容器几乎全都由塑料制成,例如汽油罐、塑料瓶、塑料桶,以及用于盛放易燃液体、危险材料或类似物品的塑料容器。塑料容器和油箱的特别有利之处在于它们具有较低的容重比,并且消除了腐蚀问题,同时也具有低廉的生产成本。
生产空心塑料制品可使用多种工艺。除了公知的转动烧结法外,吹塑法是特别用于生产大规模产品的一种工艺,其中包括共挤吹塑法。
现实社会中广泛规定减少形成臭氧的排放物,例如与燃烧有关的排放物,这意味着所有机动车辆上的塑料油箱(PFTs)在车辆停止和运行的条件下不得不防止燃料的泄漏。如果用于生产塑料油箱的塑料没有固有的阻隔性能,那么就不得不采取其它的措施来减少渗透作用的发生,例如通过氟化作用(在线或离线)、涂漆或镀膜、等离子聚合、混合用法(Selar法)、或共挤压法(各种阻隔性能的聚合物合成到一个多层的合成物中)。
为了达到避免从燃料装置中排放燃料的规定要求,除了上述措施外,还必需逐渐在油箱的内部集成一些部件。例如管线或阀之类的上述部件可以在所要求的镀膜工艺之前或之后合并。只有在镀膜工艺中合并部件不被损坏时,才可能在镀膜工艺前合并部件。如果镀膜工艺在所有部件合并之前实施,那么镀膜可能会损坏油箱中的连接点(焊接点)。
上述的共挤压吹塑法是一种用于生产多层空心品的工艺。吹塑法或共挤压吹塑法是一种广泛使用的技术,但它存在一定的缺点,即不能在空心塑料制品成型后集成零部件,例如燃料系统的部件,或者仅仅是非常有限度地集成。
DE19814314描述了一种可被称为熔融压缩法的工艺。其中,共挤压的型坯(例如以吹塑设备中形成的管的形式)放置于模中,并且通过使用冲模或阴模,使其受压形成半壳体。其缺点在于在焊接过程之前冲模不得不从模子中移去,这样它就不可能利用焊接的热量。另外,有标记的熔融压缩流体在挤压的过程中平行于模面,并且虽然这样能通过模子和冲模的几何尺寸良好地控制总壁厚,但是大部分自由流动的具有阻隔性能的聚合物熔体得到了局部稀释,因此在空心塑料制品上就出现了不一致的阻隔性能。
现有技术中公知的另一生产工艺是一种可被称为热成型法或双板法的工艺,首先通过热成型合适的半成型板制造两个半壳体,然后在该工艺的第二步将它们彼此都焊接起来。然而,这种工艺其中一个主要的缺点在于,油箱半壳体的壁厚分布不能完全控制。不能完全控制壁厚分布,进而不能控制阻隔层厚分布,其原因在于半成型板具有统一的壁厚,因此取决于热成型过程中的伸长,这样可以标记壁厚或阻隔层厚的局部减小。
DE10042121公开了一种用于生产空心塑料制品的工艺,其首先在吹塑或共挤压吹塑设备上生产管状塑料型坯,然后将其切开形成至少有一平面的部件,而后热成型生成的平面部件以形成半壳体,并且彼此焊接它们形成空心成品。
生产空心塑料制品的工艺的原理在于,在吹塑或共挤压吹塑设备上生产塑料型坯,将其沿轴向切开,其生成的熔融的平面半成型板置于两个热成型模子中,并且形成期望的形状。这种工艺中形成的两个半壳体能利用热成型的热量彼此相互焊接。这种工艺具有缺点,因为当零部件合并到迅速变冷的半壳体内部时,其结果是零部件不得不在焊接之前加热,这就会导致焊接中应力的出现,在成型的塑料油箱中增大了出现开槽和脆点的危险。塑料油箱的稳定性也主要取决于半壳体上夹断边缘的质量。在此处塑料中引起的应力同样对空心塑料制品的机械承载能力具有不利的影响。
美国专利申请2001/0015513描述了现有技术的另一种工艺。其中,利用一种单阶段工艺通过在切开挤压管状塑料预成型毛坯形成两部分后即时焊接和吹塑两个半壳体,从而在两部件的吹塑设备上生产空心成品。此处任何合并部件被装入到空心成品中,同时利用机械手关闭所述半模。这种工序意味着高设备成本和控制费用。
上面的描述表明了现有技术中公知的用于生产空心塑料制品的工艺具有许多严重的缺点。
本发明的目的是为了满足当前紧迫需要而提供一种生产空心塑料制品的工艺,并且消除了现有技术中的上述缺点。本发明的另一个目的是提供了一种新工艺,该工艺继续使用现有的广泛应用于工业的共挤吹塑或吹塑设备。其它的目的在本发明的下述描述中是显而易见的。
我们可知,通过权利要求1的技术特征可以实现关于所述工艺的目的。
本发明所述工艺的优选实施方式在所述工艺的附属权利要求中详细说明。
本发明提供了一种用于生产空心塑料制品的工艺,包括如下步骤:
a)通过挤压或共挤压生产管状塑料型坯;
b)切开塑料型坯形成两平面部件;
c)在两半模中压制平面部件以形成半壳体,其中可移动的中间框体至少沿周围边缘将两半模彼此分开,因此半成型品/半壳体彼此不接触;
d)打开所述半模并且移去中间框体;
e)关闭所述半模,从而半壳体沿着周围轮缘与另一个接触;并且
f)连结半壳体形成空心成品。
在本发明所述工艺的一个优选实施方式中,如果预先装配合适的话,诸如管线、阀、泵、过滤器等之类的合并部件在所述工艺的步骤d)后被装入一个半壳体中,如果合适的话,合并部件甚至被装入到两个半壳体中。
根据本发明的目的,“塑料型坯”是挤压的且优选管状的预成型毛坯,其从挤压或共挤压设备上生产,且保持熔融的热量,至少由一层塑料组成,如果合适的话,可以是两层或多层。“半成型品”是一种通过切开型坯形成的平面结构件,然后这些半成型品在吹塑法成型模具和/或热成型法模具中被成型,即具有规定的三维空间结构,其中一边开口。根据本发明,“半壳体”是指通过成型半成型品从而形成壳状结构,然后相互粘结形成空心塑料制品。
可以知道,本发明的所述工艺消除了用于生产空心塑料制品的现有技术中公知工艺的缺点。根据本发明,使用中间框体或平板型隔板,并且在不同的关闭点打开和关闭半模,容许将DE10042121中先前公知的工艺再细分到功能步骤中,并且这样实质上便于将零部件装入到空心成品的内部,使得空心成品在质量上具有极大的改进。本发明的所述工艺也能在基本不接触到未成型的半成型品的条件下,毫无问题地将相当大的零件装入到空心成品的内部。
本发明用于生产空心塑料制品的所述工艺的原理在于,在吹塑或共挤压吹塑设备上生产塑料型坯,将其沿轴向切开,其生成的熔融的平面半成型板被装入到两个半模中,可移动的中间框体沿关闭模子的周围边缘将它们分开,因此在两个半成型塑料品之间基本上不接触。利用中间框体(图5)使两个半壳体在各自的半模中完全成型,基本上彼此独立,然后在移去中间框体之后,在不从模子上移去半壳体的条件下,使它们彼此相互连接。这种工艺也可装入大型合并部件,也允许半壳体随后彼此焊接,例如,“当还很热时”,即基本不需要重新加热整个半壳体。
本发明中间框体也可设计为平板型隔板,其基本上完全填充两个半模之间的区域。根据本发明的目的,因此,中间框体可以为平板形式的框体。该中间框体或平板型隔板可以设计为单个部件,也可设计为多个部件,并且它的形状必须适配模子的边缘轮廓。由于分开模子的要求,因此它具有弯曲。即使分开面可能会很复杂,但选择框体的接触面尽可能最大地简化3D轮廓(图5)。如果单个使用分开的、多部件结构的中间框体或平板型隔板,所述部件优选彼此独立,或者要么彼此可移动地连接在一起。
本发明的多阶段工艺首先以下述方式将半模合到中间框体上,即在每个半模和框体之间有一个型坯,其在此之前已被分成两个部件,但型坯或半成型品相互并不直接接触。在第一步中半成型品在半模中成型后,打开模子并且移去中间框体。在这个时机,可以完全进入到后来生成的空心成品的内部,因此,此时甚至可装入大型的合并部件,并将其精确定位。
在第二步中,另一个闭合动作就是将半模最终闭合在一起,所以半成型品相互直接接触,然后可被连结或焊接。因此,术语多阶段用于所描述的工艺。在所述的两个阶段中,被认为闭合的模子上的那段位移不同于中间框体的厚度。
通过平移或转动从半模之间的空隙中移去中间框体,并且也可使用合适的机械手来达到此目的。
图1示出了本发明所述工艺的位移/时间曲线图。平面部件的成型周期以打开模子的时间t0开始。一旦半成型品置入半模中,它们就合到中间框体或平板型隔板上,然后在T1时间段内通过吹塑法和/或热成型法在其内部使两半壳体成型。然后在本工艺的第一阶段的终点重新打开模子。在T2时间段内,此时开放式地进入到两个半壳体的内部,例如,提供时机安放合并部件或对半壳体的内部进行涂敷。同时中间框体被移去。然后所述半模闭合在一起,此时没有中间框体,于是半成型品被连结或焊接在一起。在T3时间段内,随着模子的闭合,此时本工艺的第二阶段利用吹塑法或者,如果合适的话,热成型法使从焊接的半壳体形成的空心成品基本上成完整的形状并且使其冷却。然后重新打开模子,并且在T4时间段内,从模子中移走空心成品,并且重新插入中间框体,使上述周期从开始重新循环。
本发明所述的工艺通过变换在第一步(=阶段1)中的工艺参数完全自由地控制半壳体成型的工序状态,控制着带有中间框体的模子的闭合,以及在第二步(=阶段2)中不带框体的闭合。这是可能的,因为T1-T4时间段是变化的,并且能根据各自的要求自由地选择。
例如,如果在第一阶段中被选的时间(T1)长于不带框体的第二次闭合时间T3,那么其结果基本上是通过热成型法成型。相反,如果第二次闭合时间T3较长,那么空心成品基本上是通过吹塑法形成的。在上述两者之间的情况中,可设定上述两种成型工艺的比值之间的任何值,即任何期望的单阶段或多阶段的热成型法工序和吹塑法工序的混合值。
如果设定所述工艺的参数使得阶段1的值接近于整个周期的时间值,那么这种工艺对应于热成型半壳体的生产,所述的半壳体被独立地移去以进行后续加工。阶段1与阶段2比值的中间值-尤其是该值取决于最终的产品-导致了借助被称为EVBM工艺(挤压真空吹塑法)的成型。如此选择阶段1的持续时间(T1),以致于半壳体保持它们的形状来容许在T2时间段内并入其它部件,但同时塑料在第二次闭合时间T3内有足够高的温度被焊接。改进形状稳定性的一种方法是在模子和塑料之间设置真空空间,例如借助穿过模子延伸到模腔中的合适的孔。相反,如果本工艺中的第一阶段(带框体闭合)的持续时间极大地缩短以致于其接近于零,那么该工艺符合公知的吹塑法。
本发明所述工艺是可变化,其变化允许成型步骤分别精确适合模子和要生产的空心成品的结构要求。
另外,选择吹塑和热成型步骤合适于各个使用塑料的流变学原理,其目的是为了使半成型品以合理的方式和恒定的厚度与半模适配。
在本发明的所述工艺中,另外一个特定的优点在于,当打开模子移去中间框体时,两个半壳体完全可以接近,在容器的内部并入零部件相当方便。因为半成型品和半壳体保持在半模中,所以合适地控制着模子和中间框体/平板型隔板的温度,避免了塑料-特别是在空心成品的内部-过度冷却,因此可直接焊接合并部件至仍保持熔融热量的塑料上,并且确保半壳体在后续的步骤中仍有足够高的温度相互直接焊接。
由于成型步骤的高灵活性,由吹塑设备生产的平面部件产品也具有精确可重复地控制壁厚的特点以及高的设计自由度。当使用共挤压吹塑设备时,由具有阻隔性能的聚合物组成的层能被融合到半成型品中。如果在吹塑设备上生产单层的半成型品,那么其后可以通过例如氟化作用或涂漆来使用具有阻隔性能的层。采取镀膜工序的优点在于,在打开模子之后可完全进入半壳体,且能在合并部件装好之前或之后进行。
本发明的中间框体实现了许多功能。最主要的功能是在成型工序中保持或固定半模中的半成型品的周围边缘。该框体也作为一个表面在夹断半成型品过程中通过模子上的夹断边缘施加压力。中间框体和模子两者的边缘区域的几何尺寸和设计结构对上述固定和夹断的功能起着决定性的影响。在本发明中,对模子的边缘采取不同的设计结构是有利的,这样是为了控制半成型品和中间框体之间的接触。采取半成型品的非密封方式,是为了在第一成型阶段结束之前至少在一定程度上对半成型品进行吹塑,这样就不妨碍形成后续的清晰夹断焊线。
特别地,在本发明的优选实施方式中,中间框体或平板型隔板也具有其它功能,例如通过合适的孔来控制压缩空气充入或排出。这也可用来行使冲洗或通风功能。也可能有布置或集成到框体上的其它功能单元,包括可移动的功能单元,例如模冲或夹片。也可把中间框体当作被加入的零部件的支持件。
为了支持中间框体的功能,具有用来冷却或加热框体上至少一个分区的设备。作为时间和/或位置的函数,温度控制是有差异的,并且如果合适的话,框体/平板上某一区域在所述工艺的周期内可能会控制着不同的温度。控制温度方法的一个例子是让合适的致冷却剂或加热剂流经管道。也可使用电子筒形加热器或热电偶。精确的温度控制应特别给予优先考虑,且优先加热模子的夹断棱边,为了从夹断棱边上的应力中获得更好的均匀性和自由度。
在热成型法的过程中,由于固定半成型品的边缘会局部冷却,因此在夹断的工序中塑料上会出现应力,其对机械性能和夹断焊线的质量具有不利的影响。如果合适的话,冷却的另一结果是必须重新加热,目的是为了获得后续焊接半壳体形成成型空心成品所需的焊接温度。塑料中的应力同样会导致在成型的空心成品中出现开槽和脆点。由于上述原因,在本发明的一个优选实施方式中,对半壳体的边缘区进行局部加热或者局部温度控制。优先对平板型隔板两边的边缘上控制温度,或者在当前仅有的一边的边缘上控制温度,其中上述边缘的区域与模子夹断边缘相接触。
本发明也提供一种通过上述工艺生产的空心塑料制品。通过本发明所述工艺生产的空心塑料制品,本发明优先提供它作为机动车辆上的塑料油箱使用,或者作为用于储存或运输燃料油、柴油或其类似物的油罐或塑料桶使用,或者作为多用途车辆上的运输容器使用,例如用于作物喷射器,或者作为溶剂容器、塑料瓶或类似物使用。
本发明产品制造工艺的另一优点在于,在粘结半成型品之前,如果合适的话,安装诸如燃料装置之类的合并部件到半壳体内部毫无困难。因此本发明在热成型的半成型品焊接之前将合并部件安装到半壳体,其中合并部件例如包括用于在箱体中保持压力平衡的通风管线、用于在箱体中保持液体平衡的燃油管线、阀、防喘振杯,或者相关的泵和/或箱体传感模块。
半成型品可通过合适粘胶剂进行粘结,或通过高温焊接,或混合使用上述两种连接方式。优选使用焊接。“当半成型品仍是高温时”,优先对半成型品进行焊接,即在第1阶段成型和移去中间框体后,仍保持熔融热量的半壳体边缘通过第2阶段中闭合半模而相互直接接触,并且半壳体沿着夹断模缝相互直接被焊接。
在本发明的所述工艺中,有这样的好处,即在粘结两个半成型品之前不会出现冷却现象,或稍微冷却一点而已。主要在外表面上冷却是本工艺的特性。在较长的时间内,半成型品的内部,其边缘在T3时间段内第2阶段中相互接触并被焊接,通常保持熔融热量,因此具有可焊接性。在本工艺的一个特别优选的实施方式中,对生产空心塑料制品不需要其它的加热或冷却步骤,所述空心塑料制品从保持熔融热量的(共)挤压的管状型坯中制成。
根据本发明,通过提供在中间框体中冷却或加热的装置可以获得上述的结果。
本发明所述工艺的另一主要的优点在于,能精确控制从共挤压吹塑设备上生产塑料型坯的壁厚。对共挤压吹塑设备上生产的塑料型坯壁厚的精确控制极大地改进了后续的热成型法中壁厚的控制。根据型模的直径来设定塑料型坯的直径或周长,且必须达到所述工艺的后续步骤的要求。在挤压过程中借助模缝的变化在轴向上可控制塑料型坯的壁厚。也可通过使用成型模/心轴对(profiled die/mandrel pairs)或使用合适的促动器变形的弹性模圈实现径向壁厚的控制(部分壁厚控制)。
如果合适的话,从模子中排出熔融塑料形成所期望长度的期间或之后,该型坯被切开成至少一个平面部件,优选两个部件,或者更多,例如三或四个部件。所述期望长度必须达到本工艺后续步骤的要求和满足成型部件尺寸。在一优选的实施方式中,在脱离模子之前切开塑料型坯,即在挤压过程完成之前,或完成后立即切开。
在另一个特别优选的实施方式中,在切开之前借助拉伸装置沿垂直于挤压方向上拉伸塑料型坯。如果管状型坯仅有一边被切开,结果是形成大平面区的半成型品,其置于带有上模壳和下模壳的两个模腔的热成型模之上,这样就生成了两个半壳体,然后将它们彼此分开,而后焊接在一起。优选切开管状型坯的两边,这样就可获得两个平面部件,每一个部件都在热成型模中成型。本发明也提供将型坯切开得到不止两个部件,并且如果合适的话,将从不止两个的子模壳中制造出成型部件。
然后通过热成型法进一步加工生成的塑料部件,得到半壳体状的半成型品。现有的共挤压吹塑设备在本发明所述的工艺中使用也具有优点。对于吹塑设备来说,仅仅需要补充合适的切割单元(优选机械手)以及热成型单元,而且在原理上也可在此处使用吹塑设备上现有的夹持单元用于热成型、完工和焊接过程。
可以发现,应用例如传统钢制刀片之类的传统切割装置分开塑料网膜具有严重的缺点。特别地,可以发现熔融的塑料经常会粘结到上述装置或刀片上。这种粘结导致型坯上出现不期望的变形,以及分开工序后获得的熔化半成型板(作为幕状物为人所知)上出现不期望的变形。也可以发现,在许多实例中,特别是在挤压工序开始时,上游熔化物的压力对于所期望的将要实施的切割工序是不够的,由切割装置或刀具施加在型坯上的阻力非常频繁,以至导致型坯的显著变形,特别是在挤压工序开始的时候,即,管子从模子中开始移出的时候。这导致在生成的切割边缘上产生相当大的变形,也导致幕状物本身相当大的变形。
因而,在本发明一个优选实施方式中,切割塑料型坯的方式如下:
将环形管切割成一个或多个熔融的半成型板(作为幕状物为人所知)的切割装置在原理上具有任何期望的刀具设计或刀具几何尺寸。例如,切割装置包括锐缘的切割元件,如果合适的话,该切割元件还是可替换的。除了锐缘的装置之外,也能使用无缘的或矩形或棒状的装置以及起刀具或分隔器作用的装置。然而,使用三角形刀具被证明是特别有利的,在型坯移出时,该三角形刀具将其切开形成两半。
切割装置或刀具或其部件的表面性质可以是光滑的或开槽的。根据需要,部分或全部切割装置或刀具本身可以被加热或冷却。
所用的刀具优选是三角形,给刀具镀膜是有利的,该镀膜防止高温塑料熔体的粘接。合适的镀膜包括例如聚四氟乙烯(PTFE)或其它的氟化烃。
通过布置切割装置或刀具,也可克服上述问题。在原理上,可以将刀具或切割装置布置在挤压装置的心轴和/或模子上。在一些例子中,已经证明在从模子中移出时立即切割型坯是有利的,切割装置或刀具的布置可以是水平或垂直的。
作为将切割装置安装在心轴和/或模子的替换方案,塑料熔体可以在布置于吹塑头部内部中的分流器的帮助下分开,这些分流器可以仅仅用作在型坯管中产生脆点的置换器,该脆点严重得足以使型坯自发地裂开或对型坯的裂开稍有帮助。
第二个可能性是与生产窗体条的工艺相似的工序,在该工序中通过分流器送入透明塑料,用于将管子分开的目的的塑料是与型坯的塑料不相容的,由于所述不相容性,因而被引入的“分隔器条”能毫不费力地拉开,于是剩余的管子部分(幕状物)用作本发明所述工艺中的平面部件,合适的不相容聚合物例如是聚酰胺、聚苯乙烯,如果合适的话,也可以是聚丙烯。
分开管子或型坯的另一种工艺是使用灼热的金属丝,上述灼热的金属丝可以是固定的或可移动的,也可以用激光来将熔体或型坯分开成幕状物。
上述切割装置包括刀具、分流器、灼热的金属丝和激光,其可以具有刚性布置或摆动布置。它们也可以在熔体上迅速经过,以便避免不期望的材料位移。作为替换方案,所述切割装置可以设计成可移动的。
相当大地减小型坯遭遇到切割装置时所产生阻力的一种方式是给予圆柱形型坯“脆点”。在此环境下,可以发现使用与型坯的原料聚合物不相容的聚合物能非常简单地实现所述分开。所述的不相容意味着不能将原料聚合物焊接到共挤压的聚合物上,合适的聚合物是上面提及的。
特别是在具有特别大的壁厚度和/或由特别高分子量的材料制成的型坯的情况下,已经证明提供带有动力设备的切割装置是有利的;如果在切割装置上引导具有相当大的壁厚度的型坯,在生成的切割边缘上形成翘曲或折皱(图3),这是因为在分开具有大的壁厚度的型坯的过程中,切割装置或刀具施加在型坯上的阻力特别大。
可以发现通过装配上述具有动力系统的切割装置可以克服上述问题,该动力装置可以抽出或传送型坯和/或生成的幕状物。抽出机构使得型坯或幕状物在切割装置上被拉动,因而弥补由切割装置施加在型坯上的上述阻力或出现的力。用此工艺能加工具有薄或厚壁层的型坯,所述薄或厚壁层由高到(包含)低分子量材料和/或由高到(包含)低密度的材料制成。
一个特别优选的抽出系统包括在每个半成型品上的一个或多个滚筒型的抽出单元,例如从动辊,特别优选的是气动导向托辊。从动单元或从动辊将拉力施加在型坯或幕状物上,该拉力与挤压过程产生的压力一起作用,以在切割装置上以期望的方式恒定地引导型坯。
从动辊或滚筒的使用具有其它的优点,即在型坯分开之后,型坯部件立即偏移切割刀具,从而避免任何粘接。在一个特别优选的实施方式中,从动辊被集成在切割装置中,切割装置优选地是三角形的切割刀具。作为替换方案,从动辊也可以单独地安装,即,安装在切割装置外部。
为了分别确保足够的摩擦力或热塑性合成物的连续输送,从动单元具有型面或沟槽或合适的镀膜。
相对于从动单元速度,型坯或型坯部件的速度可以从0到有利于从动单元速度的正差值,有利于从动单元的正差值是优选的。
在另一个优选实施方式中,用于引导型坯或型坯部件(幕状物)的装置也包括导辊,如果合适的话,这些导辊也是从动的。使用这些导辊的例子是控制所获得的型坯部分之间的距离、或者是使型坯部件变形,特别是使其变平。切割装置或引导装置具有导辊和上述的从动辊。
一个特别优选的驱动系统包括滚筒型驱动单元,例如从动辊,特别优选地是气动导向托辊。从动单元或从动辊对型坯或幕状物施加拉力,该拉力与挤压过程产生的压力一起作用,以在切割装置上以期望的方式恒定地引导型坯。
使用从动辊或滚筒具有另外的优点,即在型坯分开之后,型坯部件立即偏移切割刀具,从而避免任何粘接。在一个特别优选的实施方式中,从动辊被集成在切割装置中,切割装置优选地是三角形的切割刀具。作为替换方案,从动辊也可以单独地安装,即,安装在切割装置外部。
对于所述工艺的单独操作,本发明提供机械手的使用,特别是对于塑料型坯的分开、输送和切割,以及将合并部件插入到空心成品中。
由本发明所述工艺生产的空心塑料制品优选地具有两层或多层结构,这是因为塑料材料遭受高应力水平,并且例如相对于阻隔作用,要求是严格的。
本发明的空心塑料制品优选地具有至少两层的结构,这些层总是包括通常形成空心成品内表面的支承底层,因而该层对于容器防漏性和其机械稳定性是相当重要的。
在一个特定实施方式中,生成的塑料型坯至少有一层由聚合材料制成,聚合材料优选地选自聚乙烯、聚丙烯、聚氯乙烯、聚酰胺、聚酮、聚酯及它们的混合物。生成的塑料型坯优选地具有至少一层由聚乙烯制成的层,特别是密度从0.93到0.97克/立方厘米的聚乙烯。
在另一个优选实施方式中,塑料型坯具有包括两层或多层的结构,优选地包括底层、再研磨层、增粘剂层和/或阻隔层。
在成型部件及其型坯内的层厚度分布取决于层的数量。下面给出的是在塑料型坯中的层厚度分布,该塑料型坯由本发明所述工艺产生并具有由六层组成的结构。一个特别优选的实施方式分别产生塑料型坯和空心塑料制品,塑料型坯和空心塑料制品具有由六层组成的结构,该六层结构从外到内包括:由HDPE制成的层,其占厚度的5%到30%;再研磨层,其占厚度的10%到82%;增粘剂层,其占厚度的1%到5%;阻隔层,其占厚度的1%到10%;增粘剂层,其占厚度的1%到5%;由HDPE制成的层,其占厚度的10%到40%,上述所有情况下百分比是基于容器壁总厚度作出的。
合适的基底材料包括密度从0.940到0.960克/立方厘米的高密度聚乙烯(HDPE),特别是从0.943到0.955克/立方厘米,特别优选地是从0.943到0.950克/立方厘米。适合于本发明的聚乙烯材料的熔体流量比是从1.5到20克/10分钟(MFR(190℃/21.6千克)),特别是从2到10克/分钟,特别优选的从3到8克/10分钟。当然,其它的上述聚合物材料也适合作为支承基底材料。
合适的阻隔材料包括乙烯-乙烯醇共聚物(EVOH)、聚酰胺和其它的阻隔聚合物,例如聚酯,特别是聚对苯二甲酸乙二酯、含氟聚合物,例如聚偏二氟乙烯、乙烯-四氟乙烯共聚物(ETFE)、四氟乙烯-六氟-丙烯-亚乙烯基氟化共聚物(THV)和液晶聚合物(LCPs)。其它合适的材料是上述具有纳米颗粒的阻隔材料的混合物。根据本发明的目的,纳米颗粒是无机页硅酸盐,其原子层分开,从而被居中的有机分子松散。原子层能通过结合到聚合材料中导致颗粒极其精密的分布来分开,散开颗粒的表面导致任何透过分子的分散路径极度延长,结果是减少了渗透作用。
适合于本发明的增粘剂包括变极聚乙烯(HDPE或LLDPE和LDPE),极性改变通常是接枝共聚具有C=C双键的极性分子的结果,例如富马酸、马来酸或马来酸酐。嫁接的聚乙烯也可以在下游反应中发生化学变化,例如通过引入氨基。其它在原理上作为增粘剂适合的材料是乙烯与醋酸乙烯酯、丙烯酸或其酯的共聚物。
可以被称为再研磨层的层优选地由作为闪光件为人所知的物质生成,例如在空心塑料制品的生产过程中形成并表现为残余材料或产品残余物的形式的闪光件。
本发明的另一实施方式分别在两个热成型的半成型品焊接之前和之后提供了半壳体或空心塑料制品,所述的半成型品由其它的降低渗透性能的涂布形成。例如可通过直接氟化作用、涂漆或等离子聚合在塑料容器上获得降低渗透性能的镀膜。
明确地参考如下事实,即本发明所述工艺的下面描述仅仅覆盖了可能的实施方式。本发明也提供了同样能使本发明所述工艺的原理实例化的其它实施方式。
在本发明所述工艺的第一步中,首先生产塑料型坯,例如用6层的共挤压吹塑设备生产,其由克鲁卜·考特克斯机械厂(Krupp KautexMaschinenbau)生产和出售。该共挤压工艺提供了包括有六层的管状型坯。型坯的层结构对应于上述的结构(从外到内:HDPE层、再研磨层、增粘剂层、阻隔聚合物层、增粘剂层、HDPE层)。型坯层厚分布同样在上述给定的范围内。
在共挤压工艺中,使型坯壁厚适合于成型部件的几何尺寸,在这种方式下能在成型部件不薄的区域上最大地获得壁厚分布的恒定性。此处通过合适的程序控制型坯壁厚,该程序作为时间函数控制模缝(WDS),并且如果合适的话,也可通过径向模缝控制(PWDS)。壁厚分布取决于材料机械性能的要求,在塑料箱体的情况下也取决于点火性能的要求。型坯管的直径和周长满足模子的要求,并且能根据选择的模子直径毫不费力被设定。
根据各自模子所要求的长度挤压塑料型坯。本发明通过适当的拉伸装置挤压型坯,例如,在最简单的情况下上述拉伸装置由竖直固定的两根杆组成,并且通过液压能相互移去。如果平行或彼此成一定角度布置并且定位于型坯管内部的两根杆彼此相互移去,那么型坯管整个长度上的熔体相对于挤压方向横向延伸。上述拉伸装置当然也可设计成多个部件,其使型坯管在轴向上承受各种程度的受控的拉伸或伸展。使用定型材料的拉伸装置不仅是一种控制共挤压管预成型的工艺,而且是一种控制型坯壁厚的工艺。
生成的塑料型坯在挤压头部的模子下被分开。在拉伸装置中被拉伸和固定的熔融型坯此时从型坯挤压区中旋出,从而在下一操作中它至少能沿两条线被切开,该两条线与所述工艺的后续步骤和成型部件的要求匹配。最后,固定装置被置于塑料型坯的两边。这样能固定和定位在切割工艺中生产的型坯半模。合适的固定装置例如是吸入压头。例如,分开和输送熔融管是现有技术中已知的一个步骤,并且已在EP0653286中详细描述。在轴向上分开塑料型坯优选使用机械手,该机械手能对切割工具进行三维控制。这样,半成型品的平面型面可适合于热成型模子的边缘弯曲,并且这样能使产生的闪光物比例降至最低。如果理想的话,在从模子中分开之前,熔融管也能沿轴向在挤压工艺完成之前或之后立即被切割。如果切割工艺出现在挤压工艺的期间,那么平面部件本身会在垂直于挤压方向上被拉伸。
然后,下一步将大多数为板形结构的生成的平面部件形成两个热成型半模,优选将上述两半模彼此对立。机械手也可执行这种功能。如果合适的话,热成型半模在生成的空心塑料制品的上部和下部分别具有不同的形状。在第一步骤中,两个半模闭合到中间框体上,每个半模闭合到所述框体的一边。中间框体这样设计是为了避免两个半成型品相互接触。在半模中施加低于大气压的压力,并且/或从闭合模子的中心注入压缩空气,因此通过压缩空气分别将熔融的半成型品吸入模子,或者在模子中挤压它们,并且在此处使用合适的压力时间图能更一步优化熔体的多轴向拉伸,从而也优化所要制造的半壳体的壁厚分布。也可能连续或者同时以任何期望的顺序和组合来执行热成型步骤和吹塑步骤。
在半成型品成型于半模之后,打开模子并移走中间框体。如果合适的话,此时将合并部件装配到半壳体中,和/或半壳体的内部被镀膜。在制造塑料箱体期间,例如可以将用于在箱体中保持压力平衡的通风管线、用于在箱体中保持液体平衡的燃油管线、阀、防喘振杯、或者相关的泵和/或用于补给燃料的箱体传感模块插入到箱体半壳体中,并且将它们焊接到仍保持熔融热量的内表面上。在此工艺中,也优先使用机械手。在制造的最后一步中,合并仍然位于模子中的两个半壳体,并且通过挤压两个模子,且通过再次闭合模子使它们彼此粘结在一起,但此次没有中间框体。此时,那些位于半模表面的半成型品的部分彼此相互接触且优先焊接。如此设计模子和它们的闭合动作,是为了当半壳体被挤压在一起时,在焊接时材料能流入到合适的模腔,因此焊接的几何尺寸满足零部件强度和防止燃料渗透的要求。在连接工艺后,如果合适的话,在借助吹塑或热成型的进一步成型之后,箱体完全成型对应于本工艺技术要求的冷却时间。
图2A是本发明装置用于分开塑料型坯的图形。当塑料型坯从挤压设备(1)的模子中移出时,其成管状。一个任选的可冷却的物体(3)具有三角形横截面,与挤压方向成横向布置,用作切割装置或将塑料型坯分开的装置。该装置还包括可加热的保持件(4),切割装置已经连接在该保持件上。紧靠切割装置布置的两个气动从动辊(2)充当发明的驱动装置,紧靠物体(3)安装具有下列优点,即在型坯分开之后,两个生成的型坯部分(6)立即与切割装置隔开一定距离,从而避免半成型板粘接到所述装置上。从动辊(2)施加的拉力在切割装置上恒定地引导塑料型坯,所以生成的半成型板没有皱折或参差不齐,或具有相当少的皱折或参差不齐,特别是在边缘处,即在切割边缘处。
图2B是本发明的另一个用来分开塑料型坯的装置的图。图2中所示的装置不同于图1的装置,其不同处仅仅在于两个另外安装的导辊(5),这些导辊消除了在分开工序之后在半成型品(6)之间不期望的接触,并且还为将要引入的零部件和装置提供了期望的自由空间。导辊(5)可以横向于挤压方向移动,导辊横向于挤压方向上的可移动性允许对获得的半成型品之间的距离设定进行控制。图2的装置中的从动辊(2)设置在或集成到切割装置(3)中。
图3示出了当没有使用本发明的装置时的型坯的变形(没有驱动装置),这提供了生成的切割边缘以及半成型品本身的相当大的变形。
图4示出了本发明的装置以及所生成的被分开的型坯或生成的半成型板。它们没有皱折或参差不齐,特别在边缘处,即在切割边缘处。被加工的聚合物与图3中的相同。
图5示出了在两个半模壳(7)之间的中间框体(8)。
Claims (21)
1.一种用于生产空心塑料制品的工艺,包括如下步骤:
a)通过挤压或共挤压生产管状塑料型坯;
b)切开塑料型坯形成两平面部件;
c)在两半模中成型平面部件以形成半壳体,其中可移动的中间框体至少沿周围边缘将两半模彼此分开,因此半成型品/半壳体彼此不接触;
d)打开所述半模并且移去中间框体;
e)关闭所述半模,从而半壳体沿着周围轮缘与另一个接触;并且
f)连结半壳体形成空心成品。
2.如权利要求1所述的工艺,其特征在于,在移去中间框体后,合并部分可被连接到至少一个成型的半壳体的内部。
3.如权利要求2所述的工艺,其特征在于所述合并部件例如是用于在箱体中保持压力平衡的通风管线、用于在箱体中保持液体平衡的燃油管线、阀、防喘振杯,或者相关的泵和/或箱体传感模块。
4.如上述任一权利要求所述的工艺,其特征在于通过热成型法和/或吹塑法,在半模中将平面部件成形为半壳体。
5.如上述任一权利要求所述的工艺,其特征在于通过粘接和/或焊接对半壳体进行连结。
6.如权利要求5所述的工艺,其特征在于来自热成型的热量被用来焊接半壳体。
7.如上述任一权利要求所述的工艺,其特征在于在半壳体的粘接之后,借助热成型法和/或吹塑法进一步成型空心塑料制品。
8.如上述任一权利要求所述的工艺,其特征在于所用的中间框体包括平板型隔板,该平板型隔板基本上完全填充两个半模之间的区域。
9.如上述任一权利要求所述的工艺,其特征在于中间框体具有冷却或加热的设备。
10.如上述任一权利要求所述的工艺,其特征在于中间框体具有对成型的半壳体边缘进行控制加热的设备。
11.如上述任一权利要求所述的工艺,其特征在于中间框体具有用来加热至少一个半模的夹断边缘的装置,优选具有用来加热两个半模的夹断边缘的装置。
12.如上述任一权利要求所述的工艺,其特征在于中间框体或平板型隔板设计为单个部件或多个部件。
13.如上述任一权利要求所述的工艺,其特征在于其在没有其它加热步骤或冷却步骤的情况下进行。
14.如上述任一权利要求所述的工艺,其特征在于在剪开塑料型坯的过程中,使用滚筒型的从动单元,优选从动导向托辊,用于在切割装置上的恒定引导。
15.如上述任一权利要求所述的工艺,其特征在于在从模子分开之前切割塑料型坯,即在挤压工艺完成之前或在其之后立即进行切割。
16.如上述任一权利要求所述的工艺,其特征在于塑料型坯至少有一层由聚合材料制成,聚合材料优选地选自聚乙烯、聚丙烯、聚氯乙烯、聚酰胺、聚酮、聚酯及它们的混合物。
17.如上述任一权利要求所述的工艺,其特征在于塑料型坯具有包括两层或多层的结构,优选地包括底层、再研磨层、增粘剂层和/或阻隔层。
18.如上述任一权利要求所述的工艺,其特征在于塑料型坯具有包括两层或多层的结构,其从外到内包括:
由HDPE制成的层,其占厚度的5%到30%,
再研磨层,其占厚度的10%到82%,
增粘剂层,其占厚度的1%到5%,
阻隔层,其占厚度的1%到10%,
增粘剂层,其占厚度的1%到5%,
由HDPE制成的层,其占厚度的10%到40%,
上述所有情况下百分比是基于容器壁总厚度作出的。
19.一种用于生产空心塑料制品的工艺,包括如下步骤:
a)通过挤压或共挤压生产管状塑料型坯,包括至少一个由聚合材料制成的层,聚合材料优选地选自聚乙烯、聚丙烯、聚氯乙烯、聚酰胺、聚酮、聚酯及它们的混合物;
b)通过合适的切割装置切开塑料型坯形成两平面部件,使用从动导向托辊,用于在切割装置上恒定引导型坯;
c)在两半模中成型平面部件以形成半壳体,其中可移动的中间框体至少沿周围边缘将两半模彼此分开,因此半成型品/半壳体彼此不接触;
d)打开所述半模并且移去中间框体;
e)关闭所述半模,从而半壳体沿着周围轮缘与另一个接触;并且
f)焊接所述半壳体形成空心成品。
20.一种空心塑料制品,其能由权利要求1到19中任一个所述的工艺生产。
21.通过权利要求1到18中任一个所述的工艺获得的空心塑料制品,把它作为机动车辆上的塑料油箱使用,或者作为用于储存或运输燃料油、柴油或其类似物的汽油罐或塑料桶使用,或者作为多用途车辆上的运输容器使用,例如用于作物喷射器,或者作为溶剂容器、塑料瓶或类似物使用。
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- 2003-07-09 AU AU2003250916A patent/AU2003250916A1/en not_active Abandoned
- 2003-07-09 WO PCT/EP2003/007353 patent/WO2004007182A1/en active Application Filing
- 2003-07-09 CN CNB038166224A patent/CN100548640C/zh not_active Expired - Lifetime
- 2003-07-09 KR KR1020097022247A patent/KR20090128510A/ko not_active Application Discontinuation
- 2003-07-09 US US10/520,536 patent/US20060141184A1/en not_active Abandoned
- 2003-07-09 EP EP20030763751 patent/EP1534496B1/en not_active Expired - Lifetime
- 2003-07-09 JP JP2005505060A patent/JP2005532204A/ja active Pending
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2012
- 2012-09-28 US US13/631,610 patent/US8617344B2/en not_active Expired - Lifetime
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CN104802365A (zh) * | 2009-12-09 | 2015-07-29 | 赫斯基注塑系统有限公司 | 加工热流道系统的方法 |
CN102917857A (zh) * | 2010-03-08 | 2013-02-06 | 英瑞杰汽车系统研究公司 | 基于两个片材制造塑料空心体的工艺和设备 |
CN102917857B (zh) * | 2010-03-08 | 2016-03-16 | 英瑞杰汽车系统研究公司 | 基于两个片材制造塑料空心体的工艺和设备 |
US9527225B2 (en) | 2010-03-08 | 2016-12-27 | Inergy Automotive Systems Research (Societe Anonyme) | Process and equipment for manufacturing a plastic hollow body from two sheets |
CN102294816A (zh) * | 2010-06-24 | 2011-12-28 | 考特克斯·特克斯罗恩有限公司及两合公司 | 用于由热塑性材料制造中空体的方法以及用于执行所述方法的装置 |
CN104105587A (zh) * | 2012-02-02 | 2014-10-15 | 考特斯机械制造有限公司 | 用于制造塑料制品的方法以及吹塑模具的部件 |
CN104105587B (zh) * | 2012-02-02 | 2016-10-12 | 考特斯机械制造有限公司 | 用于制造塑料制品的方法以及吹塑模具的部件 |
US9511530B2 (en) | 2012-02-02 | 2016-12-06 | Kautex Maschinenbau Gmbh | Method for producing a plastic article, and part of a blow-mould |
CN108372670A (zh) * | 2018-02-09 | 2018-08-07 | 佛山市顺德区瑞良塑料制品有限公司 | 一种塑料瓶子的生产方法及生产装置 |
CN111136895A (zh) * | 2019-12-31 | 2020-05-12 | 彭磊 | 一种涂抹涂料用防溅涂料桶材料的制备方法 |
Also Published As
Publication number | Publication date |
---|---|
WO2004007182A1 (en) | 2004-01-22 |
JP2005532204A (ja) | 2005-10-27 |
US20060141184A1 (en) | 2006-06-29 |
CN100548640C (zh) | 2009-10-14 |
EP1534496A1 (en) | 2005-06-01 |
US8617344B2 (en) | 2013-12-31 |
AU2003250916A1 (en) | 2004-02-02 |
US20130025778A1 (en) | 2013-01-31 |
KR20090128510A (ko) | 2009-12-15 |
EP1534496B1 (en) | 2010-10-27 |
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