CN1988994A - 用于将附件固定在塑料燃料箱内的方法 - Google Patents

用于将附件固定在塑料燃料箱内的方法 Download PDF

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CN1988994A
CN1988994A CNA2005800249668A CN200580024966A CN1988994A CN 1988994 A CN1988994 A CN 1988994A CN A2005800249668 A CNA2005800249668 A CN A2005800249668A CN 200580024966 A CN200580024966 A CN 200580024966A CN 1988994 A CN1988994 A CN 1988994A
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annex
orifice
plastic
casing
mould
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CN100569489C (zh
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比约恩·克里埃尔
尤勒斯-约瑟夫·范沙夫廷根
帕斯卡尔·德埃诺
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Nergy Automotive Systems Research SA
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Inergy Automotive Systems Research SA
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • 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
    • B60K15/03177—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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    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/20—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/60—Riveting or staking
    • B29C65/606—Riveting or staking the rivets being integral with one of the parts to be joined, i.e. staking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C66/61—Joining from or joining on the inside
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/81427—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
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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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81431—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single cavity, e.g. a groove
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29D22/00—Producing hollow articles
    • B29D22/003—Containers for packaging, storing or transporting, e.g. bottles, jars, cans, barrels, tanks
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/20—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
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    • B29C66/81417—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being bevelled being V-shaped
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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
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Transportation (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Energy (AREA)
  • Sustainable Development (AREA)
  • Cooling, Air Intake And Gas Exhaust, And Fuel Tank Arrangements In Propulsion Units (AREA)
  • Details Of Rigid Or Semi-Rigid Containers (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

本发明涉及用于将附件(4)铆合固定在塑料燃料箱内的方法，其中：附件(4)设置有至少一个垂直穿过该附件(4)的注孔(5)；将至少部分的用来制成箱体(1)的壁的塑料熔化；以及，使部分熔化塑料在与该熔化塑料的剩余部分没有分开的情况下通过该附件的注孔(5)；突出的熔化塑料呈适当的外形(8)而获得自成型的塑料铆钉，并放置以固化；注孔(5)和/或固化塑料(8)的尺寸和外形是这样的，其使附件(4)通过至少部分的固化塑料(8)被机械地固定至箱体，所述附件(4)的铆合紧固发生在通过对开模或至少两部分型坯的模塑成型来制造箱体(1)的同时。

Description

用于将附件固定在塑料燃料箱内的方法
本发明涉及一种用于将附件固定在塑料燃料箱内的方法。
在各种类型的机动交通工具上的燃料箱通常必须满足与其被设计的应用类型相关的不渗透性和渗透性标准及其必须达到的环境方面的要求。目前，在欧洲以及全世界，正经历涉及限制将污染物排入大气和通常环境中的相当严格化的要求。因此，燃料箱的设计迅速向在变化的使用条件下能够更好保证不渗透性和安全性的技术方向发展。此外，还努力尝试将由于与箱体相关的管道和各种附件所导致的损失减小到最小程度。有时使用的一种方法是将某些附件和管件与箱体进行整合，从而消除它们与外部环境的界面。作为优选方案，这些零件被固定在箱体的内壁上但并不穿过内壁，以避免损坏通常存在于这些箱体中的阻挡层(隔离层，barrier layer)和消除与用于密封设备的部件相关的泄漏危险。
因此，以申请人公司名义的专利申请WO 01/60592披露了一种通过模塑成型的两个外壳(加以组装)来制造塑料燃料箱的方法，至少一个外壳的模塑是通过压缩在模具和冲床之间的部分塑料薄片和通过吹塑在区域中未被压缩的薄片的剩余部分来完成的。这种方法的优点在于，其使得一个或多个附件很容易地被包含在箱体的内部，由于下文提到的渗透性原因，优选焊接在箱体的内表面上。这种固定技术较简单，但令人遗憾的是，这种技术局限于这样的附件，其基础面的至少一部分是由与箱体相同的塑料(通常为HDPE)或至少与其相容的塑料制成的。目前，大量附件基于金属或基于不同于箱体的塑料，具有改进的硬度、尺寸稳定性以及对于碳氢化合物如聚缩醛(尤其是聚甲醛或POM)、聚酰胺、可能为玻璃纤维增强的聚酰胺、聚丁烯对苯二甲酸酯(PBT)等的不可渗透性。在该专利申请中提出的可替换固定技术在于，将附件在其模塑成型时至少部分地用部分薄片加以覆盖。然而，这样的实施耗用大量的材料并且有时需要对附件进行显著改进。此外，当箱体的外壳冷却时，这种技术会产生变形和内部张力。
因此，本发明的目的是提供一种方法，其允许将基于与箱体材料不同的材料的附件固定在塑料燃料箱内部，并且是快速、容易地被固定，同时无需消耗过量的材料以及没有损坏阻挡层的危险或产生过度内部张力的危险。
本发明基于利用以下事实的构思，即型坯在其模塑成型过程中被熔化，并且可以被打开(即，对开模(split)或由两个可相互分开的独立部分构成)使得附件可以被铆合固定(stake-fastening)在其中。在中请US 5,308,427中使用了这种固定技术，其仅为了将附件固定在现有(已经制造)的必须局部加热(使用热气或注入熔化材料)的燃料箱内。由于是在生产之后进行固定，所以不可能利用材料的局部熔化。因此，该技术需要外部加入材料，具有内在的不均匀性的危险。此外，在具有EVOH(乙烯和部分水解的醋酸乙烯酯的共聚物)层的多层箱体(通常由高密度聚乙烯(HDPE)制成)的情况下，有必要小心不会损坏阻挡层的连续性。因此，有必要局部地焊穿(melt through)整个厚度。这种加热步骤冗长并且消耗能量，此外，会出现变形和局部张力。
因此，本发明涉及一种用于将附件铆合固定在塑料燃料箱内的方法，其中：
-附件设置有至少一个垂直穿过该附件的注孔；
-至少部分形成箱体的壁的塑料被熔化；和
-使部分的熔化塑料在没有与该熔化塑料的剩余部分分开的情况下通过该附件的注孔；
-突出的熔化塑料具有合适的外形而获得自成型(self-formed)的塑料铆钉，并放置以固化；
所述注孔和/或固化的塑料的尺寸和外形是这样的，其使附件通过至少部分的固化塑料被机械地固定至箱体，附件的铆合紧固发生在通过对开模或至少两部分的型坯的模制成型来制造箱体的同时。
术语“燃料箱”是用来指在不同和变化的环境条件下以及使用条件下能够储存燃料的密封箱体。这种箱体的实例为适用于机动车辆的箱体。
根据本发明的方法生产的燃料箱由塑料制成，也就是说，其由包含至少一种合成树脂聚合物的材料制成。
各类塑料都可以是合适的。特别合适的塑料来自热塑性塑料类。
术语“热塑性塑料”是指任何热塑性聚合物，包括热塑性弹性体及其混合物。术语“聚合物”指均聚物和共聚物(尤其是二元或三元共聚物)。这样的共聚物的实例为但不限于无规共聚物、线性嵌段共聚物、其它嵌段共聚物和接枝共聚物。
熔点低于分解温度的任何类型的热塑性聚合物或共聚物是合适的。熔程范围超过至少10℃的合成热塑性塑料尤其适合。这样的材料的实例包括分子量呈多分散性的那些材料。
更具体地，可以使用聚烯烃、热塑性聚酯、聚酮、聚酰胺及其共聚物。也可以使用聚合物或共聚物的混合物，如同可以是聚合物材料与无机、有机和/或天然填料例如但不限于碳、盐和其它无机衍生物、天然纤维或聚合物纤维的混合物。还可以使用由粘合在一起的叠加层构成的多层结构，其包括上述聚合物或共聚物中的至少一种。
经常使用的一种聚合物是聚乙烯。使用高密度聚乙烯(HDPE)已经获得优异的结果。作为优选，箱体还包含一个对于燃料是不可渗透的树脂层，例如EVOH(乙烯聚合物和部分水解的醋酸乙烯酯的共聚物)。可替换地，也可以进行表面处理(氟化或磺化)，其目的是使其对燃料是不可渗透性的。
“附件(配件，accessory)”是用来指：
●通常与传统使用模式或操作模式的燃料箱有关的对象或功能性装置，并且其相互组合而实现某些有用的功能；或
●用于一个或多个这样的装置的支架(support)。
这样的装置的非限制性实例是：液泵、液位计、吸管(移液管)、燃料箱内部的箱子或挡板、通风装置、电子装置以及加固条。
根据本发明方法的一个有利的具体实施方式，附件实际上是预装配结构，其包括支架和通过任何合适固定方式固定的一个或多个相同或不同的装置。这些方式的实例为夹持、螺钉连接、焊接等。预装配结构还有利地具有用于允许后来添加的其它装置与其连接的装置。这些装置也是夹持装置、允许拧紧的螺纹孔或环形螺纹突起、适于焊接的表面区域等。同样地，附件可以由包括适合用于以后连接一个或多个装置的装置的单个支架构成。换句话说，作为优选，附件包括这样的支架，该支架或者设置有用于燃料箱的一个或多个功能装置(其可以是附件的盖子)的固定装置或者直接带有一个或多个这样的装置。在这种情况下，用于铆合固定的附件的注孔优选位于支架上
根据本发明，附件包括垂直穿过其壁并且允许实施“铆合”技术的注孔(orifice)(孔)。这种技术在于强制使熔化的塑料穿过注孔并且使熔化的塑料突出在所述材料进入注孔的相对侧上，同时呈合适外形的突出塑料，这样的外形使其相当于“自成型”的塑料铆钉(即，其从箱壁由熔化塑料在原位形成铆钉)。这种外形通常为平台(plateau)外形。
注孔可以具有任意外形。然而，它的横截面(平行于附件壁的截面)通常不是固定的而是将以形成合适外形的容积(用于由熔化的塑料填充)的方式加以变化，以便一旦所述材料固化后就形成不可拆卸的机械连接。此外，横截面(及其沿着垂直于附件壁的平面的变化)的外形优选地以使其更容易地让材料穿过注孔的方式加以调整，为此使用合适的工具(插入物(insert))。
从技术角度来说，通常也有利地将熔化塑料设计为不完全填满注孔，并借助合适的工具(阻挡物(counterform))来达到该目的。这种方法允许在不产生应力的情况下的待容纳塑料的体积变化(冷却时的收缩，与燃料接触时的膨胀)。在这种情况下，平台将优选具有或多或少的椭圆形(而其通常在外形上为或多或少的圆形，有时如同注孔的顶部)或半椭圆形(如果通过注孔的材料流只是在一个侧面上被阻止，则可能会是有利的方面，因为在汽油存在下收缩通常比膨胀更大)，然后注孔也优选具有或多或少的椭圆形。上文提到的工具(插入物、模具中的阻挡物)优选被冷却，以便实际上加速附件的固定并且使得组合的箱体(包括至少一个固定的附件)的制造速度被增加。
通常，在根据本发明的方法中，必须借助多个铆合注孔(stakingorifice)。这些注孔实际上非常微小(pinpoint-like)，即与附件的尺寸相比，其尺寸较小。通常，其尺寸为约数mm(10mm或更小)的数量级。
有利的具体实施方式对于椭圆或半椭圆形式的铆合注孔以尺寸变化的方向进行定位。这些变化通常沿着相交于在各个注孔中心的点的直线发生。在(或多或少的)椭圆形注孔的情况下，实现这一点的一种方式是以这样的方式布置所述注孔，其使得垂直于附件在注孔处的表面的平面和包含其纵轴的平面沿着该相同轴相交(即，沿着同一直线，这种类型的直线构成附件的对称轴)。当各个注孔的纵轴处于同一平面内时，这就是说，这些轴大约相交于在其中心的点处。这种方法使附件不会变形或相对于各个注孔的中心不会有过多的偏移。
在根据本发明的方法中，将在用于固定附件的位置处的形成箱体壁的塑料熔化(事实上也就是在半结晶聚合物如HDPE的情况下真正发生熔化，但是事实上在非晶态聚合物的情况下是塑化/软化)。然后，使糊状材料在没有与箱体壁分开的情况下强制穿过附件的注孔，并且在那里加以固化。如前所述，注孔和/或固化的塑料的尺寸和外形是这样的，其使得附件通过至少部分的固化塑料被机械地固定至箱体。
在通过模塑制造箱体的同时，附件通过根据本发明的方法被固定。这种方法在实践中可以通过以下事实实现：由对开模或至少两部分的型坯开始进行模制。更具体地说，有利地，铆合紧固在模制箱体的同时完成，其中模制箱体通过如下步骤：
●热成型薄片；
●压缩/吹塑薄片(如在前述申请WO 01/60592中所描述的，其内容也结合于本申请作为参考)；
●吹塑包含至少一个切口(cut-out)的型坯(如在专利申请EP1110697中所描述的，其内容结合于本申请作为参考)。
当通过热成型薄片(一种基本上采用由两个模腔构成的模具的技术)来制造箱体时，铆合固定可以通过自动装置(机器人)来完成，该自动装置将附件引入其中插入了薄片的模具的两部分之间，并且紧靠这些薄片推动附件以完成铆合固定。在这种情况下，上述提到的工具(插入物、模具中的阻挡物)可以整合到机械手中。
当通过吹塑或压缩/吹塑(其为同时使用型芯(core)和由模腔适当构成的实际模具的两种技术)制造箱体时，铆合固定优选借助于在模具侧面上的插入物(以使材料强制穿过注孔)和通过在型芯侧面上的撞锤致动的阻挡物(以使突出穿过注孔的材料变形)来完成。
通过吹塑(在包括型芯和模腔的模具中)制造应用这种附件的箱体和固定附件的方法，通常按下列步骤进行：
●将附件定位在型芯上；
●初始闭合模具(使模腔围绕型芯)；
●将对开模或至少两部分的型坯(或由熔化状态的塑料制成的燃料箱的壁)挤压在模具的模腔上(通过吹塑穿过型芯和在模腔后施加抽气)；
●推进固定至型芯的液压撞锤以完成铆合；
●用气针插入型坯；
●脱气、打开模具、取出型芯，再次闭合模具，并以传统方式进行吹制。
在该方法的过程中，理所当然存在在脱气之前、期间和/或之后可以进行的液压撞锤的缩回。还存在用来防止型坯的各部分的切口或边缘在模具初始闭合(为了实施铆合固定)的过程中被焊接在一起的装置。为了实现该目的，模具的模腔有利地提供有热调节装置，其允许该区域在涉及初始闭合模具的步骤的过程中被加热。这样的装置被描述在例如以申请人公司名义的专利申请FR 04.13407中，其内容结合于本申请作为参考。
在这个方法中，插入物优选带有呈道钉(spike)外形的突起，形成的角度优选为30°和60°之间，或者甚至为40°和50°之间，理想地为约45°，从而有助于制成壁的材料流过注孔。角度的任何陡变区可以提供有圆形半径以在铆合阶段期间使流动最佳化，同时防止箱体的阻挡层(如果存在)发生破裂。
考虑到强化在附件和箱体壁之间的机械连接，阻挡物优选借助于液压撞锤将压力不仅施加至附件本身而且至少部分地施加至围绕附件的箱体的壁的熔化塑料，以有助于将其压实。
本发明还涉及一种塑料燃料箱，其装配有至少一个(用于支持)直接与部分的箱体壁接触的附件，并且设置有多个大约为椭圆形的注孔，在该注孔中和其上存在有与箱体壁相同的塑料，这些注孔以这样的方式排列，其使得垂直于附件在注孔处的表面的平面和包含后者的纵轴的平面相交于同一平面以及相同轴上。
在本发明的范围中，附件可以是基于与箱体壁的材料不同的材料。有利地，附件是基于至少一种与箱体的壁相容或兼容的材料(例如，尤其是通过适当的表面处理或可替换地通过用粘合的多重注塑与HDPE兼容的PA)，其在该附件开始接触待被固定至后者的箱体的熔化材料时，获得通过两种材料之间的化学键接而强化的机械固定和不透性。可替换地，附件可以由两种材料制成，一种提供尺寸稳定性，而另一种允许在附件和箱体壁之间的粘接。例如，由不同于HDPE的材料制成(例如由POM制成)的附件可以用HDPE多重注塑而成。
图1至图4用于举例说明本发明的某些具体方面，但不以任何方式限制本发明的范围。
图1和图2各自示出了通过在工艺中将附件铆合固定至其的箱体的截面(在这里，在垂直于箱体表面的平面上)，所述箱体在通过模塑成型制造的工艺中被制造，但是截面将其本身限定在所给几何图形的铆合点附近。图3和图4示出了在图1和图2的截面(分别在平面1-1’和2-2’上)中看到的成品箱体(带有附件)的内表面的视图。
图1和图2示出了一部分燃料箱(1)的壁，包括两层HDPE(2，2’)，每一层在EVOH(3)层的每一侧上，所述箱体在通过模塑成型的两部分型坯的工艺中被制造。设置有至少一个注孔(5)的附件(4)在该工艺中被铆合固定至该箱体壁(1)。箱体壁(1)的组成材料借助于固定在模具上的插入物被强制穿过注孔(5)，并在箱体内部通过由撞锤(未示出，但是在箭头的方向上起作用)操作的阻挡物(7)产生变形，以形成一种平台(8)，其突出于注孔(5)并且在没有撕裂/破坏平台(8)的情况下防止附件(4)移动。在这些操作结束时，平台(8)具有适合用于在接触燃料之前和之后固定附件希望的机械强度的尺寸。
插入物(6)和阻挡物(7)被冷却以便加速在注孔(5)周围的熔化塑料的固化。插入物(6)具有道钉外形的突起，形成的角度为约45°(参见图1)，有助于箱体壁(1)的构成材料流过注孔(5)。在图2中，角度的陡变区可以提供有圆形半径以在铆合阶段期间使流动最佳化，同时避免EVOH层发生破裂。
在图1中图解说明的情形下，平台(8)是圆形的，并且塑料占据了整个注孔(5)。
在图2中图解说明的情形下，圆形平台(8)通过在阻挡物(7)上的适当突起(9)而发生了变形(变为椭圆形)，变为这样的外形以减缓由在冷却箱体期间的收缩和通过在接触燃料后溶胀的膨胀所引起的尺寸变化。为了确保良好地填充该平台(8)，将阻挡物(7)设计为悬垂在附件(4)的上方(参见图中的部件(10))，并压靠在附件(4)附近的箱体壁(1)上。这种方法使得有可能增加在平台(8)处的内部压力，因此，增进了在平台(8)中的压实。
在带有附件的箱体内表面的全景图中，图3和图4分别图解说明了在这两种情况下平台(8)的各自外形。在图3中，看不见的注孔(5)是圆形的，而在图4中，注孔是椭圆形的。
在这些附图中图解说明的附件(4)包括使铆合(在这些附图中以三点铆合的形式加以图解说明)更容易的支架(4’)和本身固定至其的附件(4”)。在图4中可看出，椭圆形注孔(5)的轴(见虚线)相交在差不多是水平的附件(4’)的支架的中心。

Claims (11)

1.用于将附件(4)铆合固定在塑料燃料箱内的方法，其中：
所述附件(4)设置有至少一个垂直穿过所述附件(4)的注孔(5)；
至少部分的用于形成箱体(1)的壁的塑料被熔化；以及
使部分的所述熔化塑料在没有与所述熔化塑料的剩余部分分开的情况下强制通过所述附件的所述注孔(5)；
突出的所述熔化塑料呈合适的外形(8)而获得自成型的塑料铆钉，并放置以固化；
所述注孔(5)和/或所述固化塑料(8)的尺寸和外形是这样的，其使所述附件(4)通过至少部分的所述固化塑料(8)被机械地固定至所述箱体，其特征在于，所述附件(4)的铆合固定发生在通过对开模或至少两部分的型坯的模塑成型来制造所述箱体(1)的同时。
2.根据前述权利要求所述的方法，其特征在于，所述箱体是基于HDPE(高密度聚乙烯)(2，2’)的，并且包括EVOH层(乙烯和部分水解的醋酸乙烯酯的共聚物)(3)或者进行表面处理以使其对燃料是不可渗透性的。
3.根据前述权利要求中任一项所述的方法，其特征在于，所述附件(4)包括支架(4’)，该支架或者设置有用于一个或多个燃料箱的功能装置(4”)的固定装置，或者直接带有一个或多个这样的功能装置(4”)，并且其中，所述注孔(5)位于所述支架(4’)上。
4.根据前述权利要求中任一项所述的方法，其特征在于，所述熔化的塑料没有全部填满所述注孔(5)。
5.根据前述权利要求所述的方法，其特征在于，所述注孔(5)是椭圆形的，并且所述外形(8)是椭圆形或半椭圆形的平台。
6.根据前述权利要求所述的方法，其特征在于，所述附件(4)包括设置有多个椭圆形的注孔(5)的支架(4’)和多个椭圆形或半椭圆形的平台，并且其中，所述这些构件以这样的方式被布置，其使得所述注孔的纵轴大致相交于所述支架(4’)的中心的点处。
7.根据前述权利要求中任一项所述的方法，其特征在于，所述箱体是通过吹塑或压缩/吹塑并利用型芯和由模腔构成的模具来制成的，并且其中，所述铆合固定是借助在所述模具侧面上的插入物(6)和通过在型芯侧面上的撞锤驱动的阻挡物(7)来进行的。
8.根据前述权利要求所述的方法，其特征在于，所述方法包括以下步骤：
将所述附件(4)定位在所述型芯上；
初始闭合所述模具(模腔围绕所述型芯)；
将对开模或至少两部分的型坯(1)挤压在所述模具的模腔上(由通过所述型芯的吹制和在所述模腔后面进行抽气)；
推进所述撞锤以实施铆合；
用气针插入所述型坯(1)；
脱气，打开所述模具，取出所述型芯，再次闭合所述模具，并进行吹制。
9.根据权利要求7或8所述的方法，其特征在于，所述插入物(6)带有具有圆角的道钉外形的突起，并且形成的角度为约45°。
10.根据权利要求7至9中任一项所述的方法，其特征在于，所述阻挡物(7)借助于液压撞锤，将压力或者仅仅施加至所述附件(4)或者至少部分地施加至围绕所述附件(4)的所述箱体(1)的壁的所述熔化塑料上。
11.装配有至少一个(用于支撑)附件(4)的塑料燃料箱，其特征在于，所述附件(4)直接接触部分箱体(1)的壁，并且其中，其设置有多个大致为椭圆形的注孔(5)，在所述注孔(5)之中和之上存在有与所述箱体(1)的壁相同的塑料，这些注孔以这样的方式加以布置，其使得垂直于在所述注孔处的所述附件表面的平面和包含所述注孔(5)的纵轴的平面相交于一个轴并且在相同轴上。
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