DE102015016540A1 - Method for producing a fuel tank with at least one inner component and motor vehicle with such a fuel tank - Google Patents

Abstract

The invention relates to a method for producing a fuel tank (1) having at least one inner component (3), wherein the component (3) is arranged on a carrier element (5), wherein the carrier element (5) has a greater extent at least in one direction as the component (3), and wherein the carrier element (5) on a first wall surface (7) of the fuel tank (1) is fixed.

Description

The invention relates to a method for producing a fuel tank and a motor vehicle with such a fuel tank.

Usually, plastic fuel tanks are made by blow molding. If components are placed in such containers during blow molding or blow molding, there is a risk that they will be damaged by the manufacturing process. In addition, no protection can be offered in the manufacturing process, so that such a component can exceed positional and form tolerances.

From the German patent application DE 103 35 045 A1 For example, a fuel tank with an internal swirl pot is known, which is biased against a bottom of the fuel tank. Such a permanent ground contact of a component is also referred to as Bodenreferenzierung. Especially with such components, which should have a Bodenreferenzierung, there is a risk that no soil referencing can be ensured by high tolerances over an entire surface of the fuel tank during the blowing process.

Overall, it is difficult for internal components during the manufacturing process of such a fuel tank, on the one hand to protect against damage and on the other hand, a positional and form tolerance - especially with respect to a wall surface of the fuel tank.

The invention has for its object to provide a method for producing a fuel tank with at least one internal component and a motor vehicle with such a fuel tank, said disadvantages do not occur.

The object is achieved by providing the subject matters of the independent claims. Advantageous embodiments emerge from the subclaims.

The object is achieved in particular by providing a method for producing a fuel tank with at least one inner component, the component being arranged on a carrier element, and wherein the carrier element has a greater extent than the component at least in one direction. The carrier element is fixed to a first wall surface of the fuel tank. Due to the arrangement of the component on the carrier element, which is larger in at least one direction than the component, the component is protected during manufacture of the fuel tank in particular by blow molding. Characterized in that the carrier element is fixed to a wall surface of the fuel tank, wherein, at the same time, the component is arranged on the carrier element, it is possible to arrange the component in a predetermined relative position to the wall surface in the interior of the fuel tank, said Wandungsflächenreferenzierung during the manufacturing process of Fuel tank and also retained thereafter. In particular, the carrier element ensures a permanent Wandungsflächenreferenzierung of the component.

The fact that the component is arranged on the carrier element means, in particular, that it is arranged in an immediate environment, in particular in the immediate vicinity, to the carrier element. This ensures that the component is protected by the carrier element during the manufacturing process.

It is preferably provided that the component is fastened to the carrier element. This allows for a particularly secure protection for the component and on the other hand a particularly defined and durable Wandungsflächenreferenzierung.

In the context of the method, a fuel tank is preferably obtained, which has the at least one internal component.

A fuel tank is understood in particular to mean a vessel which is set up and suitable for receiving a fuel, in particular for operating a motor vehicle. In this case, a fuel is understood in particular to mean a substance which is combustible and suitable for combustion in an internal combustion engine.

It can be a gaseous or liquid fuel under normal conditions. Preferably, the fuel tank is configured and adapted to receive a liquid fuel, in particular diesel or gasoline. Particularly preferably, the fuel tank is designed as a fuel tank for a passenger car, but it can also be designed as a fuel tank for a truck or a commercial vehicle. It is also possible that the fuel tank is designed as a fuel tank for a stationary internal combustion engine.

The fuel tank preferably has plastic or consists - at least in the region of its wall - of plastic.

A support element is understood in particular to mean an element which is set up and arranged in order to provide the fuel tank with mechanical and in particular static stability to lend. The carrier element may be a support, a carrier, a strut or a column.

The fact that the carrier element at least in one direction has a greater extent than the component means in particular that the carrier element projects beyond the component in at least one direction. In particular, the carrier element is preferably seen along a longitudinal direction of the carrier element and preferably also of the component longer than the component.

Under a wall surface of the fuel tank is in particular a surface understood, which limits the fuel tank to the outside, that separates an interior of the fuel tank from an external environment. The wall surface may be designed in particular as a bottom surface, as a ceiling surface or as a side surface of the fuel tank. The terms "floor", "ceiling" and "side" refer to a proper, correct position installation of the fuel tank to an internal combustion engine and / or in a motor vehicle.

The fact that the carrier element is fixed to the first wall surface of the fuel tank means, in particular, that it is fixed to the first wall surface. The carrier element is preferably fixed to the first wall surface in a force, material, and / or form-fitting manner. Particularly preferably, the carrier element is rigidly connected to the first wall surface.

According to one embodiment of the invention, it is provided that the carrier element is welded to the first wall surface. This means a simple as well as safe and stable fixing of the support member to the first wall surface.

According to a development of the invention, it is provided that the carrier element is additionally fixed to a second, second wall surface, viewed opposite to one of the first wall surface in the direction of a longitudinal extension of the carrier element. In this case, "fixing" here again in particular means a fixation, in particular a force, material, and / or positive fixation of the carrier element on the second wall surface. In particular, the carrier element is preferably connected rigidly to the second wall surface.

Accordingly, the support element preferably extends from the first wall surface through the interior of the fuel tank to the opposite, second wall surface. As a result, the carrier element gives the fuel tank stability and rigidity. In particular, the opposite wall surfaces are thus locally rigidly connected to one another by the carrier element. At the same time, the carrier element can protect the component in a particularly efficient manner during blow molding.

According to one embodiment of the invention, it is provided that the component is arranged on the carrier element, in particular fastened, that it is in touching contact with the first wall surface after the fixing of the carrier element to the first wall surface. In this way, a stable and permanent referencing of the component to the first wall surface can be ensured. Particularly preferably, the component is fixed to the carrier element so that it rests on the first wall surface after being fixed thereto.

According to one embodiment of the invention, it is provided that the carrier element has at least one welding foot, wherein the component is arranged adjacent to the welding foot on the carrier element. In this case, a welding foot is understood to be a region which is designed and set up to form a welded connection between the carrier element and the first wall surface. In the area of such a welding foot, particularly small tolerance deviations arise in the production process of the fuel tank, in particular during blow molding. Thus, manufacturing tolerances in the manufacture of the fuel tank for the arrangement of the component hardly relevant, and it can be a permanent and secure Wandungsflächenreferenzierung be ensured for the component when it is disposed adjacent to the welding foot. Preferably, the component is arranged as close as possible to the welding foot. The closer the component is arranged to the welding foot, the less relevant are possibly still manufacturing tolerances, since tolerance deviations become smaller, the closer an area of the first wall surface is arranged on the welding foot.

According to one embodiment of the invention it is provided that the carrier element is fixed to a bottom surface of the fuel tank as the first wall surface. In this case, a continuous Bodenreferenzierung for the component can be guaranteed.

Preferably, it is additionally provided that the carrier element is fixed to a ceiling surface of the fuel tank as a second wall surface. The support member is then fixed with its two ends on the one hand at the bottom of the fuel tank and on the other hand to the ceiling of the fuel tank, in particular welded, so that the floor and the ceiling with each other locally Area of the support element are rigidly connected. As a result, the fuel tank in this area has a particularly high stability, and the component is very efficiently protected from damage during blow molding, while at the same time a permanent, continuous Bodenreferenzierung for the component can be ensured.

According to one embodiment of the invention, it is provided that the fuel tank is formed by blow molding, wherein the support element is set before the blow molding, during blow molding, or after the blow molding on the first wall surface. In this case, the advantage of a continuous Wandungsflächenreferenzierung for the component in all three embodiments is realized. Protection against damage during blow molding for the component is ensured, in particular, when the carrier element is attached to the first wall surface before blow molding or during blow molding.

According to one embodiment of the invention it is provided that a fill level sensor or a swirl pot is attached to the carrier element as a component. In particular, level sensors are possible which measure a fuel level in the fuel tank via electromagnetic fields. These require a continuous soil referencing in order to permanently detect the fill level correctly. Even a swirl pot requires a continuous and permanently stable soil referencing.

In this respect, realize the advantages of the process in these elements as components in a special way.

Finally, the object is also achieved by providing a motor vehicle having a fuel tank, which is manufactured according to a method according to one of the previously described embodiments. In particular, the advantages which have already been explained in connection with the method are realized in connection with the motor vehicle.

The invention will be explained in more detail below with reference to the drawing.

Showing:

1 a schematic representation of an embodiment of a method for manufacturing a fuel tank, and

2 an embodiment of a fuel container produced by the method.

1 shows a method for producing an in 2 illustrated fuel tank 1 with at least one internal component 3 , In the process, the component becomes 3 initially on a support element 5 attached. The carrier element 5 has at least in one direction a greater extent than the component 3 , In 1 protrudes beyond the carrier element 5 the component 3 especially in the vertical direction, thus in the vertical direction.

As part of the process, the support element 5 on a first wall surface 7 of the fuel tank 1 fixed, especially welded there.

In 1 is shown that preferably first an oval circled here assembly 9 from the carrier element 5 and the component attached thereto 3 which is exemplified here by a first robot arm 11 is held. Through a second robot arm 13 becomes a lower shell 17 for the fuel tank 1 held, which is the first wall surface 7 having a bottom surface of the fuel tank 1 forms.

Through a third robot arm 15 becomes an upper shell here 19 for the fuel tank 1 held, which has a second wall surface 21 having a ceiling surface of the fuel tank 1 forms.

Preferably, the support element is now first 5 with the first wall surface 7 welded, especially in the area of a lower welding foot 23 , In addition, the carrier element 5 at the first wall surface 7 in the direction of a vertical longitudinal extent of the carrier element 5 opposite, second wall surface 21 welded, preferably also in the region of an upper welding foot 25 ,

The fuel tank 1 is preferably formed by blow molding. In doing so, the assembly becomes 9 preferably before or during the blow molding process on the wall surfaces 7 . 21 established.

2 shows a schematic representation of an embodiment of a fuel tank 1 manufactured according to the previously described embodiment of the method. Identical and functionally identical elements are provided with the same reference numerals, so that reference is made to the preceding description. Here it becomes clear that the component 3 inside with respect to the fuel tank 1 is arranged, so in an interior 27 of the fuel tank 1 ,

It also becomes clear that the component 3 so on the support element 5 it is established that it after fixing the carrier element 5 on the first wall surface 7 is in touching contact with this. In particular, the component stands 3 here on the floor surface as the first wall surface 7 on. By attachment to the support element 5 it has a continuous, permanently stable soil referencing.

By two ovals are here two welding areas 29 . 31 highlighted in which the carrier element 5 with his sweaty feet 23 . 25 on the wall surfaces 7 . 21 fixed, in particular welded to these. It also becomes clear that the component 3 as close as possible to the welding foot 23 , in particular adjacent thereto, on the carrier element 5 is arranged. It turns out that tolerance deviations during blow molding of the fuel tank 1 in the area of the welding foot 23 are particularly low, so that a suitable, continuous and permanently stable soil referencing of the component 3 can be guaranteed.

The component 3 is preferably designed as a level sensor or as a swirl pot.

The fuel tank 1 is particularly preferred a fuel tank of a vehicle only schematically indicated here 33 ,

Overall, it turns out that with the method a possibility is created, in a simple, cheaper and process-safe manner, a site-side Bodenreferenzierung and protection in the manufacturing process for an internal component 3 a fuel tank 1 manufacture. This can be a protected installation of the component 3 in the fuel tank 1 be ensured. Furthermore, a continuous soil referencing is also taking into account tolerances and swells in the fuel tank 1 ensured.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 10335045 A1 [0003]

Claims (9)

Method for producing a fuel tank ( 1 ) with at least one internal component ( 3 ), wherein the component ( 3 ) on a carrier element ( 5 ) is arranged, wherein the carrier element ( 5 ) at least in one direction has a greater extent than the component ( 3 ), and wherein the carrier element ( 5 ) on a first wall surface ( 7 ) of the fuel tank ( 1 ). Method according to claim 1, characterized in that the carrier element ( 5 ) with the first wall surface ( 7 ) is welded. Method according to one of the preceding claims, characterized in that the carrier element ( 5 ) on one of the first wall surface ( 7 ) in the direction of a longitudinal extent of the carrier element ( 5 ) opposite, second wall surface ( 21 ). Method according to one of the preceding claims, characterized in that the component ( 3 ) so on the support element ( 5 ) is arranged, that after fixing the carrier element ( 5 ) at the first wall surface ( 7 ) in touching contact with the first wall surface ( 7 ). Method according to one of the preceding claims, characterized in that the carrier element ( 5 ) at least one welding foot ( 23 . 25 ), wherein the component ( 3 ) the welding foot ( 23 . 25 ) adjacent to the carrier element ( 5 ) is arranged. Method according to one of the preceding claims, characterized in that the carrier element ( 5 ) on a floor surface ( 7 ) of the fuel tank ( 1 ) as the first wall surface ( 7 ), and preferably on a ceiling surface of the fuel tank ( 1 ) as second wall surface ( 21 ). Method according to one of the preceding claims, characterized in that the fuel tank ( 1 ) is formed by blow molding, wherein the carrier element ( 5 ) before blow molding, during blow molding, or after blow molding on the first wall surface ( 7 ). Method according to one of the preceding claims, characterized in that as component ( 3 ) a level sensor or a swirl pot on the carrier element ( 5 ) is arranged. Motor vehicle ( 33 ), with a fuel tank ( 1 ) produced by a method according to any one of claims 1 to 8.

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