DE102019120443A1 - Process for the production of an operating material container, molding tool, operating material container and motor vehicle - Google Patents

Abstract

The invention relates to a method for producing a fuel tank, in particular a fuel tank, the fuel tank having a built-in part and a plastic wall made from a preform, the preform being molded within a cavity formed by a multi-part molding tool using differential pressure to the fuel tank, with the multi-part molding tool has a manipulator and wherein the manipulator pulls the insert by means of a tensile force against the plastic wall produced from the preform, the insert optionally being welded to the plastic wall produced from the preform. The invention also relates to a molding tool, an operating material container and a motor vehicle .

Description

The invention relates to a method for producing an operating material container, a molding tool, an operating material container and a motor vehicle.

In particular, the invention relates to a method for producing a fuel tank, in particular a fuel tank, the fuel tank having a built-in part and a plastic wall made from a preform, the preform being molded within a cavity formed by a multi-part molding tool using differential pressure to the fuel tank, wherein the multi-part molding tool has a manipulator and wherein the manipulator pulls the built-in part against the plastic wall made from the preform by means of a tensile force, the built-in part optionally being joined, in particular welded, to the plastic wall made from the preform. Furthermore, the invention relates in particular to a molding tool having such a manipulator, which is set up to carry out the method, an operating material container produced in this way and a motor vehicle having a corresponding operating material container.

In the prior art, methods for the production of operating material containers are well known, including methods in which the operating material container produced has an insert and a plastic wall made from a preform, the insert being connected to the plastic wall.

As a result of increasing environmental standards, the requirements for the tightness of an operating material container and thus in most cases also the requirements for a connection between a built-in part and a plastic wall made from a preform are increasing.

In addition, the requirements for the tightness of an operating material container and thus the quality of a connection between the built-in part and the plastic wall of the operating material container are increased by the transformation to electromobility, since, due to the reduced usage behavior of some operating material containers, in particular a fuel tank, there are higher differential pressures between the usage cycles between the interior and the the environment.

The WO 2008/138869 A1 describes a method for producing a fuel tank which is equipped with an internal accessory and has a plastic wall made from a preform, the mold comprising cavities which are equipped with at least one movable part and wherein the pre-blown preform with the movable part locally against the Accessory is pressed to firmly connect the accessory to the preform without piercing the preform.

The invention is based on the object of providing an improvement or an alternative to the prior art.

• - Einbringen des Vorformlings in die Kavität des mehrteiligen Formwerkzeugs,
• - Einbringen des Einbauteils in die Kavität des mehrteiligen Formwerkzeugs,
• - Aufbringen einer Zugkraft auf das Einbauteil mittels dem Manipulator, wobei das Einbauteil gegen die aus dem Vorformling hergestellte Kunststoffwand gezogen wird, und
• - Entformen des Betriebsstoffbehälters.

According to a first aspect, the object is achieved by a method for manufacturing a fuel tank, in particular a fuel tank, the fuel tank having a built-in part and a plastic wall made from a preform, the plastic wall having an inner surface and an outer surface, the preform being within one of a multi-part Mold cavity formed is molded using differential pressure to the operating material container, wherein the multi-part mold has a manipulator, comprising the following steps, preferably in the order:

• - Introducing the preform into the cavity of the multi-part molding tool,
• - Insertion of the built-in part into the cavity of the multi-part mold,
• Applying a tensile force to the built-in part by means of the manipulator, the built-in part being pulled against the plastic wall produced from the preform, and
• - Demolding the operating material container.

• Zunächst sei ausdrücklich darauf hingewiesen, dass im Rahmen der hier vorliegenden Patentanmeldung unbestimmte Artikel und Zahlenangaben wie „ein“, „zwei“ usw. im Regelfall als „mindestens“-Angaben zu verstehen sein sollen, also als „mindestens ein...“, „mindestens zwei ...“ usw., sofern sich nicht aus dem jeweiligen Kontext ausdrücklich ergibt oder es für den Fachmann offensichtlich oder technisch zwingend ist, dass dort nur „genau ein ...“, „genau zwei ...“ usw. gemeint sein können.

The following terms are explained:

• First of all, it should be expressly pointed out that in the context of the present patent application, indefinite articles and figures such as “one”, “two” etc. should generally be understood as “at least” information, i.e. as “at least one ...”, "At least two ..." etc., unless it is explicitly stated in the respective context or it is obvious or technically imperative for a person skilled in the art that only "exactly one ...", "exactly two ..." etc. can be meant.

A “fuel container” is understood to mean a device which has a cavity in its interior space, the cavity being designed to separate its contents from the environment. A fuel tank can be set up to separate both gases and liquids or a mixture of gases and liquids from the environment.

In particular, in the case of a fuel tank, a fuel tank for gasoline, diesel fuel, hydrogen, ethanol, natural gas, methane or other fuels for motor vehicles is connected thought. In the context of the present description, however, a fuel tank is not exclusively understood to mean a fuel tank, but also an auxiliary tank for motor vehicles, in particular a urea tank, a washer fluid tank, an oil tank, a secondary fluid tank, an additive tank or the like.

Operating material containers are often produced by extrusion blow molding, HDPE (High Density Polyethylene) in particular being suitable for the production of extrusion blow molded operating material containers. However, extrusion blow-molded fuel containers can also be produced using other materials. In particular, the production of extrusion blow-molded operating material containers is also possible with a plurality of material layers, whereby these can each have different materials.

Extrusion blow molding refers to a process of plastics processing for the production of hollow bodies from thermoplastics. A molten polymer is formed via a screw conveyor through an annular slot nozzle or one or two slot nozzles so that, depending on the nozzle geometry, a tubular or a “preform” formed from two flat plastic webs is created.

A “preform” is understood to mean an intermediate product made from a melted polymer, from which the “plastic wall” of the operating material container is later molded.

An “inner surface” of the plastic wall of the preform or of the operating material container is understood to mean a surface which is arranged on the inside of the hollow body produced.

An “outer surface” of the plastic wall of the preform or of the operating material container is understood to mean a surface which is arranged on the outside of the hollow body produced.

In extrusion blow molding, it is conceivable that a tubular preform formed from an annular slot nozzle is separated on both sides inside or outside the annular slot nozzle and thus becomes a preform formed from two predominantly flat plastic webs. As a variant of this, a tubular preform formed from an annular slot nozzle can be separated on one side inside or outside the annular slot nozzle and thus become a C-shaped preform.

After the first molding of the preform described above, during extrusion blow molding it is transferred into a “cavity” formed by a multi-part “molding tool” and there by means of differential pressure, in particular by internal pressure and / or external vacuum, in a cavity formed by a multi-part molding tool to form a hollow body, in particular to form a fuel tank. This molding process in the cavity formed by the molding tool can take place continuously or discontinuously.

As a possible preliminary stage for the above-described shaping of the preform within the cavity formed by the molding tool, it can be preformed outside the molding tool or when the molding tool is not completely closed and / or in the presence of a joining unit and / or a central frame. This preforming of the preform can also take place by means of differential pressure and / or by means of mechanical measures, the polymer forming it still remaining melted.

If necessary, a preform formed from two flat plastic webs or a C-shaped preform is welded to one another at the edges fully or partially circumferentially to form a hollow body when it is introduced into the cavity formed by a multi-part mold and / or when the multi-part mold is closed may have multiple openings.

A preform can also be processed by means of a mechanical manipulator within a cavity formed by the open or closed multi-part mold.

As soon as the hollow body formed within the cavity formed by the multi-part mold has reached its desired shape, it cools down or is cooled down, whereby the polymer forming it solidifies or crystallizes, whereby a partially crystallized material state is predominantly achieved. As long as the polymer has not completely solidified, it is also referred to as a preform.

In addition to extrusion blow molding, other manufacturing methods for corresponding operating material containers can also be used; in particular, the operating material container proposed here can also be manufactured by means of injection molding or rotational sintering or the like.

A “built-in part” is understood to mean a component that is built into a fuel tank. In particular, in the case of a built-in part on a slosh protection wall, a stiffening element, a surge pot, a fuel pump, a holding element, a fuel line, a loading and / or vent valve, a connecting element, in particular a stiffening ring, a rib or a bead, a welding ring, a fitting, a tie rod, a volume compensation element, a liquid separator or the like. In particular, it is also conceivable that a built-in part extends not only in the interior of the operating material container but also outside the operating material container.

A built-in part can be connected directly or indirectly to an inner surface of the operating material container, in particular to the plastic wall made from the preform.

In particular, it is conceivable that a built-in part has a material which is compatible with the plastic wall produced from the preform in such a way that the built-in part can be welded to the plastic wall of the operating material container.

Specifically, a built-in part can be designed to stiffen the plastic wall of the operating material container. For this purpose, it is particularly advantageous if the built-in part is connected, in particular welded, to the wall of the operating material container in such a way that it stiffens the operating material container against loads acting axially and / or radially on the operating material container wall.

A “manipulator” is understood to mean a movable part that enables interactions with its environment, in particular interactions with the preform and / or the plastic wall made from the preform and / or the built-in part, in particular interactions with the built-in part in the interior of the multi-part mold formed cavity.

A manipulator is connected to one or more parts of the multi-part molding tool. The manipulator can be guided through the molding tool during axial movements, in particular during a translational movement in the direction of the interior of the cavity. A manipulator can be single-axis or multi-axis and thus carry out single-axis or multi-axis as well as translatory and / or rotary movements sequentially or parallel to one another.

A manipulator can have one or more tools. Concretely, inter alia, a manipulator is conceivable which is set up to split a preform, in particular to split it in a locally limited manner due to its area of action. Furthermore, it should specifically be considered that a manipulator is set up to grip a built-in part in a captive manner and / or to center a built-in part and / or to position a built-in part, with a built-in part in a uniaxial or multi-axis as well as translational and / or rotary movement the manipulator can be guided and / or to press a built-in part against the preform or to pull it against the preform and / or to join a built-in part in a non-positive and / or positive-locking manner, in particular to glue a built-in part in the interior of the operating material container and / or a built-in part to hook into one another with the plastic wall of the container and / or another built-in part, in particular in an undercut of the corresponding component provided for this type of connection, and / or weld a built-in part to the preform. For this purpose, a manipulator can also have gripping systems or measuring means in addition to or instead of tools.

With regard to welding a built-in part to the wall of the operating material container, it should be specifically considered that the manipulator grabs a built-in part, guides it to the position at which it is to be welded and presses it into the melt of the wall of the operating material container already formed from the preform.

In the prior art it was previously provided that built-in parts were pressed against the plastic wall produced from the preform by means of a compressive force acting on them. In other words, either the still viscous or not yet solidified wall of the preform was pressed with a compressive force against the built-in part or the built-in part was pressed from the inside with a compressive force against the not yet solidified wall of the preform.

For this purpose, manipulators are known in the prior art which are connected to a joining unit and / or a central frame, the compressive force applied by the manipulator being supported against the central frame and / or the joining unit.

In contrast, it is proposed here to arrange a manipulator in such a way that it can pull the built-in part against the plastic wall made from the preform by means of a tensile force. In contrast to the prior art, such a manipulator is not supported on a joining unit or a central frame, but on one or more parts of the molding tool; in particular, the manipulator proposed here can be supported on a part of the molding tool that is used in conjunction with one or more others Parts of the mold in the closed state forms the cavity.

A “tensile force” is understood to mean that, starting from the support of the manipulator, a force acts on the manipulator, the direction of which runs essentially in the direction of a first manipulator axis and leads away from the cavity. In the simplest case of a uniaxial manipulator Use this tensile force to pull an unblocked manipulator out of the cavity. In the case of multi-axis manipulators, the same applies to a first manipulator axis.

With regard to the amount of tensile force, values between 0.01 N / mm ² and 1.00 N / mm ² , preferably an amount of tensile force between 0.05 N / mm ² and 0.70 N / mm ² , are particularly preferred an amount of tensile force between 0.10 N / mm ² and 0.40 N / mm ² . With the aforementioned amounts for the tensile force, the reference area corresponds to the designated contact area between the built-in part and the plastic wall produced from the preform

It should be expressly pointed out that the above values for the amount of tensile force should not be understood as sharp limits, but rather should be able to be exceeded or undercut on an engineering scale without departing from the described aspect of the invention. In simple words, the values should provide an indication of the size of the range of values proposed here for the amount of tensile force.

A “first manipulator axis” is understood to mean that manipulator axis with which the manipulator can penetrate the molding tool in a translational movement or can be moved from the molding tool in a translational movement into the interior of the cavity. In other words, the first manipulator axis is understood to mean that manipulator axis which the manipulator has at the interface between the cavity and the molding tool.

It is also concretely conceivable, among other things, that the manipulator proposed here, viewed from the direction of the cavity, is supported outside of the molding tool and is only guided by one or more parts of the molding tool. It can advantageously be achieved in this way that the counterforce to the tensile force on the built-in part is not supported on the molding tool itself, which means that it is not deformed either, as a result of which better tolerances can be achieved in the operating material containers produced.

In the method proposed here, the manipulator enables the built-in part to be pulled by the manipulator directly against the plastic wall formed from the preform. In this way, compared to the prior art, a higher overall contact force can be achieved between the built-in part and the plastic wall formed from the preform. The higher contact force can be achieved in particular because the manipulator does not have to be supported on a joining unit that is comparatively soft in terms of deformation to the variant proposed here and / or on a center frame that is comparatively soft in deformation. In addition, the manipulator does not have to be attached completely inside the cavity, so that larger manipulators can be used, especially in the case of operating material containers with particularly restrictive installation space requirements, which can apply higher forces and, due to their own rigidity, lead to more precise positioning of the built-in part.

Due to the overall possible higher contact force between the built-in part and the plastic wall made from the preform, it can advantageously be achieved that a built-in part whose material is compatible with that of the plastic wall made from the preform in such a way that the built-in part can be welded to the plastic wall of the operating material container , can be welded with particularly high demands on the tightness of the resulting weld, so that a particularly emission-tight interface can be achieved between the plastic wall of the operating material container and the built-in part.

Plastic material combinations that can be easily welded to one another have predominantly a low barrier effect against hydrocarbons. The method proposed here and the associated higher contact forces during welding as well as the higher positioning accuracy of the built-in part can increase the quality of the weld between the plastic wall of the operating material container and the built-in part, which results in a better barrier effect against hydrocarbons even with materials that are compatible for welding can be so that a total of a more emission-tight tank can be achieved. In particular, the higher contact force enables a thinner contact layer to be achieved whose emission path for hydrocarbons is as small as possible.

Compared to the prior art, the manipulator proposed here can also ensure a more uniform transmission of force to the built-in part, which further increases the quality of the weld between the built-in part and the plastic wall of the operating material container.

During use of the operating material container or a built-in part, in particular a slosh protection wall, dynamic forces can occur between the plastic wall of the operating material container and the built-in part, which must also be absorbed by the connection between these components. The higher quality of the weld that can be achieved here means that the The sealing effect of the weld is largely retained even with dynamic forces between these two components and the service life of the operating material container can be increased, since material fatigue can be weakened under dynamic forces.

It is preferably proposed here that the insert is pulled by the manipulator directly against the plastic wall formed from the preform, with the plastic wall produced from the preform directly against it on its outer surface in the area of the corresponding contact surface on the inside between the insert and the plastic wall of the operating material container the inner surface of the mold is pulled.

In this way, it can advantageously be achieved that the plastic wall, which has not yet solidified, lies directly on its outside against the particularly rigid inside surface of the molding tool, while on its inside it experiences the contact force from the built-in part. In this way, a very precise bracing of the plastic wall can be achieved, which enables a particularly thin contact layer between the built-in part and the plastic wall, whereby the emission tightness can be improved.

If the plastic wall were not in direct contact with the inside of the molding tool, as suggested, but if an already solidified plastic component were still present here, this would lead to a loss of prestressing force due to the elasticity of this component when the tensile force is applied by the manipulator, which makes controllability the development of force at the interface between the built-in part and the plastic wall would worsen. This in turn would lead to poorer reproducibility of the welding results and thus overall to thicker contact layers and thus to higher emissions at the connection between the wall of the operating material container and the built-in part.

When carrying out the proposed method, between the step of introducing the preform into the cavity of the mold and the step of introducing the built-in part into the cavity of the multi-part mold and / or between the step of introducing the built-in part into the cavity of the multi-part mold and the In the step of applying the tensile force to the built-in part by means of the manipulator, the preform is pre-blown.

When the preform is pre-blown, it is preformed by means of differential pressure, in particular by internal pressure and / or external vacuum. The preform is preformed to 50% to 99.9% of the target volume of the operating material container, preferably to 60% to 95% and particularly preferably to 70% to 90%.

In this way, it can advantageously be achieved that the introduction of the built-in part is facilitated or a material distribution of the preform is optimized, in particular with regard to the wall thickness distribution of the operating material container that is to be achieved.

It should be expressly pointed out that the above values for the preforming of the preform by the pre-blowing should not be understood as sharp limits, but rather should be able to be exceeded or undercut on an engineering scale without departing from the aspect described. In simple terms, the values are intended to provide an indication of the size of the preforming of the preform proposed here by the pre-blowing.

It is also proposed that the preform be blown to completion between the step of applying the tensile force to the built-in part by the manipulator and the step of demolding the operating material container, whereby the preform is shaped to the target volume of the operating material container.

With regard to the introduction of the built-in part, various variants are proposed here in combination with the method according to the first aspect.

In particular, it should be considered that the built-in part is introduced into a tubular preform from below or from above through the respectively still open end faces of the tubular preform.

In addition, in the case of a C-shaped preform or a preform formed from two flat plastic webs, the built-in part can also be introduced into the preform from the side.

The introduced preform can be held in position within the preform by means of a separate device. In addition to other alternatives known in the prior art, a device should be considered here which holds the built-in part in position when coming from the direction of the ring or slot nozzle. The built-in part can also be introduced into the preform with this device.

Before a tensile force can be applied to the built-in part by means of the manipulator, the manipulator takes over the built-in part from the The device described above accordingly and grips the built-in part, in particular the manipulator grips the built-in part in a captive manner. Optionally, the manipulator aligns the built-in part before gripping, so that its position in relation to the gripping tool of the manipulator can be checked in accordance with the target specifications for gripping the built-in part, whereby the built-in part can be gripped with a reproducible position in relation to the manipulator.

In particular, it is proposed that the manipulator can be introduced into the volume within the preform through a vent opening formed during the pre-blowing of the preform.

The multi-part mold is preferably closed when the tensile force is applied to the built-in part.

In particular, it is proposed here that the manipulator penetrates the mold cavity when the mold is closed, brings the insert into contact with the plastic wall made from the preform and then presses the insert against the plastic wall by means of a tensile force.

In particular, it can advantageously be achieved that the built-in part is welded to the plastic wall, in particular if the plastic of the built-in part and the plastic wall formed from the preform have a plastic that is compatible with one another in such a way that welding is possible.

By applying the tensile force when the mold is closed, it can advantageously be achieved that the built-in part can be welded during the final blow-molding of the operating material container. Since the joint and the wall of the operating material container solidify at the same time, a particularly high dimensional stability can be achieved.

Only the positioning of the manipulator proposed here enables the built-in part to be joined when the mold is closed. In this way, particularly small operating material containers can advantageously be produced with a built-in part, which additionally also have a particularly good and reproducible dimensional stability.

Optionally, the manipulator forms an opening in the plastic wall made from a preform.

It is proposed here that the manipulator is set up to shape the plastic wall produced from the preform in such a way that an opening is created in the plastic wall.

An opening in the plastic wall can be understood to mean a locally delimited opening which enables the manipulator to penetrate into the interior of the preform with or without a built-in part. Alternatively, an opening can also be understood to mean a larger opening in the preform, in particular the partial or complete separation of one side of the preform is also intended.

An opening can be understood both with and without material shrinkage on the preform.

In order to achieve this objective, the manipulator can have a tool which is specially set up for this objective and which supports the manipulator when it is separated, punched out or the like, so that an opening can be formed in the plastic wall.

Such a tool can be changed after the opening in the plastic wall has been formed. Alternatively, the manipulator can be designed in such a way that, in addition to the tool for forming the opening, it also has a further tool in parallel with which it can apply the tensile force to the built-in part. It goes without saying that the manipulator can also have further tools or can change them in a tool magazine specially set up for this purpose. A tool changing device can be provided on the manipulator for this purpose.

Likewise, a manipulator is specifically thought of which has a sharp edge and / or a mandrel on its side facing the plastic wall so that the manipulator can form an opening in the plastic wall without a specially set up additional tool and without material shrinkage of the preform. Specifically, this can be achieved in particular with a mandrel-shaped manipulator.

In this way, it can advantageously be achieved that the manipulator can perform other tasks in addition to applying the tensile force to the built-in part during the manufacture of the operating material container. Functional integration in the manipulator can thus advantageously contribute to a simplification of the overall process and a reduction in production time and / or production costs.

Specifically, it is also conceivable, among other things, that the opening can be carried out by a second manipulator. In particular, it should be considered that the second manipulator opens the opening in the plastic wall made from a preform with a working movement in the direction of the multi-part molding tool. In other words, it is intended that the second manipulator is positioned within the cavity formed by the multi-part molding tool and executes a working stroke and / or a working movement in the direction of the multi-part molding tool in order to form the opening.

In this way it can advantageously be achieved that the formed opening can have particularly smooth edges.

A preferred embodiment can be implemented in that the manipulator is guided to the position of the built-in part within the preform and grips the built-in part there.

Specifically, it should be considered here that the manipulator is set up to grip the built-in part within the preform, that is to say within the volume delimited by the inside of the preform. This means that the built-in part is already to be found inside the preform at this point in time, the introduction of the built-in part into the preform being achieved in some other way or not taking place by using the manipulator proposed here.

To grip the built-in part, the manipulator can have a tool specially provided for this purpose. This can also be stored in a tool magazine and changed independently by the manipulator.

In particular, when gripping the built-in part, a captive gripping of the built-in part should be considered.

When gripping the built-in part, active gripping should be considered, in which a gripping tool grips the built-in part by means of a closing movement and can release it again by means of an opening movement.

Alternatively, a passive gripping of the built-in part should be considered, in which the manipulator can build up a form fit and / or force fit to the built-in part by means of a translatory and / or rotary movement.

In particular, a manipulator is intended that has a mandrel, a translational movement of the manipulator in a contact surface of the built-in part corresponding to the mandrel leads to a fixed but also releasable connection between the manipulator and built-in part. In this specific embodiment, a conical design of the mandrel and the corresponding contact surface of the built-in part can also center the built-in part relative to the manipulator. Furthermore, it should be specifically considered that this connection requires a force for loosening that is greater than the tensile force that is intended to be applied by the manipulator to the built-in part for joining, in particular when welding the built-in part to the plastic wall. It can thus advantageously be achieved that the built-in part is centered, gripped and joined with a comparatively simply designed manipulator, and it can then be released from the manipulator again by increasing the tensile force applied to the required level. At the same time, such a manipulator can also be set up for forming an opening in the plastic wall produced from the preform.

Furthermore, it should also be considered here that the built-in part is positioned by a second manipulator, which is positioned within the cavity formed by the multi-part molding tool and operates from the interior of the cavity.

Specifically, it should be considered that the second manipulator is guided in the interior of the cavity to the position of the built-in part within the preform and grips the built-in part there, in particular grips it in a captive manner.

An alternative embodiment can be realized in that the manipulator is guided to the position of the built-in part outside the preform, grips the built-in part there and introduces it into the preform.

Notwithstanding, it is proposed here that the built-in part is held outside the preform, where it is gripped by the manipulator and introduced into the interior of the preform.

A magazine for the corresponding built-in part outside the cavity should also be thought of, from which the manipulator can remove a built-in part in accordance with the cycle.

In this way, it can advantageously be achieved that the built-in part does not have to be kept within the preform, so that smaller operating material containers can be produced. In addition, a functional integration can be implemented in the manipulator proposed here, which can advantageously reduce the manufacturing costs for the operating material container.

The manipulator preferably grips the built-in part by means of an expandable rubber element.

Here it is specifically proposed that the manipulator actively grasp the built-in part is implemented by a radially expanding rubber element.

In particular, expansion of the rubber element by applying internal pressure to the rubber element should be considered. For this purpose, a fluid can be introduced into a cavity in the rubber element and an internal pressure can thereby be applied in the rubber element, which pressure can be reduced again by the outflow of the fluid and thus the gripping effect can be canceled.

Likewise, a rubber element should be considered, which can be actively axially braced so that a radial expansion of the rubber element is achieved, whereby the built-in part can be gripped reversibly.

The manipulator preferably grips the built-in part by means of a mechanical lock.

It is proposed here that the manipulator grips the built-in part by means of a mechanical lock, in particular with a form-fitting and / or material-locking lock.

Specifically, a bayonet lock is intended for a mechanical lock, which is set up to establish a connection between the manipulator and the built-in part. In particular, the connection between the built-in part and the manipulator can be established and released again by means of a bayonet lock.

In this way it can advantageously be achieved that a stable, positionally accurate and at the same time releasable connection between the manipulator and the built-in part can be established and released again.

Optionally, the manipulator aligns the built-in part before gripping the built-in part.

In this way it can advantageously be achieved that the position of the gripped built-in part relative to the manipulator can be guaranteed in a reproducible manner within small form and position tolerances.

A preferred embodiment can be realized in that the manipulator guides the built-in part into contact with the inner surface of the plastic wall, the manipulator aligning the built-in part coaxially with a first manipulator axis and then applying the tensile force to the built-in part.

• Unter einer „ersten Manipulatorachse“ wird diejenige Manipulatorachse verstanden, mit welcher der Manipulator in einer translatorischen Bewegung das Formwerkzeug durchdringen kann oder aus dem Formwerkzeug in einer translatorischen Bewegung in das Innere der Kavität bewegt werden kann. Mit anderen Worten wird unter der ersten Manipulatorachse diejenige Manipulatorachse verstanden, die der Manipulator an der Grenzfläche zwischen der Kavität und dem Formwerkzeug aufweist.

The following terms are explained:

• A “first manipulator axis” is understood to mean that manipulator axis with which the manipulator can penetrate the molding tool in a translational movement or can be moved from the molding tool in a translational movement into the interior of the cavity. In other words, the first manipulator axis is understood to mean that manipulator axis which the manipulator has at the interface between the cavity and the molding tool.

Here, it is specifically proposed that the built-in part be welded or otherwise joined to the operating material container with regard to one of its axes coaxially to the first manipulator axis.

The built-in part can be brought into contact with the plastic wall made from the preform with respect to one of its axes coaxially to the first manipulator axis by the manipulator and welded or otherwise joined to the operating material container while applying a tensile force.

A variant of this embodiment can be implemented in that the manipulator guides the insert into contact with the inner surface of the plastic wall, the manipulator aligning the insert parallel to the first manipulator axis and then applying the tensile force to the insert.

As a variant, an embodiment is proposed here in which the built-in part is not joined coaxially to the first manipulator axis with the operating material container with regard to one of its axes, but rather parallel to the first manipulator axis.

In this way it can advantageously be achieved that the range of variants with which a built-in part can be joined to the operating material container increases.

Another variant of this embodiment can be implemented in that the manipulator guides the insert into contact with the inner surface of the plastic wall, the manipulator aligning the insert at an angle to the first manipulator axis and then applying the tensile force to the insert.

As a further variant, it is now proposed here that the built-in part is joined to the operating material container at an angle to the first manipulator axis with regard to one of its axes.

Another variant of this embodiment can be implemented in that the Manipulator guides the built-in part into contact with the inner surface of the plastic wall, the manipulator aligning the built-in part at an angle to the first manipulator axis and then applying the tensile force to the built-in part.

In addition to a coaxial, parallel and angled alignment of the built-in part with respect to one of its axes to the first manipulator axis, a skewed alignment is specifically proposed here.

In this way, too, it can advantageously be achieved that the range of variants with which a built-in part can be joined to the operating material container increases.

The manipulator is preferably set up to be able to vary an air pressure inside the built-in part.

Specifically, it is proposed here, inter alia, that the manipulator has an air duct which is set up to print on a cavity formed by the built-in part in the interior of the molded preform.

In this way, in particular, a pressure equalization can be established between the cavity formed by the built-in part in the interior of the shaped preform and the otherwise remaining volume inside the shaped preform.

Specifically, it should be considered that the cavity formed by the built-in part in the interior of the molded preform is in fluid communication with the mold by the manipulator and that the volume remaining next to the cavity formed by the built-in part is otherwise in fluid communication with the mold.

In this way it can advantageously be achieved that no pressure forces act on the built-in part, in particular not while the preform or the operating material container is being formed.

This can also advantageously ensure that the built-in part in the interior of the molded preform does not come into undesired contact with the preform or the consumable container during the molding of the preform or the operating material container with suitable printing.

According to a second aspect, the object is achieved by a molding tool, in particular a multi-part molding tool, for the production of a fuel tank, in particular a fuel tank, the molding tool having a manipulator which is set up to carry out a method according to the first aspect.

It goes without saying that the advantages of a method for producing a fuel tank, in particular a fuel tank, wherein the fuel tank has a built-in part and a plastic wall made from a preform, the preform within a cavity formed by a multi-part molding tool using differential pressure to the Operating material container is molded, the multi-part molding tool having a manipulator and wherein the manipulator pulls the built-in part according to the first aspect by means of a tensile force against the plastic wall produced from the preform, as described above, directly onto a molding tool for the production of an operating material container, the molding tool comprises a manipulator which is configured to carry out a method according to the first aspect.

According to a third aspect, the object is achieved by a fuel tank, in particular a fuel tank, which was produced by means of a method according to the first aspect and / or with a molding tool according to the second aspect.

It goes without saying that the advantages of a method for producing a fuel tank, in particular a fuel tank, wherein the fuel tank has a built-in part and a plastic wall made from a preform, the preform within a cavity formed by a multi-part molding tool using differential pressure to the Operating material container is molded, wherein the multi-part molding tool has a manipulator and wherein the manipulator pulls the insert according to the first aspect by means of a tensile force against the plastic wall made from the preform, and / or the advantages of a molding tool according to the second aspect, as described above, directly to an operating material container which was produced by means of a method according to the first aspect and / or with a molding tool according to the second aspect.

According to a fourth aspect, the object is achieved by a motor vehicle having a fuel tank according to the third aspect.

It goes without saying that the advantages of a fuel tank according to the third aspect, as described above, extend directly to a motor vehicle having a fuel tank according to the third aspect.

• 1: schematisch eine Schnittdarstellung eines mehrteiligen Formwerkzeugs zum Ausformen eines Betriebsstoffbehälters mit einem Manipulator, wobei der Manipulator dazu eingerichtet ist ein Einbauteil koaxial zu einer ersten Manipulatorachse auszurichten und mit dem Betriebsstoffbehälter zu fügen; und
• 2: schematisch eine Schnittdarstellung eines mehrteiligen Formwerkzeugs zum Ausformen eines Betriebsstoffbehälters mit einem Manipulator, wobei der Manipulator dazu eingerichtet ist ein Einbauteil in einer komplexen Ausrichtung zu einer ersten Manipulatorachse auszurichten und mit dem Betriebsstoffbehälter zu fügen.

Further advantages, details and features of the invention emerge from the exemplary embodiments explained below. In detail:

• 1 : schematically, a sectional view of a multi-part molding tool for forming an operating material container with a manipulator, wherein the manipulator is set up to align a built-in part coaxially to a first manipulator axis and to join it with the operating material container; and
• 2 : a schematic sectional view of a multi-part molding tool for shaping an operating material container with a manipulator, wherein the manipulator is set up to align a built-in part in a complex alignment with a first manipulator axis and to join it with the operating material container.

In the description that follows, the same reference symbols denote the same components or the same features, so that a description made with reference to a figure with regard to a component also applies to the other figures, so that a repetitive description is avoided. Furthermore, individual features that have been described in connection with one embodiment can also be used separately in other embodiments.

The multi-part molding tool 1 , 2 in 1 consists essentially of a first mold half 1 and a second mold half 2 .

The two mold halves 1 , 2 together form a cavity 3 , which are used to shape a preform 4th is set up to a fuel tank.

The second mold half 2 assigns a manipulator 6 on, which through an opening (not designated) in the preform 4th into the cavity 3 can penetrate. The manipulator 6 have a separate tool (not shown).

The manipulator has a first manipulator axis 7th on and is set up a traction force 8th on a built-in part 5 to raise.

Furthermore, the manipulator 6 be arranged to have an opening (not designated) in the preform 4th form through which the manipulator 6 through the preform 4th into the through the first mold half 1 and the second mold half 2 formed cavity 3 can penetrate.

The manipulator 6 is by means of its manipulator head 9 set up for this purpose, the built-in part 5 to grab. The manipulator head 9 the joints 10 , 11 through which this function can be enabled.

The manipulator 6 to be set up, the built-in part 5 to align before gripping, so that the built-in part is within slight shape and position tolerances to the manipulator 6 can be positioned.

In a first variant is the manipulator 6 configured to move to a predetermined position within the preform 4th located built-in part 5 to be guided and to grab it there.

The manipulator is a second variant 6 set up to a predetermined position of the outside of the preform 4th located built-in part 5 to be guided, to grip it there and to pass it through an opening (not labeled) in the preform 4th into the cavity 3 to introduce.

By applying a tensile force 8th on the built-in part 5 by the manipulator 6 can the manipulator 6 the built-in part 5 join with the fuel tank.

The manipulator 6 in 1 the built-in part 5 coaxial with the first manipulator axis 7th align.

The manipulator 6 in 2 is multi-axis and has the joints for this purpose 12 , 13 on. By means of the joint 14th and the resulting gripping tool (not denoted) the manipulator 6 the built-in part 5 actively grab.

The manipulator 6 in 2 is set up for this purpose, the built-in part 5 parallel to the first manipulator axis 7th align.

Furthermore is the manipulator 6 in 2 is set up for this purpose, the built-in part 5 at an angle to the first manipulator axis 7th align.

Also is the manipulator 6 in 2 set up for this purpose, the built-in part 5 skewed to the first manipulator axis 7th align.

Thus the manipulator enables 6 in 2 extensive positioning options for the built-in part 5 .

List of reference symbols

1

Mold half

2

Mold half

3

cavity

4th

Preform

5

Mounting part

6th

manipulator

7th

First manipulator axis

8th

traction

9

Manipulator head

10

joint

11

joint

12

joint

13

joint

14th

joint

QUOTES INCLUDED IN THE DESCRIPTION

This list of the documents listed by the applicant was 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.

Patent literature cited

• WO 2008/138869 A1 [0006]

Claims (16)

A method for producing a fuel tank, in particular a fuel tank, the fuel tank having a built-in part (5) and a plastic wall made from a preform (4), the plastic wall having an inner surface and an outer surface, the preform (4) being inside one of a multi-part mold (1, 2) formed cavity (3) is molded using differential pressure to the operating material container, wherein the multi-part mold (1, 2) has a manipulator (6), comprising the following steps: - Introducing the preform (4) into the cavity (3) of the multi-part molding tool (1, 2), - Introducing the built-in part (5) into the cavity (3) of the multi-part mold (1, 2), - applying a tensile force (8) to the built-in part (5) by means of the manipulator (6), the built-in part (5) being pulled against the plastic wall made from the preform (4), and - Demolding of the operating material container. Procedure according to Claim 1 , characterized in that the multi-part mold (1, 2) is closed when the tensile force (8) is applied to the built-in part (5). Method according to one of the Claims 1 or 2 , characterized in that the manipulator (6) forms an opening in the plastic wall made from a preform (3). Method according to one of the preceding claims, characterized in that the manipulator (6) is guided to the position of the built-in part (5) within the preform (4) and grips the built-in part (5) there. Method according to one of the Claims 1 to 3 , characterized in that the manipulator (6) is guided to the position of the built-in part (5) outside the preform (4), grips the built-in part (5) there and introduces it into the preform (4). Method according to one of the preceding claims, characterized in that the manipulator (6) grips the built-in part (5) by means of an expandable rubber element. Method according to one of the Claims 1 to 5 , characterized in that the manipulator (6) grips the built-in part (5) by means of a mechanical lock. Method according to one of the Claims 4 to 7th , characterized in that the manipulator (6) aligns the built-in part (5) before gripping the built-in part (5). Method according to one of the preceding claims, characterized in that the manipulator (6) guides the built-in part (5) into contact with the inner surface of the plastic wall , the manipulator (6) aligning the built-in part (5) coaxially with a first manipulator axis (7) and then applying the tensile force (8) to the built-in part (5). Method according to one of the Claims 1 to 8th , characterized in that the manipulator (6) guides the built-in part (5) into contact with the inner surface of the plastic wall , the manipulator (6) aligning the built-in part (5) parallel to the first manipulator axis (7) and then the tensile force (8 ) applies to the mounting part (5). Method according to one of the Claims 1 to 8th , characterized in that the manipulator (6) guides the built-in part (5) into contact with the inner surface of the plastic wall , the manipulator (6) aligning the built-in part (5) at an angle to the first manipulator axis (7) and then the tensile force (8 ) applies to the mounting part (5). Method according to one of the Claims 1 to 8th , characterized in that the manipulator (6) guides the built-in part (5) into contact with the inner surface of the plastic wall , the manipulator (6) aligning the built-in part (5) at an angle to the first manipulator axis (7) and then the tensile force (8 ) applies to the mounting part (5). Method according to one of the preceding claims, characterized in that the manipulator (6) is set up to be able to vary an air pressure inside the built-in part (5). A molding tool (1, 2), in particular a multi-part molding tool (1, 2), for the production of an operating material container, in particular a fuel tank, the molding tool (1, 2) having a manipulator (6) which is set up to implement a method according to a the Claims 1 to 13 perform. Fuel tank, in particular fuel tank, which by means of a method according to one of the Claims 1 to 13 and / or with a molding tool (1, 2) according to Claim 14 was produced. Motor vehicle having a fuel tank according to Claim 15 .

Images