FR2812838A1 - Apparatus for molding half of fuel tank, etc. has parts defining mold cavity and jack movable relative to parts to compact and/or change movement of thermoplastic injected into cavity - Google Patents

Abstract

Apparatus has parts (2a,2b) defining at least one mold cavity (2) and jack(s) (11) movable relative to the mold parts in order to compact and/or change the movement of thermoplastic injected into the cavity. A controller (18) moves the jack in a predetermined manner An Independent claim is included for injection molding a thermoplastic article as above.

Description

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The present invention relates to the manufacture of parts made of thermoplastic material by injection molding.

The invention relates more particularly to the manufacture of motor vehicle fuel tanks.

To compensate for the phenomenon of shrinkage of the thermoplastic material in the mold cavity during its cooling, which is particularly sensitive with polyolefins and in particular polyethylene, it is known to compact the thermoplastic material in the mold cavity after the latter has been filled.

In known injection machines, the material is injected into the mold cavity by means of an injection screw rotating in a sleeve and the pressure necessary for compaction is obtained by means of this screw.

The injection screw generally communicates with the mold cavity by one or more supply channels, so that the pressure generated by the screw is not immediately reflected on the material filling the cavity, and the conduct of the phase of compaction is all the more problematic as the material is viscous.

The time required to balance the pressures affects the duration of the manufacturing cycle.

There is a need to facilitate and improve the manufacture by injection molding of parts made of thermoplastic material, and in particular to reduce the duration of the manufacturing cycle.

The subject of the invention is in particular a new device for producing at least one part by injection molding of thermoplastic material, in particular a half-shell of a fuel tank, of the type comprising at least one mold cavity formed between mold parts, the shape of this cavity being adapted to that of the part to be produced, this device remedying all or part of the drawbacks encountered in the prior art thanks to the fact that it comprises, associated with the mold cavity, at least one actuator movable by relative to said mold parts, capable of compacting the thermoplastic material contained in the mold cavity and / or of modifying the circulation of the material therein, and a control device for controlling the movement of this jack in a predetermined manner .

The jack can be movable in an annex chamber communicating with the mold cavity, between a retracted position in which it is set back from the

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 mold cavity and an advanced position.

Thanks to the invention, it is possible to reduce the duration of the manufacturing cycle because the compaction can be assisted or carried out by the jack (s) in one or more locations of the mold cavity, which makes it possible to accelerate the balancing. pressures in the mold cavity.

Furthermore, by adequately choosing the location where the cylinder or cylinders are located relative to the mold cavity, it is possible to improve the quality of the part produced.

It is in particular possible to obtain a more homogeneous compaction of the material by placing the jack or jacks in the vicinity of the regions of the mold cavity last filled.

The invention thus makes it possible to improve the mechanical characteristics of the part produced, in particular to reduce the rate of internal stresses and to improve dimensional stability.

The invention also makes it possible to widen the choice of possible forms for the part to be produced, thanks to the fact that certain regions of the part which could not have been compacted satisfactorily in the absence of the jack or jacks, in particular by their geometry and / or their location relative to the injection points, can now be thanks to the presence in their vicinity of one or more cylinders.

The duration of the manufacturing cycle being able to be shortened thanks to the invention, the risk that the material freezes prematurely in the feed channels or in certain regions of the mold cavity is reduced.

In addition, the invention may allow, ultimately, to load the sheath in which the injection screw rotates with a new dose of thermoplastic material, intended for molding a next part, while the compaction of the thermoplastic material in the mold cavity by means of the jack (s).

The invention can also make it possible to reduce the cross section of the supply channels since these can, in certain cases, as indicated above, no longer be used during compaction to transmit the pressure generated by the injection screw.

However, it does not depart from the scope of the invention when the injection screw participates in the compaction of the material in the mold cavity and the cylinder or cylinders do not

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 only assist compaction.

It is also possible, in a particular example of implementation of the invention, to use at least one jack to modify the flow of the material in the mold cavity during its filling.

Thus, it is possible to position at least one jack so that it projects into the mold cavity and constitutes at least at a predetermined instant of filling an obstacle to the flow of the material in the mold cavity.

We can then slow down the progression of the material in a part of the mold cavity in order to have a more homogeneous filling.

The device can comprise at least two mold cavities of different shapes for the substantially simultaneous molding of two different parts, in particular of two half-shells of a fuel tank, supplied from the same source of thermoplastic material, at least one cylinder controlled by the control device being associated with each mold cavity.

The use of a common source of thermoplastic material is made easier thanks to the fact that compaction can be carried out, in a particular implementation of the invention, independently or with less dependence on the injection screw.

The invention can then make it possible to avoid the use of two injection screws to supply each of the cavities.

The section of the supply channels can be chosen so as to obtain different material flow rates in the supply channels and a substantially simultaneous end of filling in the two mold cavities, without fear that the different sections of the supply channels do not pose a problem during compaction, which is assisted by the jacks, or in the limit is carried out by means of the jacks alone.

The device may comprise at least one shutter making it possible to isolate the or each mold cavity from the source of thermoplastic material, this shutter preferably being controlled by the abovementioned control device.

In a particular implementation of the invention, at least one jack is located in its advanced position set back from the mold cavity.

As a variant, at least one jack comes into its advanced position flush with the mold cavity.

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 In yet another variant, at least one cylinder protrudes in its advanced position in the mold cavity.

The device can comprise two mold parts coming to bear against each other from the start of the injection cycle, to form the mold cavity.

Thus, these two mold parts may not participate in the compaction of the material inside the mold cavity.

In general, at least one cylinder is moved by a hydraulic mechanism.

The control device can be arranged to bring at least one actuator into a retracted position at the start of filling the mold cavity.

The control device can also be arranged to bring at least one cylinder into an advanced position at the start of filling of the mold cavity.

The control device can also be arranged to allow at least one cylinder to retreat under the effect of the pressure of the thermoplastic material in the mold cavity, during its filling.

The recoil can be carried out with a certain back pressure, so as to allow the material to continue to fill the mold cavity during the recoil of the jack. At least one cylinder can be arranged so as to compact the thermoplastic material in the mold cavity at a pressure between 200 and 500 bars. The invention makes it possible to use a thermoplastic material of grade (HLMI) of for example between 1 and 50, preferably 5 and 30, measured according to standard ISO 1133 (unit: g / 10 min).

Advantageously, the control device receives information from pressure and / or temperature sensors associated with the mold cavity and it is arranged to control the movement of at least one jack as a function of information supplied by the sensors.

Another subject of the invention is a method for producing a part made of thermoplastic material by injection molding, this method being characterized in that it comprises the following steps - injecting by one or more injection points into a mold cavity defined by mold parts of the thermoplastic material from a source of thermoplastic material, and

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 - Move at least one cylinder relative to the mold parts so as to compact the material in the mold cavity, assist in its compaction and / or modify its flow.

The cylinder, being advanced, can perform a local injection of a volume of material, between 1 and 10 cm3 for example, or even between 3 and 8 cm3, for example close to 5 cm 3.

In a particular implementation of the method, the jack is advanced at the end of the filling of the mold cavity and / or past a certain degree of filling of the mold cavity, so as to compact the material therein and / or assist the end of its filling.

Still in a particular implementation of the method, the cylinder is allowed to retract gradually under the effect of the pressure of the material in the mold cavity, before advancing it.

Still in a particular implementation of the method, the cylinder is advanced so that it projects into the mold cavity, and modifies the flow of the material therein during its filling.

After filling the cavity and before compacting the material therein, the injection point (s) can be closed.

This obturation can be carried out by means of one or more mechanical shutters or alternatively by allowing the material to cool to their level.

In a particular implementation of the method, after filling the mold cavity, the latter is isolated from the source of thermoplastic material and the material is then compacted in the mold cavity using one or more jacks while carrying out the loading of a sheath used to supply the mold cavity.

In a particular implementation of the method, two mold cavities are filled corresponding to different parts, in particular two half-shells of a fuel tank, from the same dose of thermoplastic material and the material is compacted thermoplastic in each of these mold cavities where we assist its compaction by means of at least one jack.

The invention also relates to a part made of thermoplastic material, in particular a motor vehicle fuel tank, obtained by placing

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 implementation of the process as defined above.

The invention also relates to a part made of thermoplastic material, characterized in that it comprises the trace of one or more injection points and the trace of a communication of the mold cavity with one or more annex chambers of variable volume.

The invention will be better understood on reading the detailed description which follows, of nonlimiting examples of implementation, and on examining the appended drawing, in which - FIG. 1 is a schematic and partial view, in section of an injection device according to an exemplary implementation of the invention, during filling of the mold cavity, - Figure 2 is a view similar to Figure 1, at the end of filling of the mold cavity, - Figure 3 is a view similar to Figures 1 and 2 showing the device after displacement of the cylinders, - Figure 4 is a view similar to Figures 1 to 3 illustrating the use of the cylinders to modify the flow of the material in the mold cavity, - Figure 5 shows schematically a double mold cavity device, - Figure 6 shows schematically, in perspective, a tank obtained by implementing the method according to the invention, and - figs ures 7 and 8 are schematic and partial views, similar to Figures 1 and 2, illustrating another example of implementation of the invention.

There is shown in Figures 1 and 2 an injection device 1 according to the invention, for producing by injection molding of thermoplastic material a part such as for example a half-shell of a motor vehicle fuel tank, intended to be welded to another half-shell.

The device 1 comprises a mold cavity 2 formed between mold parts 2a and 2b shown diagrammatically, bearing against one another.

The shape of the mold cavity 2 corresponds to that of the part to be produced.

The mold cavity 2 communicates by one or more injection points 3 with a source of thermoplastic material, not shown in the drawing, comprising

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 conventionally a sleeve in which an injection screw rotates.

In Figures 1 and 2, there is shown a single injection point 3 supplied by a nozzle 4 comprising an outlet channel 7 defined by a wall 5 of frustoconical shape. The nozzle 4 may or may not have a shutter.

A central shutter 6 is shown by way of example in FIG. 4, capable of coming to bear against the wall 5 to close the outlet channel 7.

The cavity 2 communicates with annex chambers 10 in which the cylinders 11 can move along axes X.

The annex chambers 10 are formed, in the embodiment described, by attached structures 12 arranged to guide the movement of the jacks 11. Each annex chamber 10 has, in the example described, a side wall 10a of generally frustoconical shape around of the axis X and a bottom wall 10b surrounding the jack 11.

Each annex chamber 10 is dimensioned in the example described according to the volume shrinkage to be compensated.

The advancement of the jacks 11 causes the expulsion of a certain amount of material contained in the annex chambers 10 towards the cavity 2.

In FIG. 1, the device 1 is being filled, the thermoplastic material 17 flowing through the channel 7 of each nozzle 4 and gradually filling the cavity 2.

In the example considered, the jacks 11 are initially in the retracted position, their front face 11a being set back, by a few mm for example, from the cavity 2. The jacks 11 remain in the example described in the retracted position until the end of the filling of the cavity 2, as seen in FIG. 2, and does not advance until the cavity 2 is filled, as illustrated in FIG. 3.

The jacks 11 can advance only a relatively small distance, for example of the order of mm.

In the example considered, the pressure applied by the cylinders 11 on the thermoplastic material 17 contained in the cavity 2 is of the order of 300 bars.

The cylinders can only assist compaction of the material in the mold cavity, the injection screw can be used for compaction.

The jacks 11 can also be actuated, after the closure of the one or more

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 channels 7, to cause compaction of the thermoplastic material 17 in the cavity 2.

It is then possible, if necessary, to reload the sleeve while the compaction phase lasts by means of the jacks.

In the example considered, temperature and pressure sensors 15 are provided for measuring the temperature and the pressure in the mold cavity 2 at various locations and are connected to a control device 18 arranged to control the operation of the jacks 11 and possibly the displacement of the shutter 6 associated with each injection nozzle 4.

The control device 18 is arranged so as to move the jacks 11 at predetermined times in the manufacturing cycle.

FIG. 6 shows a fuel tank 20 of which at least part has been obtained by means of the device 1 of FIGS. 1 and 2.

The thermoplastic material was injected through three secondary supply channels 21, shown in dotted lines, supplied from a primary supply channel 22.

The injection nozzles have not been shown in this figure, for the sake of clarity.

The cylinders 11 are partially shown in dotted lines for locally compacting the thermoplastic material.

The positioning of the annex chambers and of the corresponding jacks is chosen so as to best respond to the problems posed by the circulation of the material in the mold cavity during filling.

In particular, it may be advantageous to position the annex chambers and the corresponding cylinders in locations relatively distant from the injection points.

Thus, it is possible, during the advance of the jacks, to generate a local injection of material and a compaction favorable to good filling of the regions of the mold cavity remote from the injection points.

The jacks 11 can also be used to modify the flow of the material in the mold cavity 2 during the filling of the latter.

To do this, the jacks 11 are advanced so as to project into the

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 cavity 2 so that their front end constitutes an obstacle for the flow of the material and creates a local pressure drop slowing down the filling of the mold cavity.

The jacks 11 can be used for the sole purpose of modifying the flow of the material in the cavity 2, but preferably they will be used at least to assist in compacting the material in the cavity 2.

The invention also makes it possible to produce an injection assembly 30 shown very diagrammatically in FIG. S, comprising two injection devices such as that previously described, referenced 1 and 1 ′.

These two devices 1 and 1 'are connected to a common source 31 of thermoplastic material.

The device 1 'is similar to the device 1 previously described, and comprises one or more shutters 6' for closing the injection nozzles and one or more jacks 11 'for compacting the thermoplastic material.

A control device 32 connected to pressure and temperature sensors, not shown, manages in particular the operation of the shutters 6 and 6 'and that of the jacks 11 and 11'.

The devices 1 and 1 ′ have mold cavities 2 and 2 ′ of different shapes, intended for example for the production of two half-shells from the same fuel tank.

These two half-shells correspond, for example, to different volumes and masses of material.

The device 1 communicates with the source 31 via a supply channel 33 and the device 1 'communicates with the source 31 via a supply channel 34.

The channels 33 and 34 are preferably dimensioned so that the end of the filling of the cavities 2 and 2 'takes place substantially simultaneously for the devices 1 and the.

The compaction of the thermoplastic material within the mold cavities 2 and 2 'can be carried out independently of the source 31 after closing the shutters 6 and 6', thanks to the jacks 11 and 11 '.

Thus, the material can be introduced into the barrel of the injection screw

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 necessary for a next injection during the compacting phase of the thermoplastic material contained in the cavities 2 and 2 '.

The duration of a manufacturing cycle is thereby reduced.

The cylinders 11 and 11 'allow each cavity 2 and 2' to be kept under pressure without having to use two injection screw and sheath assemblies.

It is not going beyond the scope of the present invention when the injection screw is used to compact the material in the cavities 2 and 2 'and the cylinders 11 and 11' are only used to assist compaction.

Of course, the invention is not limited to the examples which have just been described.

In particular, the displacement of the cylinders can be carried out in multiple ways throughout the manufacturing cycle.

Thus, instead of positioning the jacks in a retracted position when the mold cavity is filled, on the contrary, as illustrated in FIG. 7, they can be positioned in an advanced position, for example a position in which the face 11a comes substantially to flush with the mold cavity.

The jacks can be kept in this position until the filling of the cavity 2 is completed.

Once the cavity 2 is filled, the jacks 11 can be moved back and the annex chambers 10 are left to fill, as illustrated in FIG. 8.

The jacks 11 can then be advanced to compact the material.

It is also possible to let the jacks 11 gradually retreat under the effect of the filling pressure and once the cavity 2 is filled, advance the jacks.

An advantage of making the cylinders move back with the pressure of the material in the mold cavity is to reduce the appearance defects, since the filling front is less disturbed when it reaches the cylinders when the latter have not yet declined.

It will be noted that the presence of the annex chambers 10 leaves traces on the part produced, which however are not troublesome in the case of a motor vehicle fuel tank, since the tank is not intended to be visible.

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Claims (26)

1. Device for producing at least one part by injection molding of thermoplastic material (17), in particular a fuel tank half-shell, comprising at least one mold cavity (2; 2 ') formed between parts (2a, 2b) of the mold, the shape of this cavity being adapted to that of the part (20) to be produced, characterized in that it comprises, associated with this mold cavity, at least one movable jack (11; 11 ') relative to said mold parts, capable of compacting the thermoplastic material contained in the mold cavity and / or modifying the circulation of the material therein, and a control device (18; 32) for controlling the movement of this cylinder (11; 11 ') in a predetermined manner. 2. Device according to claim 1, characterized in that the jack is movable in an annex chamber (10) communicating with the mold cavity, between a retracted position in which it is set back from the mold cavity, and a advanced position. 3. Device according to claim 2, characterized in that in the advanced position, the actuator is set back from the mold cavity (fig. 3). 4. Device according to claim 2, characterized in that in the advanced position, the jack comes flush with the mold cavity (fig. 7). 5. Device according to claim 2, characterized in that in the advanced position, the cylinder protrudes into the mold cavity (fig. 4). 6. Device according to any one of the preceding claims, characterized in that it comprises two mold parts (2a, 2b) bearing against one another to form the mold cavity. 7. Device according to any one of the preceding claims, characterized in that it comprises at least two mold cavities (2; 2 ') of different shapes for the simultaneous molding of two different parts, in particular of two half-shells a fuel tank, supplied from the same source of thermoplastic material (31), at least one jack (11; 11 ') controlled by the control device (32) being associated with each mold cavity (2; 2 '). <Desc / Clms Page number 12>  8. Device according to any one of the preceding claims, characterized in that it comprises at least one shutter (6; 6 ') making it possible to isolate the or each mold cavity (2; 2') from the source of thermoplastic material (31), this shutter (6) being controlled by the control device (18; 32). 9. Device according to any one of the preceding claims, characterized in that at least one jack (11; 11 ') is moved by a hydraulic mechanism. 10. Device according to any one of the preceding claims, characterized in that the control device (18; 32) is arranged to bring at least one cylinder (11; 11 ') into a retracted position at the start of filling of the cavity (2; 2 '). 11. Device according to any one of claims 1 to 9, characterized in that the control device (18; 32) is arranged to bring at least one jack (11; 11 ') into an advanced position at the start of filling. of the cavity (2; 2 '). 12. Device according to the preceding claim, characterized in that the control device (18; 32) is arranged to allow at least one jack (11; 11 ') to move back under the effect of the pressure of the thermoplastic material in the cavity (2; 2 ') during filling. 13. Device according to any one of the preceding claims, characterized in that at least one jack (11; 11 ') is arranged so as to be able to compact the thermoplastic material in the mold cavity (2; 2') at a pressure between 200 and 500 bars. 14. Device according to any one of the preceding claims, characterized in that it is capable of using a thermoplastic material (17) of grade (HLMI) between 1 and 50, preferably between 5 and 30, measured according to the standard ISO 1133 (unit: g / 10 min). 15. Device according to any one of the preceding claims, characterized in that the control device (18; 32) receives information from sensors (15) of pressure and / or temperature associated with the mold cavity (2; 2 ') and by the fact that it is arranged to control the movement of at least one jack (11; 11') according to information supplied by the sensors. <Desc / Clms Page number 13>  16. Method for producing a part made of thermoplastic material by injection molding, characterized in that it comprises the following steps - injecting by one or more injection points (3) into a mold cavity (2; 2 ') defined by mold parts, thermoplastic material (17) from a source of thermoplastic material, - move at least one cylinder (11; 11 ') relative to the mold parts so as to compact the material therein ci and / or assist its compaction and / or modify its flow. 17. The method of claim 16, characterized in that the cylinder, being advanced, performs a local injection of a volume of material between 1 and 10 cm3. 18. The method of claim 16 or 17, characterized in that the cylinder is advanced at the end of the filling of the mold cavity and / or past a certain degree of filling of the mold cavity, so as to compact the material in it and / or assist the end of its filling. 19. The method of claim 18, characterized in that the cylinder (11; 11 ') is allowed to retreat gradually under the effect of the pressure of the material in the mold cavity (2; 2'), before to advance it. 20. The method of claim 16, characterized in that the cylinder is advanced so that it protrudes into the mold cavity and changes the flow of material therein during filling. 21. Method according to any one of claims 16 to 20, characterized in that at the end of the filling of the cavity (2; 2 ') and before the compacting of the material therein, the or the injection points (3). 22. Method according to the preceding claim, characterized in that the injection point or points (3) are closed by means of one or more mechanical shutters (6; 6 '). 23. The method of claim 21, characterized in that the injection point (s) (3) are closed off by allowing the material to cool at their level. 24. Method according to any one of claims 16 to 23, characterized in that at the end of the filling of the mold cavity (2; 2 '), the latter is isolated from the source of thermoplastic material (31 ), and by the fact that we then compact the <Desc / Clms Page number 14>  material in the mold cavity (2; 2 ') using one or more jacks while loading the sheath used to feed the mold cavity. 25. Method according to any one of claims 16 to 24, characterized in that one fills two mold cavities (2; 2 ') corresponding to different parts, in particular two half-shells of a fuel tank (20), from the same source of thermoplastic material (31), and by the fact that the thermoplastic material is compacted in each of these mold cavities or that its compacting is assisted, by means of at least one cylinder. 26. Part made of thermoplastic material, in particular a motor vehicle fuel tank, obtained by implementing the method as defined in any one of claims 16 to 25.