JP2004098886A - Automobile fuel tank and its manufacturing method - Google Patents

Automobile fuel tank and its manufacturing method Download PDF

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Publication number
JP2004098886A
JP2004098886A JP2002264258A JP2002264258A JP2004098886A JP 2004098886 A JP2004098886 A JP 2004098886A JP 2002264258 A JP2002264258 A JP 2002264258A JP 2002264258 A JP2002264258 A JP 2002264258A JP 2004098886 A JP2004098886 A JP 2004098886A
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JP
Japan
Prior art keywords
tank
upper
lower
synthetic resin
fuel
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
JP2002264258A
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Japanese (ja)
Inventor
Joji Kasugai
春日井 条治
Original Assignee
Fts:Kk
Toyota Motor Corp
トヨタ自動車株式会社
株式会社エフティエス
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Application filed by Fts:Kk, Toyota Motor Corp, トヨタ自動車株式会社, 株式会社エフティエス filed Critical Fts:Kk
Priority to JP2002264258A priority Critical patent/JP2004098886A/en
Publication of JP2004098886A publication Critical patent/JP2004098886A/en
Application status is Withdrawn legal-status Critical

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60KARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K15/00Arrangement in connection with fuel supply of combustion engines or other fuel consuming energy converters, e.g. fuel cells; Mounting or construction of fuel tanks
    • B60K15/03Fuel tanks
    • B60K15/03177Fuel tanks made of non-metallic material, e.g. plastics, or of a combination of non-metallic and metallic material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60KARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K15/00Arrangement in connection with fuel supply of combustion engines or other fuel consuming energy converters, e.g. fuel cells; Mounting or construction of fuel tanks
    • B60K15/03Fuel tanks
    • B60K2015/03032Manufacturing of fuel tanks
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60KARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K15/00Arrangement in connection with fuel supply of combustion engines or other fuel consuming energy converters, e.g. fuel cells; Mounting or construction of fuel tanks
    • B60K15/03Fuel tanks
    • B60K2015/03032Manufacturing of fuel tanks
    • B60K2015/03046Manufacturing of fuel tanks made from more than one layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60KARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K15/00Arrangement in connection with fuel supply of combustion engines or other fuel consuming energy converters, e.g. fuel cells; Mounting or construction of fuel tanks
    • B60K15/03Fuel tanks
    • B60K2015/03328Arrangements or special measures related to fuel tanks or fuel handling
    • B60K2015/03453Arrangements or special measures related to fuel tanks or fuel handling for fixing or mounting parts of the fuel tank together
    • B60K2015/0346Arrangements or special measures related to fuel tanks or fuel handling for fixing or mounting parts of the fuel tank together by welding

Abstract

An object of the present invention is to provide an automobile fuel tank having excellent gas barrier properties and low weight.
A synthetic resin automotive fuel tank in which an upper tank (10) and a lower tank (20) are joined and welded together at the peripheral edges of respective divided openings, wherein both the upper tank and the lower tank are made of a hard synthetic resin. A layer 11 and a barrier layer 12 made of a synthetic resin with low fuel permeability are formed on the tank inner surface of the base material layer. The base material layer is formed by injection molding. A fuel tank for an automobile integrally formed by injection molding or injection compression molding, and a method of manufacturing the same.
As a result, a fuel tank that is excellent in gas barrier properties and can contribute to uniform thickness reduction in weight can be obtained by the close contact between the base material layer and the barrier layer.
[Selection diagram] Fig. 1

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to an automobile fuel tank for storing fuel such as gasoline and a method for manufacturing the same.
[0002]
[Prior art]
Conventionally, as a fuel tank for gasoline or the like used for automobiles, from the viewpoint of strength and the like, a metal fuel tank manufactured by pressing and welding an iron plate or the like, or a synthetic resin from the viewpoint of workability, etc. Blow molded synthetic resin fuel tanks have been used. In particular, fuel tanks made of synthetic resin have been used in order to reduce the weight of the vehicle and improve the degree of freedom in design.
[0003]
However, when manufacturing a large-sized fuel tank by blow molding, when a heated and fluid parison is put into a mold from the upper part of the molding machine, the upper part becomes thinner than the lower part. In some cases, thickness uniformity could not be achieved. Also, if the shape of the fuel tank is large or complex, the expansion ratio of the parison when the parison is expanded in the mold may differ depending on the part of the product, and the thickness of the product may vary. May have occurred. Therefore, it is difficult to control the thickness of the product, and in order to satisfy the performance such as the tank strength, the entire thickness of the product must be increased. Therefore, the weight of the fuel tank was increased.
In addition, since the parison is sandwiched between molds in blow molding, relatively large burrs are generated, waste of material is large, and productivity is not good.
[0004]
Further, in the blow molding, since the parison is expanded in the mold, there is a restriction in disposing devices such as a fuel pump unit and a float in the fuel tank. Therefore, as shown in FIGS. 9 and 10, the upper and lower parts of the fuel tank are separately molded using a mold to form an upper tank 110 and a lower tank 120, and after cooling, the molded articles of the upper tank 110 and the lower tank 120 are joined. There is one that manufactures a fuel tank by using a conventional method (for example, see Patent Document 1).
However, when joining molded articles that have been cooled once, the joints become large and the weight of the fuel tank increases in order to obtain sufficient strength at the joints.
[0005]
On the other hand, a fuel tank is required to have a gas barrier property that does not allow gasoline or the like to pass therethrough in order to protect the global environment. Therefore, conventionally, in order to prevent fuel such as gasoline from permeating, first, a film having gas barrier properties is set in a mold, and the film is formed into the shape of the fuel tank 1 by vacuum forming, thereby forming the upper tank 110. Then, barrier layers 112 and 122 of the lower tank 120 are formed. Thereafter, as shown in FIG. 9, the synthetic resin forming the base material layers 111 and 121 is injection-molded on the barrier layers 112 and 122, that is, such that the barrier layers 112 and 122 are on the inner side surfaces of the fuel tank. Manufactured the fuel tank. However, when the synthetic resin forming the base layers 111 and 121 is injection-molded, the films of the barrier layers 112 and 122 may be stretched by the synthetic resin, and there is a possibility that sufficient barrier properties may not be obtained. Was. Further, the adhesiveness and the bondability between the films of the barrier layers 112 and 122 and the synthetic resin constituting the base layers 111 and 121 are sometimes insufficient.
Further, in the vicinity of the joined peripheral portion, it may be difficult to spread the gas barrier sheet to the ends of all the peripheral portions without leakage, and the gas barrier property is not sufficient.
[0006]
Also, a pair of molds for forming upper and lower divided bodies of the upper tank and the lower tank in which the fuel tank is divided into two are provided, and after the divided bodies are formed by injection molding with the respective molds, the mold is slid. There has also been a manufacturing method in which, after abutting the divided bodies with each other, a molten resin is injected into a peripheral edge of a face to which the divided bodies are fused to fuse the divided bodies together (for example, see Patent Document 2).
However, in this method, the equipment for sliding the mold and the like are complicated and expensive.
[0007]
[Patent Document 1]
Japanese Patent Application Laid-Open No. H10-1557738 (page 3-4, FIG. 1)
[Patent Document 2]
JP 2001-129851 A (Pages 3-5, FIG. 1)
[0008]
[Problems to be solved by the invention]
In view of the above, the present invention provides an automobile fuel tank which is easy to manufacture with simple equipment, has excellent gas barrier properties, and has a reduced weight, by injection molding or injection compression molding. That is the purpose.
[0009]
[Means for Solving the Problems]
According to a first aspect of the present invention, there is provided an automobile fuel made of a synthetic resin in which an upper tank constituting an upper part of a fuel tank divided into upper and lower parts and a lower tank constituting a lower part are joined together at a peripheral portion of each divided opening. In the tank, both the upper tank and the lower tank are composed of two synthetic resin layers, a base layer made of a hard synthetic resin and a barrier layer made of a synthetic resin with low fuel permeability formed on the tank inner surface of the base layer. The base layer is formed by injection molding, and the barrier layer is integrally formed on the inner surface of the base layer in the tank by injection molding or injection compression molding.
[0010]
According to the first aspect of the present invention, since the upper tank and the lower tank are separately formed, it is easy to mount the fuel pump unit and the like in the fuel tank. Since the base material layer is formed by injection molding, a fuel tank having a uniform thickness can be obtained, and as a whole, it can be formed thinner than a fuel tank formed by blow molding, and a light fuel tank can be obtained. it can. Further, since the barrier layer is integrally formed on the inner surface of the base layer by injection molding or injection compression molding, the barrier layer can be provided uniformly and evenly inside the fuel tank without fail. Are sufficiently adhered to each other, so that a fuel tank having excellent gas barrier properties can be obtained.
[0011]
According to a second aspect of the present invention, the substrate layer is provided with fine irregularities on the inner surface of the tank.
According to the present invention of Claim 2, since fine irregularities are provided on the tank inner surface of the base material layer, when the barrier layer is injection-molded or injection-compressed on the tank inner surface of the base material layer, the barrier layer is formed of the base material layer. Since it can penetrate into fine irregularities and the contact area increases, the adhesion between the base material layer and the barrier layer increases.
[0012]
According to a third aspect of the present invention, at each peripheral portion of the divided openings of the upper tank and the lower tank, the tank walls of the upper tank and the lower tank are formed with a leading end portion such that their leading ends contact each other over the entire circumference of the divided opening, Each of the abutting surfaces of the tip portions is provided with a barrier layer continuously extending from the inner surface of the tank wall.
[0013]
According to the third aspect of the present invention, the front end, the joining recess, and the outer peripheral projection are provided at the respective peripheral edges of the divided openings of the upper tank and the lower tank, and the front ends are brought into contact with each other. Fuel tank can be obtained.
Furthermore, since the barrier layer is also provided on the surface where the tip of the upper tank and the lower tank contact each other, the barrier layer is provided continuously from the barrier layer provided on the inner surface of the upper tank and the lower tank to the contact surface of the tip. The gas barrier property at the joint between the upper tank and the lower tank can be ensured.
[0014]
According to a fourth aspect of the present invention, an outer peripheral projection having a substantially L-shaped cross section is formed near the front end of the outer wall surface of the tank between the upper tank and the lower tank at a peripheral edge joint between the upper tank and the lower tank. The other end is formed substantially at right angles to the wall outer surface, and the other end is formed in parallel with the tank wall outer surface and in the direction of the divided opening, and between the outer protrusions of the upper tank and the lower tank and the tip of the tank wall, the directions facing each other A joint concave portion having a substantially U-shaped cross section that opens into the upper and lower tanks is provided with a fusion synthetic resin compatible with the base material of the upper tank and the lower tank in order to weld the upper tank and the lower tank. The injected synthetic resin is fused to the joint concave portions of the upper tank and the lower tank.
[0015]
According to the fourth aspect of the present invention, a fusion synthetic resin compatible with the base layer of the upper tank and the lower tank is injected into the joint recess, and the fusion synthetic resin and the wall surface of the joint recess of the upper tank and the lower tank are fused. Since the joining concave portion is U-shaped and has a large fusion area, the upper tank and the lower tank are firmly welded.
In addition, since it is only necessary to inject the fusion synthetic resin into the joint concave portion, no labor is required and the production is easy.
[0016]
According to a fifth aspect of the present invention, an outer peripheral projection having a substantially L-shaped cross section is formed near the front end of the outer wall of the tank of the upper tank and the lower tank, and one end of the outer peripheral projection is integrally formed substantially perpendicular to the outer surface of the tank wall. At the same time, the other end is formed parallel to the outer surface of the tank wall and in the direction of the divided opening, and the outer peripheral projections at the peripheral edges of the upper tank and the lower tank are thermally fused to each other.
According to the fifth aspect of the present invention, since the outer peripheral projections at the peripheral edges of the upper tank and the lower tank are mutually heat-welded, the upper tank and the lower tank are firmly joined.
Further, since only heat welding is required, no labor is required and the production is easy.
[0017]
According to a sixth aspect of the present invention, the upper and lower fuel tanks of the fuel tank divided into upper and lower parts are separately formed, and then the upper tank and the lower tank are joined by joining the peripheral edges of the divided openings. In the method of manufacturing an automotive fuel tank made of a synthetic resin, the upper tank and the lower tank are both formed by injection molding a hard synthetic resin into a mold to form a base material layer, and by slightly opening the mold to transmit fuel. A step of injecting a low-resistance synthetic resin into the tank inner surface of the base material layer to form a barrier layer integrally by injection molding or injection compression molding, and a step of joining a peripheral joint portion between the upper tank and the lower tank. .
[0018]
According to the sixth aspect of the present invention, after the base material layer is formed by injection molding, the mold is slightly opened to inject a synthetic resin having low fuel permeability into the tank inner surface of the base material layer to close the mold and close the barrier layer. Since it has a process of integrally forming the same, the same mold can be used to reduce the cost, and a thin barrier layer can be formed by a simple process. Layers can be provided.
In addition, since the fuel tank is manufactured by injection molding using a mold, a uniform tank wall can be formed, so that the tank wall can be made thinner as a whole, and the fuel tank can be made lighter and a uniform barrier can be obtained. A layer can be formed, and the gas barrier properties of the fuel tank can be improved.
[0019]
According to a seventh aspect of the present invention, in the step of joining the peripheral portions of the upper tank and the lower tank, a fusion synthetic resin compatible with the base material of the upper tank and the lower tank is filled in the joining concave portions provided on the peripheral portions of the upper tank and the lower tank. The upper tank and the lower tank are fused by injection molding.
According to the seventh aspect of the present invention, the upper tank and the lower tank are firmly fused only by injection molding a synthetic resin having compatibility with the base material of the upper tank and the lower tank in the joint concave portions provided on the peripheral edges of the upper tank and the lower tank. And the joining can be reliably performed by a simple process.
[0020]
According to an eighth aspect of the present invention, in the step of joining the peripheral portions of the upper tank and the lower tank, the outer peripheral protruding portions of the peripheral portions of the upper tank and the lower tank are melted by a hot plate, respectively, and heat-welded to each other.
According to the eighth aspect of the present invention, since the outer peripheral projections at the peripheral edges of the upper tank and the lower tank are heat-welded using a hot plate, a strongly welded fuel tank can be obtained with simple equipment and steps.
[0021]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a perspective view of an automotive fuel tank made of synthetic resin showing an embodiment of the present invention. FIG. 2 is a sectional view taken along line LL of FIG. 1, and FIG. 3 is a sectional view taken along line WW of FIG.
The fuel tank 1 includes an upper tank 10 that forms an upper half of a half and a lower tank 20 that forms a lower half of a half. The upper tank 10 and the lower tank 20 increase the strength of the fuel tank 1 on the outer surface of the fuel tank 1. For this purpose, reinforcing ribs 15 and 25 are provided, respectively.
The upper tank 10 is provided with a pump unit mounting hole 3 for mounting the pump unit 2 and a pipe mounting hole 4 for mounting the fuel supply pipe.
[0022]
The upper tank 10 and the lower tank 20 are respectively composed of two layers of base layers 11, 21 and barrier layers 12, 22.
FIG. 4 is an enlarged view of a portion indicated by A in FIG. As shown in FIG. 4, the base layers 11 and 21 of the upper tank 10 and the lower tank 20 have fine irregularities on the inner surface of the fuel tank 1.
The fine unevenness can be provided, for example, by forming a grain pattern, a dimple pattern, or a fine undercut pattern on the surfaces of the base material layers 11 and 21. The synthetic resin forming the barrier layers 12 and 22 enters into these fine irregularities, and the base layers 11 and 21 and the barrier layers 12 and 22 are firmly joined.
[0023]
As shown in FIG. 1, the upper tank 10 and the lower tank 20 are firmly joined over the entire periphery at the peripheral edge of the divided opening. Two detailed embodiments of the joining are shown in FIGS. The joining in the embodiment of FIG. 5 is a method of injecting and fusing a molten resin between the upper tank 10 and the lower tank 20 to be joined, and the joining in the embodiment of FIG. 6 is the joining of the upper tank 10 and the lower tank 20 to be joined. This is a welding method in which surfaces are fused and joined directly.
In the embodiment shown in FIG. 5, the peripheral edges 16, 26 of the divided openings of the upper tank 10 and the lower tank 20 are composed of tip portions 16a, 26a, outer peripheral projections 16c, 26c, and joining recesses 16b, 26b located therebetween.
The description will be made taking the peripheral portion 16 of the upper tank 10 as an example, but the same applies to the peripheral portion 26 of the lower tank 20.
The front end 16a of the peripheral portion 16 of the upper tank 10 is formed as a part of the tank wall of the upper tank 10 over the entire circumference of the divided opening at the front end thereof, and is in contact with the front end 26a of the lower tank 20 over the entire circumference. Therefore, when the distal end portion 16a abuts on the distal end portion 26a of the lower tank 20, the inner surfaces of the fuel tank 1 at the peripheral edges 16, 26 of the divided openings of the upper tank 10 and the lower tank 20 integrally form a smooth continuous surface. .
[0024]
The front end portion 16a has a flat surface in contact with the front end portion 26a of the lower tank 20 at the front end, and a barrier layer 12 continuous from the barrier layer 12 on the inner surface of the upper tank 10 is provided on the flat surface. Similarly, a barrier layer 22 continuous from the barrier layer 22 on the inner surface of the lower tank 20 is provided on the flat surface of the distal end portion 26 a of the lower tank 20. Therefore, when the tip of the tip 16a of the upper tank 10 abuts on the tip of the tip 26a of the lower tank 20, the barrier layers 12, 22 are uniformly and continuously provided on the inner surface of the fuel tank 1, and the peripheral edges 16, Since the barrier layers 12 and 22 are formed up to the joint surface between the tip portions 16a and 26a of the fuel cell 26, the barrier properties of the joint surface of the fuel tank 1 can be secured.
[0025]
The joint concave portion 16b is provided between the distal end portion 16a and the outer peripheral protrusion 16c, adjacent to the outer peripheral side of the distal end portion 16a, and is a concave portion having a substantially U-shaped cross section. The concave portion having a substantially U-shaped cross section of the joint concave portion 16b opens in a direction in which the joint concave portion 16b is joined to the lower tank 20. Therefore, when the distal end portion 16a comes into contact with the distal end portion 26a of the lower tank 20, the concave portion having a substantially U-shaped cross section of the joint concave portion 16b faces the opening of the joint concave portion 26b of the lower tank 20, and has a substantially elliptical cross section. A recess is formed.
In the embodiment shown in FIG. 5, a fused synthetic resin compatible with the base layers 11 and 21 of the upper tank and the lower tank is injected into the recesses having a substantially elliptical cross section, that is, the two joining recesses 16b and 26b. Therefore, the injected fused synthetic resin and the wall of the joint concave portion between the upper tank and the lower tank can be fused. Further, since the joining concave portion 16b has a U-shaped cross section and has a large fusion area, the upper tank and the lower tank are strongly joined.
[0026]
The outer peripheral protrusion 16c is provided near the distal end 16a and adjacent to the outer peripheral side of the joint recess 16b. That is, it is formed so that the joint concave portion 16b is sandwiched between the front end portion 16a and the outer peripheral protrusion 16c.
The outer peripheral projection 16c is formed in a substantially L-shaped cross section near the tip 16a on the outer surface of the tank wall of the upper tank 10. That is, one end is formed integrally with the outer surface of the tank wall at a substantially right angle from the outer surface of the tank wall slightly separated from the tip of the tip portion 16a of the upper tank, and the other end is formed parallel to the outer surface of the tank wall and in the direction of the divided opening. The lower tank 20 is provided so as to face the outer peripheral projection 26c. Therefore, the outer peripheral projection 16c constitutes the bottom wall and the outer peripheral side wall of the joint recess 16b.
[0027]
The outer peripheral projection 16c can also be integrally extended from the outer wall near the peripheral edge 16 of the divided opening of the upper tank 10 in a substantially T-shaped cross section. In this case, the point at which the T-shaped leg extends from the outer wall of the upper tank 10 and the point at which one end of the T-shaped head projects in the direction facing the outer peripheral projection 26c of the lower tank 20 are approximately L-section. This is the same as the embodiment of the character shape, except that the other end of the T-shaped head protrudes in the opposite direction to that of the embodiment having a substantially L-shaped cross section. In the case of the outer peripheral projection 16c having a substantially T-shaped cross section, when the upper tank 10 and the lower tank 20 are joined, the other end of the T-shaped head different from that of the embodiment having a substantially L-shaped cross section is sandwiched. Can be pressed against each other, so that the peripheral portions of the upper tank 10 and the lower tank 20 can be more firmly joined.
[0028]
In the embodiment of FIG. 5, when the upper tank 10 and the lower tank 20 are joined, the outer peripheral projections 16c and 26c face each other to form a recess having a substantially elliptical cross section as described above. However, the tips of the outer peripheral projections 16c and 26c do not come into contact with each other and there is a gap. Since the fusion synthetic resin compatible with the base layers 11 and 21 of the upper tank and the lower tank is injected from this gap, the upper tank 10 and the lower tank 20 are firmly joined.
[0029]
In the embodiment of FIG. 6, the distal ends of both outer peripheral projections 16c and 26c extend longer than the embodiment of FIG. The tips of the outer peripheral projections 16c and 26c are welded to each other by thermal welding. For this reason, the upper tank 10 and the lower tank 20 are firmly joined. When welding, the outer peripheral projections 16c and 26c are strongly pressed against each other until the distal ends 16a and 26a abut against each other over the entire circumference of the divided opening, and the distal ends are melted. Barrier layers 12 and 22 continuous from the inner surfaces of the upper tank 10 and the lower tank 20 are provided on the planes of the tip portions 16a and 26a. Therefore, when the distal end portion 16a of the upper tank 10 abuts on the distal end portion 26a of the lower tank 20, the barrier layers 12, 22 are uniformly and continuously provided on the inner surface of the fuel tank 1, and the joining surfaces of the peripheral portions 16, 26 are formed. Since the barrier layers 12 and 22 are formed to this extent, the barrier properties of the fuel tank 1 can be ensured.
[0030]
Further, the concave portion in which the two joining concave portions 16b and 26b face each other to form a concave portion having a substantially elliptical cross section can accommodate the protruding portions of the molten resin of the two outer peripheral projecting portions 16c and 26c generated at the time of heat welding. Thus, the welding between the upper tank 10 and the lower tank 20 can be sufficiently performed.
This thermal welding is performed by pressing the outer peripheral projections 16c and 26c, the distal ends of which are heated and melted, as described above, so that the distal ends 16a and 26a come into strong contact with each other.
[0031]
The synthetic resin used for the base layers 11 and 21 in the present invention is not particularly limited as long as it is a hard thermoplastic resin material having strength. Preferably, a polyolefin resin material containing a polyolefin resin as a main component is used. it can. As the polyolefin resin, any of a polypropylene resin and a polyethylene resin may be used.
As the polypropylene resin, a propylene homopolymer or a propylene-ethylene block copolymer can be used.
As the polyethylene resin, high-density polyethylene or medium-density polyethylene can be used.
[0032]
As the hard thermoplastic resin other than the polyolefin resin, a polyamide resin or a polyvinyl resin can be used. These thermoplastic resins can be used alone or as a blend of two or more resins.
Further, the hard synthetic resin used for the base material layers 11 and 21 in the present invention can be filled with glass fiber, inorganic fiber, carbon fiber, metal fiber or the like used for reinforcement.
Further, rubber components such as EPDM and EPR can be blended and used for improving elasticity.
[0033]
As the synthetic resin used for the barrier layers 12 and 22 in the present invention, a resin having a good gas barrier property and capable of preventing fuel permeation of gasoline or the like and having excellent fluidity is used. As this resin, for example, ethylene vinyl alcohol resin (EVOH), polyphenylene sulfide (PPS), liquid crystalline polymer (LCP), or the like can be used. However, the resin is not limited to these resins, and any resin having gas barrier properties against fuel permeation and excellent fluidity can be used.
[0034]
Next, a method for manufacturing a fuel tank for an automobile according to the present invention will be described with reference to FIGS.
The upper tank 10 and the lower tank 20 are formed separately. The description will be made taking the upper tank 10 as an example. As shown in FIG. 7A, the upper tank 10 is formed by injecting the above-described hard synthetic resin for forming the base layer 11 into the mold 40 from the injection gate 43a to form the base layer 11 first. .
Thereafter, as shown in FIG. 7B, the movable mold 42 is slightly opened, and the synthetic resin forming the barrier layer 12 is injected from the injection gate 43b into the base material layer 11. Thereby, the barrier layer 12 is thinly and uniformly formed on the inner surface of the base material layer 11, that is, on the side on which the inner surface of the fuel tank 1 is formed. Since the synthetic resin to be injected uses a synthetic resin having a high fluidity, the synthetic resin flows over the entire inner surface of the base layer 11 and the barrier layer 12 can be formed.
[0035]
The barrier layer 12 is formed by injection compression in which the movable mold 42 is slightly opened to inject the resin forming the barrier layer 12 into the base material layer 11, and then the mold 40 is closed again to compress the injected resin in the barrier layer 12. It can also be formed by molding. In this case, since the barrier layer 12 can be strongly compressed to the base material layer 11, the barrier layer 12 can be made thinner and the adhesion between the barrier layer 12 and the base material layer 11 is further improved.
[0036]
When the barrier layer 12 is formed, the mold 40 is slightly opened to inject the resin of the barrier layer 12. At this time, as shown in FIG. Since the side wall, that is, the surface of the wall forming the joining concave portion 16b is the same as the moving direction of the mold 40, no gap is formed between the outer peripheral wall of the distal end portion 16a and the fixed mold 41. Therefore, the injected synthetic resin forming the barrier layer 12 stops at the distal end surface of the distal end portion 16a. Therefore, the barrier layer 12 is reliably formed from the inner surface of the upper tank 10 to the front end surface of the front end portion 16a, and is not further formed to the joint recess 16b.
[0037]
Thus, the upper tank 10 and the lower tank 20 are formed separately. Thereafter, the peripheral edges 16, 26 of the upper tank 10 and the lower tank 20 are firmly joined to each other.
In the embodiment shown in FIG. 5, the distal ends 16a, 26a of the peripheral portions 16, 26 of the upper tank 10 and the lower tank 20 abut against each other. At this time, the joint concave portions 16b and 26b have openings facing each other to form a space having a substantially elliptical cross section, and the outer peripheral protrusions 16c and 26c face each other with a gap therebetween. A synthetic resin compatible with the base layers 11 and 21 is injected into the space having a substantially elliptical cross section from this gap. The fusion synthetic resin compatible with the base layers 11 and 21 is preferably the same synthetic resin as the base layers 11 and 21, but any suitable synthetic resin can be used. The upper tank 10 and the lower tank 20 are firmly joined by fusing the fusion synthetic resin and the base layers 11 and 21. Since the tip portions 16a and 26a are strongly pressed against each other when the fusion synthetic resin is injected, the joining surfaces of the upper tank 10 and the lower tank 20 are in close contact with each other and no gap is generated.
[0038]
In the embodiment shown in FIG. 6, the outer peripheral projections 16c and 26c are extended as described above. The distal ends of the long outer projections 16c and 26c are heated by a heating means such as a hot plate to be melted or softened. The melted or softened outer peripheral projections 16c and 26c of the upper tank 10 and the lower tank 20 are brought into contact with each other and firmly pressed. Then, the tips of the outer peripheral projections 16c and 26c are welded to each other, and the dimensions of the outer peripheral projections 16c and 26c are melted and shortened. The joining surfaces of 20 are in close contact with each other and no gap is generated.
[0039]
When the outer peripheral projections 16c and 26c abut against each other and are pressed firmly, the synthetic resin that has melted or softened protrudes to both sides, but the synthetic resin that protrudes to the vehicle interior can be accommodated in the joint recesses 16b and 26b. The barrier properties of the fuel tank 1 are ensured because the contact surfaces of the tips 16a and 26a are not affected.
The synthetic resin protruding outside the vehicle can be cut off with a knife or the like.
Through the above steps, the upper fuel tank 10 and the lower tank 20 can be separately formed, and then joined and welded to produce the integrated fuel tank 1 for an automobile.
[0040]
【The invention's effect】
ADVANTAGE OF THE INVENTION Since the wall of the fuel tank which was excellent in the gas barrier property with respect to fuel permeation was able to be made uniform and the weight was lightened, it can contribute to the weight reduction of a vehicle. Further, a fuel tank in which the upper tank and the lower tank are firmly joined can be obtained. Further, it is possible to obtain a fuel tank in which the barrier layer and the base material layer of the fuel tank are firmly joined at a low cost with less waste of material.
Further, the present invention is a method for manufacturing a fuel tank which can manufacture a fuel tank having excellent gas barrier properties against fuel permeation by a simple method quickly and inexpensively.
[Brief description of the drawings]
FIG. 1 is a perspective view of an automotive fuel tank of the present invention.
FIG. 2 is a cross-sectional view of the vehicle fuel tank of the present invention, taken along line LL of FIG.
FIG. 3 is a sectional view of the fuel tank for an automobile of the present invention, taken along line WW of FIG. 1;
FIG. 4 is a partially enlarged sectional view of a portion A in FIG. 2 of the fuel tank for an automobile of the present invention.
FIG. 5 is a partially enlarged sectional view of a portion B of FIG. 2 of the fuel tank for an automobile of the present invention.
6 is a partially enlarged sectional view of a portion B of FIG. 2 of the fuel tank for an automobile of the present invention.
FIG. 7 is a cross-sectional view of a mold for manufacturing the automobile fuel tank of the present invention. (A) is a diagram before the synthetic resin of the base material layer is injected, and (b) is a diagram in which the mold is slightly opened after the synthetic resin of the base material layer is injected.
FIG. 8 is a cross-sectional view of a mold for manufacturing the automotive fuel tank of the present invention, and is a partially enlarged cross-sectional view of a portion C.
FIG. 9 is a sectional view of a mold for manufacturing a conventional automobile fuel tank.
FIG. 10 is a cross-sectional view of a conventional automobile fuel tank.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Fuel tank 10 Upper tank 11, 21 Base material layer 12, 22 Barrier layer 16, 26 Peripheral edge 16a, 26a Tip 16b, 26b Joint recess 16c, 26c Outer peripheral projection 20 Lower tank 40 Mold

Claims (8)

  1. In an automotive fuel tank made of synthetic resin, an upper tank constituting an upper part of a fuel tank divided into two parts and a lower tank constituting a lower part are joined together at a peripheral portion of each divided opening.
    Each of the upper tank and the lower tank is composed of two synthetic resin layers, a base layer made of a hard synthetic resin and a barrier layer made of a synthetic resin with low fuel permeability formed on the tank inner surface of the base layer. ,
    A fuel tank for an automobile, wherein the base layer is formed by injection molding, and the barrier layer is integrally formed on the tank inner surface of the base layer by injection molding or injection compression molding.
  2. 2. The fuel tank for an automobile according to claim 1, wherein the base material layer has fine irregularities on the inner surface of the tank.
  3. At each peripheral edge of the divided opening of the upper tank and the lower tank,
    The tank walls of the upper tank and the lower tank are formed with a leading end so that their leading ends abut each other over the entire circumference of the divided opening, and the abutting surfaces of the leading ends extend continuously from the inner surface of the tank wall. 3. The fuel tank for an automobile according to claim 1, further comprising a barrier layer in contact therewith.
  4. At the peripheral joint of the upper tank and the lower tank,
    An outer peripheral projection having a substantially L-shaped cross section is formed near the front end of the outer wall of the tank of the upper tank and the lower tank, and one end of the outer peripheral projection is integrally formed substantially perpendicular to the outer surface of the tank wall, and the other end is formed. Is formed parallel to the outer surface of the tank wall and in the direction of the divided opening,
    Between the outer peripheral protrusion of the upper tank and the lower tank and the tip of the tank wall, a joint concave portion having a substantially U-shaped cross section that opens in a direction facing each other is provided.
    For the welding of the upper tank and the lower tank, a fusion synthetic resin compatible with the base material of the upper tank and the lower tank is injected into the joining recesses provided in the upper tank and the lower tank, respectively. 4. The fuel tank for an automobile according to claim 3, wherein the joint concave portions of the upper tank and the lower tank are fused.
  5. An outer peripheral projection having a substantially L-shaped cross section is formed near the front end of the outer wall of the tank of the upper tank and the lower tank, and one end of the outer peripheral projection is integrally formed substantially perpendicular to the outer surface of the tank wall, and the other end is formed. Is formed parallel to the outer surface of the tank wall and in the direction of the divided opening,
    4. The fuel tank for an automobile according to claim 3, wherein the outer peripheral projections at the peripheral edges of the upper tank and the lower tank are thermally fused to each other.
  6. A synthetic resin automobile fuel manufactured by separately forming an upper tank constituting an upper part and a lower tank constituting a lower part of a vertically divided fuel tank and joining peripheral edges of the divided openings of the upper tank and the lower tank. In the tank manufacturing method,
    Both upper tank and lower tank, a step of forming a base material layer by injection molding a hard synthetic resin into a mold,
    A step of injecting a synthetic resin having a low fuel permeability into the tank inner surface of the base material layer by slightly opening the mold, and integrally forming a barrier layer by injection molding or injection compression molding,
    A method of manufacturing a synthetic resin-made automobile fuel tank, comprising a step of joining a peripheral joint portion between the upper tank and the lower tank.
  7. In the step of joining the upper tank and the periphery of the lower tank,
    7. The upper tank and the lower tank according to claim 6, wherein the upper tank and the lower tank are fused by injection-molding a fusion synthetic resin having compatibility with the base material of the upper tank and the lower tank in a joint recess provided at a peripheral edge of the upper tank and the lower tank. A method for manufacturing an automotive fuel tank made of synthetic resin.
  8. In the step of joining the upper tank and the periphery of the lower tank,
    7. The method for manufacturing a synthetic resin fuel tank for an automobile according to claim 6, wherein the outer peripheral projections at the peripheral edges of the upper tank and the lower tank are melted by a hot plate and heat-welded to each other.
JP2002264258A 2002-09-10 2002-09-10 Automobile fuel tank and its manufacturing method Withdrawn JP2004098886A (en)

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Cited By (17)

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Publication number Priority date Publication date Assignee Title
JP2006192919A (en) * 2005-01-11 2006-07-27 Fts:Kk Fuel tank for automobile and its manufacturing method
JP2006200521A (en) * 2005-07-22 2006-08-03 Tokyo Radiator Mfg Co Ltd Aqueous urea tank
JP2006321309A (en) * 2005-05-18 2006-11-30 Fts:Kk Automobile fuel tank and its manufacturing method
GB2426952A (en) * 2005-06-06 2006-12-13 Im Pak Technologies Ltd Method and apparatus for forming an article
EP1872996A1 (en) * 2006-06-30 2008-01-02 HONDA MOTOR CO., Ltd. Fuel tank
WO2008041645A1 (en) 2006-09-29 2008-04-10 Daikin Industries, Ltd. Fuel tank and method for producing the same
JP2008238901A (en) * 2007-03-27 2008-10-09 Honda Motor Co Ltd Fuel tank of motorcycle
JP2010030298A (en) * 2008-07-04 2010-02-12 Taisei Plas Co Ltd Joint plated metal structure
JP2013119274A (en) * 2011-12-06 2013-06-17 Toyota Motor Corp Fuel tank
JP2013536108A (en) * 2010-07-13 2013-09-19 コーテックス テクストロン ジーエムビーエイチ アンド シーオー ケージー Resin fuel tank and its manufacturing method
WO2014147138A1 (en) * 2013-03-22 2014-09-25 Kautex Textron Gmbh & Co. Kg Operating fluid container for a motor vehicle
WO2014147014A1 (en) * 2013-03-22 2014-09-25 Kautex Textron Gmbh & Co. Kg Operating-fluid container
ITTO20130837A1 (en) * 2013-10-16 2015-04-17 Plastic Components And Modules Auto Motive S P A Fuel tank for a vehicle with improved resistance to combustion and process for its manufacture
ITTO20130836A1 (en) * 2013-10-16 2015-04-17 Plastic Components And Modules Auto Motive S P A A process for the manufacture of a fuel tank for a vehicle and obtainable by such a process tank
CN105050846A (en) * 2013-03-22 2015-11-11 考特克斯·特克斯罗恩有限公司及两合公司 Operating fluid tank
FR3064216A1 (en) * 2017-03-27 2018-09-28 Rm Tech Pressurized fuel tank of hybrid motor vehicle
DE102017119707A1 (en) * 2017-08-28 2019-02-28 Kautex Textron Gmbh & Co. Kg Liquid container and method of manufacturing a liquid container

Cited By (26)

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Publication number Priority date Publication date Assignee Title
JP2006192919A (en) * 2005-01-11 2006-07-27 Fts:Kk Fuel tank for automobile and its manufacturing method
JP2006321309A (en) * 2005-05-18 2006-11-30 Fts:Kk Automobile fuel tank and its manufacturing method
GB2426952A (en) * 2005-06-06 2006-12-13 Im Pak Technologies Ltd Method and apparatus for forming an article
JP2006200521A (en) * 2005-07-22 2006-08-03 Tokyo Radiator Mfg Co Ltd Aqueous urea tank
JP4652919B2 (en) * 2005-07-22 2011-03-16 東京ラヂエーター製造株式会社 Urea water tank
EP1872996A1 (en) * 2006-06-30 2008-01-02 HONDA MOTOR CO., Ltd. Fuel tank
WO2008041645A1 (en) 2006-09-29 2008-04-10 Daikin Industries, Ltd. Fuel tank and method for producing the same
EP2067648A4 (en) * 2006-09-29 2012-01-25 Daikin Ind Ltd Fuel tank and method for producing the same
US8334032B2 (en) 2006-09-29 2012-12-18 Daikin Industries, Ltd. Fuel tank and method for producing the same
JP2008238901A (en) * 2007-03-27 2008-10-09 Honda Motor Co Ltd Fuel tank of motorcycle
JP2010030298A (en) * 2008-07-04 2010-02-12 Taisei Plas Co Ltd Joint plated metal structure
JP2013536108A (en) * 2010-07-13 2013-09-19 コーテックス テクストロン ジーエムビーエイチ アンド シーオー ケージー Resin fuel tank and its manufacturing method
JP2013119274A (en) * 2011-12-06 2013-06-17 Toyota Motor Corp Fuel tank
CN105050846A (en) * 2013-03-22 2015-11-11 考特克斯·特克斯罗恩有限公司及两合公司 Operating fluid tank
WO2014147014A1 (en) * 2013-03-22 2014-09-25 Kautex Textron Gmbh & Co. Kg Operating-fluid container
US10035416B2 (en) * 2013-03-22 2018-07-31 Kautex Textron Gmbh & Co. Kg Operating-fluid container
US10011168B2 (en) 2013-03-22 2018-07-03 Kautex Textron Gmbh & Co. Kg Operating fluid tank
CN105073471A (en) * 2013-03-22 2015-11-18 考特克斯·特克斯罗恩有限公司及两合公司 Operating-fluid container
WO2014147138A1 (en) * 2013-03-22 2014-09-25 Kautex Textron Gmbh & Co. Kg Operating fluid container for a motor vehicle
EP2878476A1 (en) * 2013-10-16 2015-06-03 Plastic Components and Modules Automotive S.p.A. Fuel tank for a vehicle with improved fire resistance and method for the manufacture thereof
ITTO20130836A1 (en) * 2013-10-16 2015-04-17 Plastic Components And Modules Auto Motive S P A A process for the manufacture of a fuel tank for a vehicle and obtainable by such a process tank
ITTO20130837A1 (en) * 2013-10-16 2015-04-17 Plastic Components And Modules Auto Motive S P A Fuel tank for a vehicle with improved resistance to combustion and process for its manufacture
FR3064216A1 (en) * 2017-03-27 2018-09-28 Rm Tech Pressurized fuel tank of hybrid motor vehicle
EP3381730A1 (en) * 2017-03-27 2018-10-03 RM Technologies Pressurised fuel tank of hybrid motor vehicle
DE102017119707A1 (en) * 2017-08-28 2019-02-28 Kautex Textron Gmbh & Co. Kg Liquid container and method of manufacturing a liquid container
WO2019042901A1 (en) * 2017-08-28 2019-03-07 Kautex Textron Gmbh & Co. Kg Liquid container and method for producing a liquid container

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