JP3637832B2 - Method for producing hollow resin container - Google Patents

Method for producing hollow resin container Download PDF

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Publication number
JP3637832B2
JP3637832B2 JP2000053469A JP2000053469A JP3637832B2 JP 3637832 B2 JP3637832 B2 JP 3637832B2 JP 2000053469 A JP2000053469 A JP 2000053469A JP 2000053469 A JP2000053469 A JP 2000053469A JP 3637832 B2 JP3637832 B2 JP 3637832B2
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Japan
Prior art keywords
resin
intermediate molded
container
jig
joint
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JP2000053469A
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JP2001239586A (en
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洋一 石丸
高志 長瀬
秀昭 高橋
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Toyota Motor Corp
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Toyota Motor Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • B29C66/1312—Single flange to flange joints, the parts to be joined being rigid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/20—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools with direct contact, e.g. using "mirror"
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/82—Testing the joint
    • B29C65/8207—Testing the joint by mechanical methods
    • B29C65/8238—Impact tests
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/24—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight
    • B29C66/242—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours
    • B29C66/2424—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being a closed polygonal chain
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/32—Measures for keeping the burr form under control; Avoiding burr formation; Shaping the burr
    • B29C66/326—Shaping the burr, e.g. by the joining tool
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • B29C66/7234—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered comprising a barrier layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/712—Containers; Packaging elements or accessories, Packages
    • B29L2031/7172—Fuel tanks, jerry cans

Description

【０００１】
【発明の属する技術分野】
本発明は中空樹脂容器の製造方法に係り、特に、自動車に搭載されるフューエルタンク等の中空樹脂容器の製造方法に関する。
【０００２】
【従来の技術】
従来、自動車に搭載されるフューエルタンク等の中空樹脂容器の製造方法の一つとして、分割成形された複数の樹脂製中間成形品を、互いの接合面を溶着することによって中空状の一体に成形する方法があり、その一例を次に説明する。
【０００３】
図１０に示される如く、この中空樹脂容器の製造方法では、樹脂製中間成形品１００を支持する上治具１０４と、樹脂製中間成形品１０２を支持する下治具１０６を接近させると、下治具１０６のシール部１０６Ａの先端部が、上治具１０４の外周部１０４Ａの外側に重なるため、樹脂製中間成形品１００の接合部と樹脂製中間成形品１０２の接合部とを溶着する際に、圧縮した樹脂が矢印Ｗに示される如く、容器の内側のみに流れるようになっている。この結果、この中空樹脂容器の製造方法では、中間成形品１００の接合部と中間成形品１０２の接合部において溶融した樹脂により、溶着部１０８の容器内側に凸部１１０が形成され、溶着部１０８の根元部にくびれを有する小さなバリが発生するのを抑制できるようになっている。
【０００４】
【発明が解決しようとする課題】
しかしながら、この中空樹脂容器の製造方法では、凸部１１０の根元の曲率半径（以下、溶着バリ根元ｒという）が小さくなる場合があり、この溶着バリ根元ｒが小さくなると、凸部１１０に荷重が作用した場合に根元部への応力集中が大きくなり、溶着部強度低下の原因になる。
【０００５】
本発明は上記事実を考慮し、溶着部強度を向上できる中空樹脂容器の製造方法を得ることが目的である。
【０００６】
【課題を解決するための手段】
請求項１記載の本発明は、シート材の外側に樹脂層を有する複数の中間成形品の周縁部を重ねて溶着する中空樹脂容器の製造方法であって、
前記シート材の前記周縁部溶着時での溶融樹脂流れ値を、前記樹脂層を構成する樹脂の前記周縁部溶着時での溶融樹脂流れ値より低くすると共に、前記周縁部溶着時に前記複数の樹脂製中間成形品の各接合部の接合面と内側面とを溶融させた後、前記複数の中間成形品の周縁部溶着時に前記複数の樹脂製中間成形品の各接合部を支持する上下治具の一方の治具に他方の治具に向けて立設したシール部を前記他方の治具の外周部の外側に重ね各接合部に圧力をかけることで、圧縮された溶融樹脂を容器内側に流すことにより、溶着部の容器内側のみに凸部を形成することを特徴とする。
【００１３】
従って、溶着部の容器内側部を形成するシート材の周縁部溶着時での溶融樹脂流れ値が、樹脂層を構成する樹脂の周縁部溶着時での溶融樹脂流れ値より低いと共に、周縁部溶着時に複数の樹脂製中間成形品の各接合部の接合面と内側面とを溶融させた後、複数の中間成形品の周縁部溶着時に複数の樹脂製中間成形品の各接合部を支持する上下治具の一方の治具に他方の治具に向けて立設したシール部を他方の治具の外周部の外側に重ね各接合部に圧力をかけることで、圧縮された溶融樹脂を容器内側に流すため、溶着部の内側面での樹脂の膨出がシート材によって抑制され、溶着部に形成される溶着バリ根元ｒを大きくできる。この結果、凸部の根元への応力集中を緩和できるため、溶着部強度を向上できる。
【００１４】
【発明の実施の形態】
本発明の一実施形態に係る中空樹脂容器（本実施形態では、自動車用フューエルタンク）の製造方法を図１〜図３に従って詳細に説明する。
【００１５】
図２に示される如く、本実施形態では、凹状でかつ開口周縁部を有する複数（本実施形態では、上下２個）の樹脂製中間成形品１０、１２を溶着プレスするための一対の上治具１４と下治具１６にそれぞれセットする。また、樹脂製中間成形品１０、１２はそれぞれ射出成形等により成形されており、燃料漏れを防止するための多層フィルムで構成されたシート材１３を樹脂層１５の内周面に有する構成とされている。
【００１６】
シート材１３を構成する多層フィルムの中の少なくとも１層の溶融樹脂流れ値（以下、ＭＦＲという）は、樹脂層１５を構成する母材樹脂のＭＦＲより低く設定されている。例えば、シート材１３のＭＦＲを０．１ｇ／１０ｍｉｎ以下とし、樹脂層１５のＭＦＲを０．２ｇ／１０ｍｉｎ以上とするために、シート材１３としては、日本合成化学（株）のエチレンビニルアルコールＤＴ−２９０３を使用し、樹脂層１５を構成する母材樹脂としては、日本ポリオレフィン（株）の押し出しグレードＳ４００２を使用している。
【００１７】
図３に示される如く、上側の中間成形品１０には、カットオフバルブ１８等の付属部品が配設されている。このカットオフバルブ１８は上部側中間成形品１０と下部側中間成形品１２とからなる中空樹脂容器２０としてのフューエルタンクにインレットパイプ２２を通して燃料を入れていくときフューエルタンク内の上部に溜まる気体を抜くためのパイプであり、燃料がバルブ位置まで上がってくると閉まり、燃料液面がバルブ位置より下にあると開いた状態になる。なお、カットオフバルブ１８から逃がされる気体は、燃料ポンプ装着開口部２４を挿通しているパイプ（図示省略）を通してタンク外部に逃がされるようになっている。
【００１８】
なお、図３に示される如く、下部側中間成形品（フューエルタンク下部品）１２に形成する付属部品であるサブタンク２６及びセパレータ２８は下部側中間成形品成形時に一体成形されている。
【００１９】
図１（Ａ）に示される如く、中間成形品１０の接合部１０Ａと中間成形品１２の接合部１２Ａとは、互いに対向するフランジ部となっており、接合部１０Ａ、１２Ａの容器外側端部には、それぞれ離間する側、即ち、接合部１０Ａでは紙面上側、接合部１２Ａでは紙面下側へ向けて凸部１０Ｂ、１２Ｂが形成されている。
【００２０】
中間成形品１０の接合部１０Ａと中間成形品１２の接合部１２Ａとの間には、熱板３０が配設されており、この熱板３０によって、中間成形品１０の接合部１０Ａと中間成形品１２の接合部１２Ａとの双方を溶融するようになっている。なお、各図面では中間成形品１０、１２の溶融部分を斑点付きハッチングによって示している。
【００２１】
熱板３０の側断面形状はＴ字状となっており、中間成形品１０、１２の内側に位置し、接合部１０Ａ、１２Ａの内側面１０Ｃ、１２Ｃを溶融する立ち壁部３０Ａ、３０Ｂと、この立ち壁部３０Ａ、３０ＢとＴ字状に交わり接合面１０Ｄ、１２Ｄを溶融する水平部３０Ｃとで構成されている。このため、熱板３０を加熱すると、熱板３０の水平部３０Ｃによって、中間成形品１０、１２の接合面１０Ｄ、１２Ｄの双方が溶融すると共に、熱板３０の立ち壁部３０Ａ、３０Ｂによって、接合部１０Ａ、１２Ａの内側面１０Ｃ、１２Ｃがそれぞれ溶融するようになっている。また、中間成形品１０、１２の接合部１０Ａ、１２Ａの接合面１０Ｄ、１２Ｄと内側面１０Ｃ、１２Ｃとの境には、面取り部１０Ｅ、１２Ｅが形成されている。また、シート材１３の縁部１３Ａは、面取り部１０Ｅ、１２Ｅまで延設されており、先端部は、接合面１０Ｄ、１２Ｄに達している。
【００２２】
即ち、本実施形態では、シート材１３のＭＦＲを、樹脂層１５を構成する母材樹脂のＭＦＲより低くすると共に、中間成形品１０、１２の接合部１０Ａ、１０Ａに面取り部１０Ｅ、１２Ｅを形成することで、図１（Ｃ）に示すように、溶着部３５の内側面での樹脂の膨出がシート材１３によって抑制される。この結果、図１（Ｄ）に示すように、溶着部３５の内側面に形成される凸部３７周縁の曲率半径（溶着バリ根元ｒ）を大きくすることができる。
【００２３】
また、本実施形態では、図２に示される如く、上治具１４の外周部に、中間成形品１０の接合部１０Ａの根元部近傍を保持する凸部１４Ａと、中間成形品１０の接合部１０Ａの凸部１０Ｂを保持する凹部１４Ｂとが形成されており、凸部１４Ａと凹部１４Ｂとの間では、上治具１４と接合部１０Ａとの間に隙間３１が形成されている。
【００２４】
同様に、下治具１６の外周部には、中間成形品１２の接合部１２Ａの根元部近傍を保持する凸部１６Ａと、中間成形品１２の接合部１２Ａの凸部１２Ｂを保持する凹部１６Ｂとが形成されており、凸部１６Ａと凹部１６Ｂとの間では、下治具１６と接合部１６Ａとの間に隙間３３が形成されている。
【００２５】
また、下治具１６には、凹部１６Ｂの外側部に、上治具１４に向けてシール部１６Ｃが立設しており、図１（Ｂ）に示される如く、中間成形品１０の接合部１０Ａと中間成形品１２の接合部１２Ａとを溶着する際に、上治具１４と下治具１６を接近させると、シール部１６Ｃの先端部が、上治具１４の外周部１４Ｃの外側に重なるようになっている。なお、図１（Ｂ）に符号１７で示す隙間は無くても良い。
【００２６】
次に、本実施形態の作用を説明する。
【００２７】
本実施形態では、例えば、２００℃の熱板３０によって３分間加熱し中間成形品１０、１２の接合部１０Ａ、１２Ａの溶融が完了した後に、上治具１４と下治具１６とともに、中間成形品１０と中間成形品１２を離間する方向へ所定距離移動し、熱板３０を容器外方向（図１（Ａ）の矢印Ａ方向）へ引き抜く。その後、上治具１４と下治具１６とともに、中間成形品１０と中間成形品１２を接近する方向（例えば、上治具１４を図１（Ｂ）の矢印Ｂ方向）へ移動し、図１（Ｂ）に示す状態にする。その後、さらに中間成形品１０と中間成形品１２を接近する方向（例えば、上治具１４を図１（Ｃ）の矢印Ｂ方向）へ移動し、図１（Ｃ）に示す状態にする。その後、図１（Ｄ）に示される如く、中空樹脂容器に内圧（図１（Ｄ）の矢印Ｃ）をかけた状態で冷却した後、上治具１４と下治具１６とから中空樹脂容器２０を取り出す。
【００２８】
この際、本実施形態では、溶着部３５の容器内側部を形成するシート材１３のＭＦＲが、樹脂層１５を構成する樹脂のＭＦＲより低いため、溶着部３５の内側面での樹脂の膨出がシート材１３によって抑制される。この結果、溶着部３５の内側面に形成される溶着バリ根元ｒ径を大きくすることができる。従って、溶着部強度を向上でき、凸部３７周縁を起点とする破損を低減できる。
【００２９】
また、本実施形態の下治具１６には、凹部１６Ｂの外側部に、上治具１４に向けてシール部１６Ｃが立設されており、圧縮された樹脂が図１（Ｃ）の矢印Ｗに示される如く、容器の内側のみに流れる。このため、溶着部３５の容器内側に凸部３７を確実に形成することができ、更に溶着部強度を向上できる。
【００３０】
次に、シート材１３のＭＦＲと樹脂層１５を構成する樹脂のＭＦＲとに付いて図４〜図８に従って詳細に説明する。
【００３１】
図４に示される如く、試験片５０（長さＬ：５０ｍｍ、幅：４ｍｍ、厚さＨ：４ｍｍ）を一対の試験台５２に架設し、試験片５０の長手方向中央に形成した溶着部５０Ａに、試験錘５４（重量２５０ｇ）を高さ３ｍから落下する衝撃落錘試験を室温−４０℃において５本の試験片５０で行い、その結果を図５に示される如く、溶着バリ根元ｒ（ｍｍ）と非破壊（割れていない）割合（％）とのグラフとした。
【００３２】
このグラフから、溶着バリ根元ｒを３ｍｍ以上にすれば、溶着バリ根元への応力集中を緩和でき、非破壊割合が増加するといえる。また、溶着バリ根元ｒとＭＦＲとの関係は、図６のグラフに示される如くなるため、ＭＦＲを０．１ｇ／１０ｍｉｎ以下にすることで、溶着バリ根元ｒを３ｍｍ以上にできる。従って、溶着部強度を向上するためには、シート材１３のＭＦＲを０．１ｇ／１０ｍｉｎ以下とする必要がある。
【００３３】
一方、樹脂層１５においては、樹脂製中間成形品１０、１２を所定時間内に所定の形状に成形する必要があるため、ＭＦＲを極端に小さくできないため、ＭＦＲの下限値が決まる。具体的には、樹脂製中間成形品１０、１２に図７に示すリブ８０（長さＳｍｍ、下幅Ｋ１：５ｍｍ、上幅Ｋ２：２ｍｍ）を一体成形する場合のＭＦＲとリブ充填高さＳｍｍとの関係は、図８に示されるようになる。この結果、樹脂製中間成形品１０、１２において、必要となるリブの高さＳ＝８０ｍｍ以上を所定時間内に成形するには、樹脂層１５のＭＦＲを０．２ｇ／１０ｍｉｎ以上とする必要がある。
【００３４】
以上に於いては、本発明を特定の実施形態について詳細に説明したが、本発明はかかる実施形態に限定されるものではなく、本発明の範囲内にて他の種々の実施形態が可能であることは当業者にとって明らかである。例えば、前記実施形態では、下治具１６に、凹部１６Ｂの外側部に、上治具１４に向けてシール部１６Ｃを立設しており、図１（Ｂ）に示される如く、中間成形品１０の接合部１０Ａと中間成形品１２の接合部１２Ａとを溶着する際に、上治具１４と下治具１６を接近させると、シール部１６Ｃの先端部が、上治具１４の外周部１４Ｃの外側に重なるようになっているが、これに代えて、図９（Ａ）、（Ｂ）、（Ｃ）に示される如く、下治具１６の形状を上治具１４と同じにしても良い。なお、この場合には、図１（Ｄ）に示される如く、中空樹脂容器に内圧（図１（Ｄ）の矢印Ｃ）をかける工程は行わない。
【００３５】
また、前記実施形態では、シート材１３を多層フィルムで構成したが、これに代えて、シート材１３を一層構造としても良い。
【００３６】
また、前記実施形態では、中空樹脂容器２０として自動車のフューエルタンクを例にとったが、中空樹脂容器２０は自動車のフューエルタンクに限定されず他の中空樹脂容器でも良い。また、前記実施形態では、中空樹脂容器２０が樹脂製中間成形品１０、１２に二分割されているが、中空樹脂容器は３個以上の樹脂製中間成形品に分割されていても良い。
【００３７】
【発明の効果】
請求項１記載の本発明は、シート材の外側に樹脂層を有する複数の中間成形品の周縁部を重ねて溶着する中空樹脂容器の製造方法であって、シート材の周縁部溶着時での溶融樹脂流れ値を、樹脂層を構成する樹脂の周縁部溶着時での溶融樹脂流れ値より低くすると共に、周縁部溶着時に複数の樹脂製中間成形品の各接合部の接合面と内側面とを溶融させた後、複数の中間成形品の周縁部溶着時に複数の樹脂製中間成形品の各接合部を支持する上下治具の一方の治具に他方の治具に向けて立設したシール部を他方の治具の外周部の外側に重ね各接合部に圧力をかけることで、圧縮された溶融樹脂を容器内側に流すことにより、溶着部の容器内側のみに凸部を形成するため、溶着部強度を向上できるという優れた効果を有する。
【図面の簡単な説明】
【図１】（Ａ）〜（Ｄ）は本発明の一実施形態に係る中空樹脂容器の製造方法の中間成形品接合工程を順に示した、中空樹脂容器の接合部と装置を示す拡大断面図である。
【図２】本発明の一実施形態に係る中空樹脂容器の製造方法の中間成形品接合工程の加熱時を示した、中空樹脂容器の接合部と装置を示す断面図である。
【図３】本発明の一実施形態に係る中空樹脂容器の製造方法で製造された容器を示す分解斜視図である。
【図４】衝撃落錘試験の試験片と試験錘を示す概略斜視図である。
【図５】溶着バリ根元ｒと非破壊割合との関係を示すグラフである。
【図６】ＭＦＲと溶着バリ根元ｒとの関係を示すグラフである。
【図７】樹脂製中間成形品に形成するリブを示す拡大断面図である。
【図８】ＭＦＲとリブ充填高さとの関係を示すグラフである。
【図９】（Ａ）〜（Ｃ）は本発明の他の実施形態に係る中空樹脂容器の製造方法の中間成形品接合工程を順に示した、中空樹脂容器の接合部と装置を示す拡大断面図である。
【図１０】従来技術における中空樹脂容器の製造方法の中間成形品接合工程の一部を示した、中空樹脂容器の接合部と装置を示す拡大断面図である。
【符号の説明】
１０ 樹脂製中間成形品
１２ 樹脂製中間成形品
１３ シート材
１４ 上治具
１５ 樹脂層
１６ 下治具
３０ 熱版[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a hollow resin container , and more particularly to a method for manufacturing a hollow resin container such as a fuel tank mounted on an automobile.
[0002]
[Prior art]
Conventionally, as one method of manufacturing a hollow resin container such as a fuel tank mounted on an automobile, a plurality of resin-molded intermediate molded products are molded into a hollow body by welding the joint surfaces to each other. An example of this will be described next.
[0003]
As shown in FIG. 10, in this method of manufacturing a hollow resin container, when the upper jig 104 that supports the resin intermediate molded product 100 and the lower jig 106 that supports the resin intermediate molded product 102 are brought close together, Since the tip end portion of the seal portion 106A of the jig 106 overlaps the outer side of the outer peripheral portion 104A of the upper jig 104, the joining portion of the resin intermediate molded product 100 and the joint portion of the resin intermediate molded product 102 are welded. Further, as indicated by the arrow W, the compressed resin flows only inside the container. As a result, in this method for manufacturing the hollow resin container, the convex portion 110 is formed inside the container of the welded portion 108 by the resin melted at the joined portion of the intermediate molded product 100 and the joined portion of the intermediate molded product 102, and the welded portion 108 is formed. It is possible to suppress the generation of small burrs having a constriction at the root portion of the base.
[0004]
[Problems to be solved by the invention]
However, in this method of manufacturing a hollow resin container, the radius of curvature of the base of the convex portion 110 (hereinafter referred to as a weld burr root r) may be small, and when the weld burr root r is small, a load is applied to the convex portion 110. When it acts, the stress concentration at the root portion increases, causing a decrease in weld strength.
[0005]
In view of the above facts, an object of the present invention is to obtain a method for producing a hollow resin container capable of improving the weld strength.
[0006]
[Means for Solving the Problems]
The present invention according to claim 1 is a method for producing a hollow resin container in which peripheral edges of a plurality of intermediate molded products having a resin layer on the outside of a sheet material are stacked and welded,
The molten resin flow value at the time of peripheral edge welding of the sheet material is made lower than the molten resin flow value at the time of peripheral edge welding of the resin constituting the resin layer, and the plurality of resins at the time of peripheral edge welding. Upper and lower jigs that support the joints of the plurality of intermediate resin-molded products when the peripheral surfaces of the plurality of intermediate-molded products are welded after melting the joint surfaces and inner surfaces of the joints of the intermediate product in over one pressure jig to the other jig seal portion erected toward each joint superposed on the outer side of the outer peripheral portion of the other jig of Rukoto, the compressed molten resin container inner flowing in by, and forming a protrusion only on the container inside the welding unit.
[0013]
Therefore, the molten resin flow value at the peripheral edge welding of the sheet material forming the container inner part of the welded portion is lower than the molten resin flow value at the peripheral edge welding of the resin constituting the resin layer, and the peripheral edge welding. The upper and lower sides that support the joints of the plurality of resin intermediate molded products at the time of welding the peripheral portions of the plurality of intermediate molded products after sometimes melting the joint surface and the inner surface of the joints of the plurality of resin intermediate molded products in Rukoto applying pressure to the joint overlaid on the outer side of the outer peripheral portion of the one jig jig toward the other jig erected the seal portion other jig, vessel compressed molten resin Since it flows inside, the swelling of the resin on the inner surface of the welded portion is suppressed by the sheet material, and the weld burr root r formed in the welded portion can be increased. As a result, stress concentration at the base of the convex portion can be alleviated, so that the welded portion strength can be improved.
[0014]
DETAILED DESCRIPTION OF THE INVENTION
A method for manufacturing a hollow resin container (in this embodiment, an automobile fuel tank) according to an embodiment of the present invention will be described in detail with reference to FIGS.
[0015]
As shown in FIG. 2, in this embodiment, a pair of superiors for welding and pressing a plurality of (in the present embodiment, two upper and lower) resin intermediate molded products 10 and 12 having a concave shape and an opening peripheral edge. Set on tool 14 and lower jig 16 respectively. The resin intermediate molded products 10 and 12 are each molded by injection molding or the like, and have a sheet material 13 formed of a multilayer film for preventing fuel leakage on the inner peripheral surface of the resin layer 15. ing.
[0016]
The molten resin flow value (hereinafter referred to as MFR) of at least one layer in the multilayer film constituting the sheet material 13 is set lower than the MFR of the base material resin constituting the resin layer 15. For example, in order to set the MFR of the sheet material 13 to 0.1 g / 10 min or less and the MFR of the resin layer 15 to 0.2 g / 10 min or more, the sheet material 13 is ethylene vinyl alcohol DT of Nippon Synthetic Chemical Co., Ltd. -2903 is used, and as a base material resin constituting the resin layer 15, extrusion grade S4002 of Nippon Polyolefin Co., Ltd. is used.
[0017]
As shown in FIG. 3, the upper intermediate molded product 10 is provided with accessory parts such as a cut-off valve 18. This cut-off valve 18 is a gas that accumulates in the upper part of the fuel tank when the fuel is introduced through the inlet pipe 22 into the fuel tank as the hollow resin container 20 composed of the upper intermediate molded product 10 and the lower intermediate molded product 12. This pipe is used to close the pipe when the fuel reaches the valve position. When the fuel level is below the valve position, the pipe is opened. The gas released from the cut-off valve 18 is released to the outside of the tank through a pipe (not shown) inserted through the fuel pump mounting opening 24.
[0018]
As shown in FIG. 3, the sub tank 26 and the separator 28 that are accessory parts formed on the lower intermediate molded product (fuel tank lower component) 12 are integrally formed when the lower intermediate molded product is molded.
[0019]
As shown in FIG. 1A, the joint portion 10A of the intermediate molded product 10 and the joint portion 12A of the intermediate molded product 12 are flange portions facing each other, and the container outer end portions of the joint portions 10A and 12A. The convex portions 10B and 12B are formed on the sides that are separated from each other, that is, on the bonding portion 10A toward the upper side of the paper surface and on the bonding portion 12A toward the lower surface of the paper surface.
[0020]
A hot plate 30 is disposed between the joint portion 10A of the intermediate molded product 10 and the joint portion 12A of the intermediate molded product 12, and the hot plate 30 allows the joint portion 10A of the intermediate molded product 10 and the intermediate molding to be formed. Both the joint 12A of the product 12 are melted. In each drawing, the melted portions of the intermediate molded products 10 and 12 are indicated by spotted hatching.
[0021]
The side cross-sectional shape of the hot plate 30 is T-shaped, is located on the inner side of the intermediate molded products 10 and 12, and the standing wall portions 30A and 30B for melting the inner side surfaces 10C and 12C of the joint portions 10A and 12A, The standing wall portions 30A and 30B and a horizontal portion 30C that intersects in a T shape and melts the joint surfaces 10D and 12D. For this reason, when the hot plate 30 is heated, both the joining surfaces 10D and 12D of the intermediate molded products 10 and 12 are melted by the horizontal portion 30C of the hot plate 30 and the standing wall portions 30A and 30B of the hot plate 30 are The inner side surfaces 10C and 12C of the joint portions 10A and 12A are melted. Further, chamfered portions 10E and 12E are formed at the boundary between the joint surfaces 10D and 12D of the joint portions 10A and 12A of the intermediate molded products 10 and 12 and the inner side surfaces 10C and 12C. Further, the edge portion 13A of the sheet material 13 extends to the chamfered portions 10E and 12E, and the leading end portion reaches the joining surfaces 10D and 12D.
[0022]
That is, in the present embodiment, the MFR of the sheet material 13 is made lower than the MFR of the base resin constituting the resin layer 15, and the chamfered portions 10E and 12E are formed at the joint portions 10A and 10A of the intermediate molded products 10 and 12, respectively. By doing so, as shown in FIG. 1C, swelling of the resin on the inner surface of the welded portion 35 is suppressed by the sheet material 13. As a result, as shown in FIG. 1D, the radius of curvature (the weld burr root r) of the periphery of the convex portion 37 formed on the inner surface of the weld portion 35 can be increased.
[0023]
In the present embodiment, as shown in FIG. 2, the convex portion 14 </ b> A that holds the vicinity of the root portion of the joint portion 10 </ b> A of the intermediate molded product 10 and the joint portion of the intermediate molded product 10 on the outer peripheral portion of the upper jig 14. A concave portion 14B for holding the convex portion 10B of 10A is formed, and a gap 31 is formed between the convex portion 14A and the concave portion 14B between the upper jig 14 and the joint portion 10A.
[0024]
Similarly, on the outer peripheral portion of the lower jig 16, a convex portion 16A that holds the vicinity of the root portion of the joint portion 12A of the intermediate molded product 12 and a concave portion 16B that holds the convex portion 12B of the joint portion 12A of the intermediate molded product 12 are provided. And a gap 33 is formed between the lower jig 16 and the joint 16A between the convex portion 16A and the concave portion 16B.
[0025]
Further, the lower jig 16 is provided with a seal portion 16C standing on the outer side of the recess 16B toward the upper jig 14, and as shown in FIG. When the upper jig 14 and the lower jig 16 are brought close to each other when welding the joint portion 12A of the intermediate molded product 12 and 10A, the tip portion of the seal portion 16C is placed outside the outer peripheral portion 14C of the upper jig 14. It is supposed to overlap. Note that the gap indicated by reference numeral 17 in FIG.
[0026]
Next, the operation of this embodiment will be described.
[0027]
In the present embodiment, for example, after the heating of the hot plate 30 at 200 ° C. for 3 minutes to complete the melting of the joint portions 10A and 12A of the intermediate molded products 10 and 12, the intermediate molding is performed together with the upper jig 14 and the lower jig 16. The product 10 and the intermediate molded product 12 are moved by a predetermined distance in a direction away from each other, and the hot plate 30 is pulled out in the container outward direction (the direction of arrow A in FIG. 1A). Thereafter, together with the upper jig 14 and the lower jig 16, the intermediate molded product 10 and the intermediate molded product 12 are moved in a direction (for example, the upper jig 14 is moved in the direction of arrow B in FIG. 1B). The state shown in FIG. Thereafter, the intermediate molded product 10 and the intermediate molded product 12 are further moved in a direction in which the intermediate molded product 10 and the intermediate molded product 12 approach each other (for example, in the direction of arrow B in FIG. 1C) to obtain the state shown in FIG. Thereafter, as shown in FIG. 1D, the hollow resin container is cooled in a state where an internal pressure (arrow C in FIG. 1D) is applied to the hollow resin container. 20 is taken out.
[0028]
At this time, in this embodiment, since the MFR of the sheet material 13 forming the container inner portion of the weld portion 35 is lower than the MFR of the resin constituting the resin layer 15, the resin bulges on the inner surface of the weld portion 35. Is suppressed by the sheet material 13. As a result, the weld burr root r diameter formed on the inner surface of the weld portion 35 can be increased. Therefore, the welded portion strength can be improved, and damage starting from the periphery of the convex portion 37 can be reduced.
[0029]
Further, in the lower jig 16 of the present embodiment, a seal portion 16C is erected on the outer side of the recess 16B toward the upper jig 14, and the compressed resin is indicated by an arrow W in FIG. As shown in the figure, it flows only inside the container. For this reason, the convex part 37 can be reliably formed in the container inner side of the welding part 35, and also the welding part intensity | strength can be improved.
[0030]
Next, the MFR of the sheet material 13 and the MFR of the resin constituting the resin layer 15 will be described in detail with reference to FIGS.
[0031]
As shown in FIG. 4, a test piece 50 (length L: 50 mm, width: 4 mm, thickness H: 4 mm) is installed on a pair of test benches 52, and a welded part 50 </ b> A formed at the center in the longitudinal direction of the test piece 50. Further, an impact weight drop test in which a test weight 54 (weight 250 g) is dropped from a height of 3 m is performed with five test pieces 50 at room temperature −40 ° C., and the result is shown in FIG. mm) and non-destructive (not cracked) ratio (%).
[0032]
From this graph, it can be said that if the weld burr root r is 3 mm or more, the stress concentration on the weld burr root can be alleviated and the non-destructive ratio increases. Further, since the relationship between the welding burr root r and the MFR is as shown in the graph of FIG. 6, the welding burr root r can be 3 mm or more by setting the MFR to 0.1 g / 10 min or less. Therefore, in order to improve the welded portion strength, the MFR of the sheet material 13 needs to be 0.1 g / 10 min or less.
[0033]
On the other hand, in the resin layer 15, since it is necessary to mold the resin intermediate molded products 10 and 12 into a predetermined shape within a predetermined time, the MFR cannot be made extremely small, so the lower limit value of the MFR is determined. Specifically, the MFR and the rib filling height Smm when the rib 80 (length Smm, lower width K1: 5 mm, upper width K2: 2 mm) shown in FIG. The relationship between and is as shown in FIG. As a result, in the resin intermediate molded products 10 and 12, in order to mold the required rib height S = 80 mm or more within a predetermined time, the MFR of the resin layer 15 needs to be 0.2 g / 10 min or more. is there.
[0034]
Although the present invention has been described in detail with respect to specific embodiments, the present invention is not limited to such embodiments, and various other embodiments are possible within the scope of the present invention. It will be apparent to those skilled in the art. For example, in the above embodiment, the lower jig 16 is provided with the seal portion 16C on the outer side of the concave portion 16B toward the upper jig 14, and as shown in FIG. When the upper jig 14 and the lower jig 16 are brought close to each other when the 10 joints 10A and the joint 12A of the intermediate molded product 12 are welded together, the tip of the seal part 16C becomes the outer peripheral part of the upper jig 14 14C, but instead, the lower jig 16 has the same shape as the upper jig 14 as shown in FIGS. 9A, 9B, and 9C. Also good. In this case, as shown in FIG. 1D, the process of applying the internal pressure (arrow C in FIG. 1D) to the hollow resin container is not performed.
[0035]
Moreover, in the said embodiment, although the sheet | seat material 13 was comprised with the multilayer film, it may replace with this and the sheet | seat material 13 is good also as a single layer structure.
[0036]
Moreover, in the said embodiment, although the fuel tank of the motor vehicle was taken as an example as the hollow resin container 20, the hollow resin container 20 is not limited to the fuel tank of a motor vehicle, Other hollow resin containers may be used. Moreover, in the said embodiment, although the hollow resin container 20 is divided | segmented into the resin intermediate molded products 10 and 12, the hollow resin container may be divided | segmented into the 3 or more resin intermediate molded products.
[0037]
【The invention's effect】
The present invention according to claim 1 is a method for manufacturing a hollow resin container in which the peripheral portions of a plurality of intermediate molded products having a resin layer on the outside of a sheet material are stacked and welded, and the peripheral material is welded at the peripheral portion of the sheet material. The molten resin flow value is made lower than the molten resin flow value at the time of welding the peripheral portion of the resin constituting the resin layer, and the bonding surface and the inner surface of each joint portion of the plurality of resin intermediate molded products at the time of the peripheral portion welding After melting the seal, a seal is erected on one jig of the upper and lower jigs that support the joints of the plurality of resin intermediate molded products when the peripheral parts of the plurality of intermediate molded products are welded. parts in Rukoto applying pressure to the joint overlaid on the outer side of the outer peripheral portion of the other jig, by flowing the compressed molten resin into the container interior, to form the protrusions only on the container inside the welding portion And, it has an excellent effect that the welded portion strength can be improved.
[Brief description of the drawings]
FIGS. 1A to 1D are enlarged cross-sectional views showing a joint part and an apparatus of a hollow resin container, sequentially illustrating an intermediate molded product joining process of a method for producing a hollow resin container according to an embodiment of the present invention. It is.
FIG. 2 is a cross-sectional view showing a hollow resin container joint and an apparatus during heating in an intermediate molded product joining step of a method for producing a hollow resin container according to an embodiment of the present invention.
FIG. 3 is an exploded perspective view showing a container manufactured by a method for manufacturing a hollow resin container according to an embodiment of the present invention.
FIG. 4 is a schematic perspective view showing a test piece and a test weight for an impact drop test.
FIG. 5 is a graph showing the relationship between the weld burr root r and the non-destructive ratio.
FIG. 6 is a graph showing the relationship between MFR and weld burr root r.
FIG. 7 is an enlarged cross-sectional view showing ribs formed on a resin intermediate molded product.
FIG. 8 is a graph showing the relationship between MFR and rib filling height.
FIGS. 9A to 9C are enlarged cross-sectional views showing a joint part and an apparatus of a hollow resin container, which sequentially show an intermediate molded product joining step of a method for producing a hollow resin container according to another embodiment of the present invention. FIG.
FIG. 10 is an enlarged cross-sectional view showing a joining portion and a device of a hollow resin container, showing a part of an intermediate molded product joining step of a manufacturing method of a hollow resin container in the prior art.
[Explanation of symbols]
10 resin intermediate molded product 12 resin intermediate molded product 13 sheet material 14 upper jig 15 resin layer 16 lower jig 30 hot plate

Claims (1)

シート材の外側に樹脂層を有する複数の中間成形品の周縁部を重ねて溶着する中空樹脂容器の製造方法であって、
前記シート材の前記周縁部溶着時での溶融樹脂流れ値を、前記樹脂層を構成する樹脂の前記周縁部溶着時での溶融樹脂流れ値より低くすると共に、前記周縁部溶着時に前記複数の樹脂製中間成形品の各接合部の接合面と内側面とを溶融させた後、前記複数の中間成形品の周縁部溶着時に前記複数の樹脂製中間成形品の各接合部を支持する上下治具の一方の治具に他方の治具に向けて立設したシール部を前記他方の治具の外周部の外側に重ね各接合部に圧力をかけることで、圧縮された溶融樹脂を容器内側に流すことにより、溶着部の容器内側のみに凸部を形成することを特徴とする中空樹脂容器の製造方法。A method for producing a hollow resin container in which peripheral edges of a plurality of intermediate molded products having a resin layer on the outside of a sheet material are stacked and welded,
The molten resin flow value at the time of peripheral edge welding of the sheet material is made lower than the molten resin flow value at the time of peripheral edge welding of the resin constituting the resin layer, and the plurality of resins at the time of peripheral edge welding. Upper and lower jigs that support the joints of the plurality of intermediate resin-molded products when the peripheral surfaces of the plurality of intermediate-molded products are welded after melting the joint surfaces and inner surfaces of the joints of the intermediate product in over one pressure jig to the other jig seal portion erected toward each joint superposed on the outer side of the outer peripheral portion of the other jig of Rukoto, the compressed molten resin container inner A method for producing a hollow resin container is characterized in that a convex portion is formed only on the inner side of the welded portion of the container by flowing it into the container.
JP2000053469A 2000-02-29 2000-02-29 Method for producing hollow resin container Expired - Fee Related JP3637832B2 (en)

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