JP5895922B2 - Fuel tank manufacturing method and fuel tank - Google Patents

Fuel tank manufacturing method and fuel tank Download PDF

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Publication number
JP5895922B2
JP5895922B2 JP2013228745A JP2013228745A JP5895922B2 JP 5895922 B2 JP5895922 B2 JP 5895922B2 JP 2013228745 A JP2013228745 A JP 2013228745A JP 2013228745 A JP2013228745 A JP 2013228745A JP 5895922 B2 JP5895922 B2 JP 5895922B2
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Japan
Prior art keywords
molten resin
resin sheet
mold
fuel tank
protrusion
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JP2013228745A
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Japanese (ja)
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JP2015085916A (en
Inventor
樹 木村
樹 木村
裕幸 川崎
裕幸 川崎
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Toyota Motor Corp
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Toyota Motor Corp
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Priority to JP2013228745A priority Critical patent/JP5895922B2/en
Priority to PCT/IB2014/002408 priority patent/WO2015063582A1/en
Publication of JP2015085916A publication Critical patent/JP2015085916A/en
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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
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/12—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor of articles having inserts or reinforcements
    • 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
    • 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
    • B29C65/24—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools characterised by the means for heating the tool
    • B29C65/30—Electrical means
    • 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
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/60—Riveting or staking
    • B29C65/606—Riveting or staking the rivets being integral with one of the parts to be joined, i.e. staking
    • B29C65/607—Riveting or staking the rivets being integral with one of the parts to be joined, i.e. staking the integral rivets being hollow
    • 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
    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
    • 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
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/532—Joining single elements to the wall of tubular articles, hollow articles or bars
    • 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
    • B29C66/61—Joining from or joining on the inside
    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/82—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps
    • B29C66/824—Actuating mechanisms
    • B29C66/8242—Pneumatic or hydraulic drives
    • 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
    • B29C66/83221—Joining or pressing tools reciprocating along one axis cooperating reciprocating tools, each tool 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
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
    • B29C2791/006—Using vacuum
    • 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
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
    • B29C2791/007—Using fluid under pressure
    • 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
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/04—Combined thermoforming and prestretching, e.g. biaxial stretching
    • B29C51/06—Combined thermoforming and prestretching, e.g. biaxial stretching using pressure difference for prestretching
    • 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
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/10—Forming by pressure difference, e.g. vacuum
    • 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
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/14—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets
    • 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
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/261—Handling means, e.g. transfer means, feeding means
    • B29C51/262—Clamping means for the sheets, e.g. clamping frames
    • 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
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/30—Moulds
    • B29C51/34—Moulds for undercut articles
    • B29C51/343—Moulds for undercut articles having recessed undersurfaces
    • 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
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/44—Removing or ejecting moulded 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
    • B29C66/01—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
    • 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
    • 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
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/812—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/8122—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the composition of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2823/00—Use of polyalkenes or derivatives thereof as mould material
    • B29K2823/04—Polymers of ethylene
    • B29K2823/08—Copolymers of ethylene
    • B29K2823/086—EVOH, i.e. ethylene vinyl alcohol copolymer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0065—Permeability to gases
    • B29K2995/0067—Permeability to gases non-permeable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0068—Permeability to liquids; Adsorption
    • B29K2995/0069—Permeability to liquids; Adsorption non-permeable
    • 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
    • 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
    • B29L2031/737—Articles provided with holes, e.g. grids, sieves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT 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
    • B60K15/00—Arrangement in connection with fuel supply of combustion engines or other fuel consuming energy converters, e.g. fuel cells; Mounting or construction of fuel tanks
    • B60K15/03—Fuel tanks
    • B60K2015/03032—Manufacturing of fuel tanks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT 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
    • B60K15/00—Arrangement in connection with fuel supply of combustion engines or other fuel consuming energy converters, e.g. fuel cells; Mounting or construction of fuel tanks
    • B60K15/03—Fuel tanks
    • B60K2015/03328—Arrangements or special measures related to fuel tanks or fuel handling
    • B60K2015/03453—Arrangements or special measures related to fuel tanks or fuel handling for fixing or mounting parts of the fuel tank together

Description

本発明は、燃料タンクの製造方法及び燃料タンクに関する。   The present invention relates to a fuel tank manufacturing method and a fuel tank.

樹脂で形成される燃料タンクに取付部品を取り付ける方法として、燃料タンクの一部を溶融させ、溶融した部分を取付部品の取付孔に押し込んだ状態で加圧して押し広げ、押し広げた部分と燃料タンクの他の部分とで取付部品の取付孔周辺部を挟んだ状態で樹脂を冷却固化させて、燃料タンクと取付部品を固定する方法がある（例えば、特許文献１参照）。   As a method of attaching the mounting part to the fuel tank made of resin, melt a part of the fuel tank, press and spread it with the molten part pushed into the mounting hole of the mounting part, and the expanded part and fuel There is a method of fixing the fuel tank and the mounting component by cooling and solidifying the resin in a state where the peripheral portion of the mounting hole of the mounting component is sandwiched between other parts of the tank (see, for example, Patent Document 1).

特表２００８−５０７６５１号公報Special table 2008-507651 gazette

ところで、特許文献１では、燃料タンクに取付部品を取り付けるための取付部を、燃料タンクの一部を溶融して形成している。このため、取付部を形成するための樹脂は、取付部を形成する部分の周囲から確保する必要がある。   By the way, in patent document 1, the attachment part for attaching attachment components to a fuel tank is formed by melting a part of fuel tank. For this reason, it is necessary to secure the resin for forming the attachment portion from around the portion forming the attachment portion.

本発明は上記事実を考慮し、燃料タンクに取付部品を取り付けるための取付部を形成するのに必要な樹脂量を確保できる燃料タンクの製造方法と、取付部品を取り付けるための取付部の強度を確保できる燃料タンクを得る。   In view of the above facts, the present invention provides a fuel tank manufacturing method capable of securing the amount of resin necessary to form a mounting portion for mounting a mounting part on the fuel tank, and the strength of the mounting portion for mounting the mounting part. Obtain a fuel tank that can be secured.

請求項１に記載の発明に係る燃料タンクの製造方法は、タンク本体を成形するための成形型の型面に対して余長分を有する溶融樹脂シートに前記成形型内で肉厚方向に突出する溶融樹脂突起を形成する賦形工程と、取付部品に設けられた取付孔に前記溶融樹脂突起を挿入して前記溶融樹脂シート上に前記取付部品を配置する配置工程と、前記取付孔に挿入された前記溶融樹脂突起を加圧して、前記溶融樹脂突起の一部を外周側に張り出させる加工工程と、備えている。   According to a first aspect of the present invention, there is provided a fuel tank manufacturing method in which a molten resin sheet having a surplus length with respect to a mold surface of a mold for molding a tank body projects in a thickness direction within the mold. A forming step of forming a molten resin projection, an arrangement step of inserting the molten resin projection into a mounting hole provided in the mounting component and placing the mounting component on the molten resin sheet, and inserting into the mounting hole A processing step of pressurizing the molten resin protrusions so as to project a part of the molten resin protrusions toward the outer peripheral side.

請求項１に記載の発明に係る燃料タンクの製造方法では、溶融樹脂突起の加圧時に、溶融樹脂突起の一部を取付部品の取付孔の周辺部まで張り出させることで、溶融樹脂の冷却固化後に、取付部品を取り付けるための取付部（突起及び突起から張り出した部分で構成される）が燃料タンク（タンク本体）に形成される。   In the fuel tank manufacturing method according to the first aspect of the present invention, when the molten resin protrusion is pressed, a part of the molten resin protrusion is projected to the peripheral portion of the attachment hole of the attachment part, thereby cooling the molten resin. After solidification, an attachment portion (consisting of a protrusion and a portion protruding from the protrusion) for attaching the attachment component is formed in the fuel tank (tank body).

ここで、燃料タンク（タンク本体）の取付部となる溶融樹脂突起は、成形型の型面に対して余長分を有する溶融樹脂シートに形成されることから、例えば、余長分を有さない溶融樹脂シートに形成されるものと比べて、必要な樹脂量を確保することができる。これにより、燃料タンクの取付部の強度が確保される。   Here, since the molten resin projections that serve as attachment portions of the fuel tank (tank body) are formed on the molten resin sheet having an extra length with respect to the mold surface of the mold, for example, there is an extra length. The required amount of resin can be ensured compared to that formed on a molten resin sheet that is not present. Thereby, the intensity | strength of the attaching part of a fuel tank is ensured.

請求項２に記載の発明に係る燃料タンクの製造方法は、請求項１に記載の燃料タンクの製造方法において、前記賦形工程の前に、溶融樹脂シートを前記成形型内にセットするセット工程と、前記セットされた溶融樹脂シートを伸張させて前記型面に対して余長分を得る伸張工程と、を備える。   A fuel tank manufacturing method according to a second aspect of the present invention is the fuel tank manufacturing method according to the first aspect, wherein the molten resin sheet is set in the mold before the shaping step. And a stretching step of stretching the set molten resin sheet to obtain an extra length with respect to the mold surface.

請求項２に記載の発明に係る燃料タンクの製造方法では、伸張工程において、溶融樹脂シートを伸張させて余長分（型面に対しての余長分）を得ることから、溶融樹脂シートの樹脂量が変化しないため、タンク本体の重量増加を抑制することができる。   In the fuel tank manufacturing method according to the second aspect of the invention, in the stretching step, the molten resin sheet is stretched to obtain a surplus length (a surplus length with respect to the mold surface). Since the amount of resin does not change, an increase in the weight of the tank body can be suppressed.

請求項３に記載の発明に係る燃料タンクの製造方法は、請求項２に記載の燃料タンクの製造方法において、前記伸張工程では、前記セットされた溶融樹脂シートと前記成形型との間の空間を加圧し、又は前記セットされた溶融樹脂シートと前記成形型に合わされた圧空成形型との間の空間を減圧して前記セットされた溶融樹脂シートを膨らませ、伸張させる。   A fuel tank manufacturing method according to a third aspect of the present invention is the fuel tank manufacturing method according to the second aspect, wherein, in the extension step, a space between the set molten resin sheet and the mold. Or pressurizing or depressurizing the space between the set molten resin sheet and the pressure forming mold fitted to the mold to expand and expand the set molten resin sheet.

請求項３に記載の発明に係る燃料タンクの製造方法では、伸張工程において、成形型にセットされた溶融樹脂シートと成形型との間の空間を加圧し、又は成形型にセットされた溶融樹脂シートと圧空成形型との間の空間を加圧して溶融樹脂シートを伸張させるため、製造工程が複雑化する、或いは製造装置が複雑化又は大型化するのを抑止できる。   In the fuel tank manufacturing method according to the third aspect of the present invention, in the expansion step, the space between the molten resin sheet set in the mold and the mold is pressurized, or the molten resin set in the mold Since the molten resin sheet is stretched by pressurizing the space between the sheet and the pressure forming mold, it is possible to prevent the manufacturing process from becoming complicated, or the manufacturing apparatus from becoming complicated or enlarged.

請求項４に記載の発明に係る燃料タンクの製造方法は、請求項３に記載の燃料タンクの製造方法において、前記伸張工程では、前記セットされた溶融樹脂シートと前記成形型との間の空間を密閉状態にして加圧し、又は前記セットされた溶融樹脂シートと前記成形型に合わされた圧空成形型との間の空間を密閉状態にして減圧する。   A fuel tank manufacturing method according to a fourth aspect of the present invention is the fuel tank manufacturing method according to the third aspect, wherein, in the extension step, a space between the set molten resin sheet and the mold. Is sealed and pressurized, or the space between the set molten resin sheet and the compressed air mold fitted to the mold is sealed and decompressed.

請求項４に記載の発明に係る燃料タンクの製造方法では、伸張工程において、成形型にセットされた溶融樹脂シートと成形型との間の空間を密閉状態にして加圧し、又は成形型にセットされた溶融樹脂シートと圧空成形型との間の空間を密閉状態にして減圧するため、溶融樹脂シートが均一に加圧又は減圧されて伸張される。   In the method for manufacturing a fuel tank according to the fourth aspect of the present invention, in the expansion step, the space between the molten resin sheet set in the mold and the mold is sealed and pressurized, or set in the mold. In order to reduce the pressure between the molten resin sheet and the pressure forming mold in a sealed state, the molten resin sheet is uniformly pressurized or decompressed and stretched.

請求項５に記載の発明に係る燃料タンクの製造方法は、請求項１に記載の燃料タンクの製造方法において、前記賦形工程の前に、前記型面に対して余長分を有する溶融樹脂シートを前記成形型内にセットするセット工程を備える。   The fuel tank manufacturing method according to claim 5 is the fuel tank manufacturing method according to claim 1, wherein the molten resin has a surplus length with respect to the mold surface before the shaping step. A setting step of setting the sheet in the mold;

請求項５に記載の発明に係る燃料タンクの製造方法では、セット工程において、型面に対して余長分を有する溶融樹脂シートを成形型内にセットすることから、製造工程が複雑化する、或いは製造装置が複雑化又は大型化するのを抑止できる。   In the fuel tank manufacturing method according to the invention of claim 5, in the setting step, the molten resin sheet having a surplus length with respect to the mold surface is set in the mold, which complicates the manufacturing process. Or it can suppress that a manufacturing apparatus becomes complicated or enlarged.

請求項６に記載の発明に係る燃料タンクの製造方法は、請求項１〜５のいずれか１項に記載の燃料タンクの製造方法において、前記賦形工程では、前記成形型と前記余長分を有する溶融樹脂シートとの間の空間を減圧し、又は前記成形型に合わされた圧空成形型と前記余長分を有する溶融樹脂シートとの間の空間を加圧して前記余長分を有する溶融樹脂シートを前記型面に沿って配置させると共に、前記余長分を有する溶融樹脂シートに前記成形型に設けられた可動部材を当接させて前記溶融樹脂突起を形成する。   A method for manufacturing a fuel tank according to a sixth aspect of the present invention is the method for manufacturing a fuel tank according to any one of the first to fifth aspects, wherein in the shaping step, the mold and the extra length are provided. The space between the molten resin sheet having pressure is reduced, or the space between the pressure forming mold fitted to the mold and the molten resin sheet having the extra length is pressurized to melt the extra length. A resin sheet is disposed along the mold surface, and a movable member provided on the mold is brought into contact with the molten resin sheet having the extra length to form the molten resin protrusion.

請求項６に記載の発明に係る燃料タンクの製造方法では、賦形工程において、可動部材を溶融樹脂シートに当接させて溶融樹脂突起を形成することから、溶融樹脂突起を加圧し、冷却固化させて形成される突起の内部が可動部材の引き抜きによって中空となる。ここで、取付部を構成する突起の内部が中空となるため、取付部を形成するのに必要な樹脂量を抑えることができる。   In the fuel tank manufacturing method according to the sixth aspect of the present invention, in the shaping step, since the molten resin protrusion is formed by bringing the movable member into contact with the molten resin sheet, the molten resin protrusion is pressurized and cooled and solidified. The inside of the protrusion formed is hollowed by pulling out the movable member. Here, since the inside of the protrusion constituting the attachment portion is hollow, the amount of resin required to form the attachment portion can be suppressed.

請求項７に記載の発明に係る燃料タンクの製造方法は、請求項６に記載の燃料タンクの製造方法において、前記加工工程では、前記可動部材を前記溶融樹脂突起の突出方向と反対方向に移動させながら、又は移動させた後で、前記溶融樹脂突起を前記反対方向に加圧する。   A fuel tank manufacturing method according to a seventh aspect of the present invention is the fuel tank manufacturing method according to the sixth aspect, wherein, in the processing step, the movable member is moved in a direction opposite to a protruding direction of the molten resin protrusion. During or after moving, the molten resin protrusion is pressed in the opposite direction.

請求項７に記載の発明に係る燃料タンクの製造方法では、加工工程において、可動部材を溶融樹脂突起の突出方向と反対方向に移動させながら、又は移動させた後で、溶融樹脂突起を突出方向と反対方向に加圧することから、溶融樹脂突起が突出方向と反対方向に均等に圧縮される（押し潰される）。これにより、溶融樹脂突起の周壁部が２重に折り畳まれて外周側に張り出すため、取付部を構成する張り出し部分（張出部）を肉厚にできる。   In the method for manufacturing a fuel tank according to the seventh aspect of the invention, in the processing step, the movable member is moved in the projecting direction while the movable member is moved in the direction opposite to the projecting direction of the molten resin projection or after the movable member is moved. Therefore, the molten resin protrusions are evenly compressed (crushed) in the direction opposite to the protruding direction. Thereby, since the surrounding wall part of a molten resin protrusion is folded twice and it overhangs to the outer peripheral side, the overhang | projection part (overhang | projection part) which comprises an attachment part can be thickened.

請求項８に記載の発明に係る燃料タンクの製造方法は、請求項１〜７のいずれか１項に記載の燃料タンクの製造方法において、前記加工工程では、前記取付部品の前記取付孔よりも部分的に内径が大きい可動型で前記取付部品を押さえ且つ前記可動型内に前記溶融樹脂突起をセットした状態で前記溶融樹脂突起を加圧して、前記溶融樹脂突起に少なくとも前記取付孔の周辺部まで張り出す張出部を形成する。 The method for manufacturing a fuel tank according to an eighth aspect of the present invention is the method for manufacturing a fuel tank according to any one of the first to seventh aspects, wherein, in the processing step, the fuel tank is more than the mounting hole of the mounting component. A movable mold having a partially large inner diameter is used to hold the mounting component and pressurize the molten resin projection in a state where the molten resin projection is set in the movable mold, so that at least the peripheral portion of the mounting hole is formed on the molten resin projection. The overhanging part that protrudes to is formed.

請求項８に記載の発明に係る燃料タンクの製造方法では、加工工程において、可動型で取付部品を押さえ且つ可動型内に溶融樹脂突起をセットした状態で溶融樹脂突起を加圧することから、溶融樹脂突起が可動型の内面形状に成形される。ここで、可動型内が取付孔よりも部分的に内径が大きい部分を備えているため、溶融樹脂突起に少なくとも取付孔の周辺部まで張り出す張出部が形成される。これにより、取付部品が取付部によって燃料タンクに確実に取り付けられる。   In the method for manufacturing a fuel tank according to the invention described in claim 8, in the processing step, the molten resin protrusion is pressed in a state where the mounting part is pressed by the movable mold and the molten resin protrusion is set in the movable mold. The resin protrusion is formed into a movable inner shape. Here, since the inside of the movable mold is provided with a portion having an inner diameter partially larger than that of the mounting hole, an overhanging portion is formed on the molten resin protrusion so as to extend at least to the peripheral portion of the mounting hole. As a result, the attachment component is reliably attached to the fuel tank by the attachment portion.

請求項９に記載の発明に係る燃料タンクの製造方法は、請求項１〜８のいずれか１項に記載の燃料タンクの製造方法において、前記配置工程では、前記溶融樹脂シートとの接触面に凸部及び凹部の一方又は両方が設けられた前記取付部品を前記溶融樹脂シートに配置する。   A method for manufacturing a fuel tank according to a ninth aspect of the present invention is the method for manufacturing a fuel tank according to any one of the first to eighth aspects, wherein in the placement step, the contact surface with the molten resin sheet is provided. The mounting component provided with one or both of a convex portion and a concave portion is disposed on the molten resin sheet.

請求項９に記載の発明に係る燃料タンクの製造方法では、配置工程において、溶融樹脂シートとの接触面に凸部及び凹部の一方又は両方が設けられた取付部品が溶融樹脂シートに配置されることから、取付部品を溶融樹脂シートに仮固定することができる。   In the fuel tank manufacturing method according to the ninth aspect of the present invention, in the disposing step, the attachment component in which one or both of the convex portion and the concave portion are provided on the contact surface with the molten resin sheet is disposed on the molten resin sheet. Therefore, the attachment component can be temporarily fixed to the molten resin sheet.

請求項１０に記載の発明に係る燃料タンクは、樹脂で形成され、燃料を収容可能なタンク本体と、前記タンク本体に形成され、肉厚方向に突出し、内部が中空で且つ頂部が閉塞された筒状とされ、取付部品に設けられた取付孔に挿入され、前記取付孔に挿入された部分の肉厚が前記タンク本体の一般部の肉厚以上とされた突起と、前記突起に形成され、前記突起の外周側に張り出し、前記取付部品の取付孔周辺部を前記一般部との間で挟んで前記取付部品を前記タンク本体に取り付ける張出部と、を備えた燃料タンク。   The fuel tank according to the invention of claim 10 is made of resin and is formed in the tank main body capable of containing fuel, and is formed in the tank main body, protrudes in the thickness direction, the inside is hollow, and the top is closed. A projection that is cylindrical and is inserted into a mounting hole provided in a mounting part, and the thickness of the portion inserted into the mounting hole is greater than the thickness of the general portion of the tank body, and is formed on the projection. A fuel tank comprising: a projecting portion that projects to the outer peripheral side of the projection, and that attaches the mounting component to the tank body with the mounting hole peripheral portion of the mounting component sandwiched between the general portion.

請求項１０に記載の発明に係る燃料タンクでは、突起の内部を中空としていることから、例えば、突起の内部が中空でないものと比べて、取付部を形成するために必要な樹脂量を確保しやすい。
一方、突起の取付孔に挿入された部分の肉厚をタンク本体の一般部の肉厚以上としていることから、突起の強度が確保される。これにより、取付部品を取り付けるための取付部（突起及び張出部で構成される）の強度を確保できる。 In the fuel tank according to the invention of claim 10, since the inside of the protrusion is hollow, for example, the amount of resin necessary for forming the attachment portion is ensured as compared with the case where the inside of the protrusion is not hollow. Cheap.
On the other hand, since the thickness of the portion inserted into the attachment hole of the protrusion is equal to or greater than the thickness of the general portion of the tank body, the strength of the protrusion is ensured. Thereby, the intensity | strength of the attaching part (it consists of a protrusion and an overhang | projection part) for attaching attachment components is securable.

請求項１に記載の本発明に係る燃料タンクの製造方法は、燃料タンクに取付部品を取り付けるための取付部を形成するのに必要な樹脂量を確保できる、という優れた効果を有する。   The method for manufacturing a fuel tank according to the first aspect of the present invention has an excellent effect that it is possible to secure an amount of resin necessary for forming a mounting portion for mounting a mounting part on the fuel tank.

請求項２に記載の本発明に係る燃料タンクの製造方法は、タンク本体の重量増加を抑制することができる、という優れた効果を有する。   The fuel tank manufacturing method according to the second aspect of the present invention has an excellent effect that an increase in the weight of the tank body can be suppressed.

請求項３に記載の本発明に係る燃料タンクの製造方法は、製造工程が複雑化する、或いは製造装置が複雑化又は大型化するのを抑止できる、という優れた効果を有する。   The fuel tank manufacturing method according to the third aspect of the present invention has an excellent effect that the manufacturing process is complicated, or that the manufacturing apparatus can be prevented from becoming complicated or large.

請求項４に記載の本発明に係る燃料タンクの製造方法は、溶融樹脂シートを加圧又は減圧して均一に伸張させることができる、という優れた効果を有する。   The method for manufacturing a fuel tank according to the fourth aspect of the present invention has an excellent effect that the molten resin sheet can be uniformly stretched by pressurization or decompression.

請求項５に記載の本発明に係る燃料タンクの製造方法は、製造工程が複雑化する、或いは製造装置が複雑化又は大型化するのを抑止できる、という優れた効果を有する。   The method for manufacturing a fuel tank according to the fifth aspect of the present invention has an excellent effect that the manufacturing process can be complicated, or the manufacturing apparatus can be prevented from becoming complicated or enlarged.

請求項６に記載の本発明に係る燃料タンクの製造方法は、燃料タンクの取付部を形成するのに必要な樹脂量を抑えることができる、という優れた効果を有する。   The method for manufacturing a fuel tank according to the sixth aspect of the present invention has an excellent effect that the amount of resin necessary for forming the attachment portion of the fuel tank can be suppressed.

請求項７に記載の本発明に係る燃料タンクの製造方法は、燃料タンクの取付部を構成する張出部を肉厚にできる、という優れた効果を有する。   The method of manufacturing a fuel tank according to the seventh aspect of the present invention has an excellent effect that the overhanging portion constituting the attachment portion of the fuel tank can be thickened.

請求項８に記載の本発明に係る燃料タンクの製造方法は、取付部品が取付部によって確実に燃料タンクに取り付けられる、という優れた効果を有する。   The method for manufacturing a fuel tank according to the eighth aspect of the present invention has an excellent effect that the attachment component is securely attached to the fuel tank by the attachment portion.

請求項９に記載の本発明に係る燃料タンクの製造方法は、取付部品を溶融樹脂シートに仮固定することができる、という優れた効果を有する。   The method for manufacturing a fuel tank according to the ninth aspect of the present invention has an excellent effect that the mounting part can be temporarily fixed to the molten resin sheet.

請求項１０に記載の本発明に係る燃料タンクは、取付部品を取り付けるための取付部の強度を確保できる、という優れた効果を有する。   The fuel tank according to the tenth aspect of the present invention has an excellent effect that the strength of the mounting portion for mounting the mounting component can be secured.

本発明の一実施形態に係る燃料タンクの断面を示す斜視図である。It is a perspective view showing the section of the fuel tank concerning one embodiment of the present invention. 図１の矢印２で指す部分の拡大図である。FIG. 3 is an enlarged view of a portion indicated by an arrow 2 in FIG. 1. タンク本体となる溶融樹脂シートを成形型にセットした状態を示す溶融樹脂シートの断面図である。It is sectional drawing of the molten resin sheet which shows the state which set the molten resin sheet used as a tank main body to the shaping | molding die. 図３の溶融樹脂シートを膨らませた状態を示す溶融樹脂シートの断面図である。It is sectional drawing of the molten resin sheet which shows the state which expanded the molten resin sheet of FIG. 図４の余長分を有する溶融樹脂シートを成形型のキャビティ面上に沿って配置した状態を示す溶融樹脂シートの断面図である。It is sectional drawing of the molten resin sheet which shows the state which has arrange | positioned the molten resin sheet which has the extra length of FIG. 4 along the cavity surface of a shaping | molding die. 図５の矢印６で指す部分の拡大図であり、取付部品が溶融樹脂シート上に配置され、溶融樹脂突起が円筒状型にセットされた状態を示している。FIG. 6 is an enlarged view of a portion indicated by an arrow 6 in FIG. 5, showing a state in which attachment parts are arranged on a molten resin sheet and molten resin protrusions are set in a cylindrical mold. 図６の溶融樹脂突起の加圧による変形で張出部が形成された状態を示す溶融樹脂突起の断面図である。It is sectional drawing of the molten resin protrusion which shows the state in which the overhang | projection part was formed by the deformation | transformation by the pressurization of the molten resin protrusion of FIG. タンク本体を成形型から離型する状態を示す突起の断面図である。It is sectional drawing of the protrusion which shows the state which releases a tank main body from a shaping | molding die. 成形装置の空圧回路及び電気回路の概略を示す回路図である。It is a circuit diagram which shows the outline of the pneumatic circuit and electrical circuit of a shaping | molding apparatus. タンク本体となる溶融樹脂シートを成形型と圧空型との間にセットして溶融樹脂シートを膨らませた状態を示す溶融樹脂シートの断面図である。It is sectional drawing of the molten resin sheet which shows the state which set the molten resin sheet used as a tank main body between a shaping | molding die and a pressure type | mold, and expanded the molten resin sheet. 図１０の溶融樹脂シートを成形型のキャビティ面上に沿って配置した状態を示す溶融樹脂シートの断面図である。It is sectional drawing of the molten resin sheet which shows the state which has arrange | positioned the molten resin sheet of FIG. 10 along the cavity surface of a shaping | molding die. 燃料タンクの取付部の第１変形例を示す、取付部周りの平面図である。It is a top view around the attachment part which shows the 1st modification of the attachment part of a fuel tank. 燃料タンクの取付部の第２変形例を示す、取付部周りの平面図である。It is a top view around the attachment part which shows the 2nd modification of the attachment part of a fuel tank. 取付部品の変形例が溶融樹脂シート上に配置された状態を示す、図６に対応する図である。It is a figure corresponding to FIG. 6 which shows the state by which the modification of an attachment component has been arrange | positioned on the molten resin sheet.

以下、本発明に係る燃料タンクの製造方法及び燃料タンクの一実施形態について説明する。図１には、本実施形態の燃料タンク２０が示されている。この燃料タンク２０は、車両に搭載される燃料タンクである。また、燃料タンク２０は、内部に燃料を収容可能な箱形状のタンク本体２２を備えている。   Hereinafter, an embodiment of a fuel tank manufacturing method and a fuel tank according to the present invention will be described. FIG. 1 shows a fuel tank 20 of the present embodiment. The fuel tank 20 is a fuel tank mounted on the vehicle. The fuel tank 20 includes a box-shaped tank body 22 that can accommodate fuel therein.

タンク本体２２は、樹脂（本実施形態では、熱可塑性樹脂）で形成されている。具体的には、タンク本体２２は、樹脂層と、この樹脂層よりも燃料透過性の低い（燃料が透過しづらい）バリアー層とを含んで構成されている。樹脂層を構成する樹脂としては、例えば、高密度ポリエチレン（ＨＤＰＥ）を用いてもよく、バリアー層を形成する材料としては、エチレンビニルアルコール（ＥＶＯＨ）を用いてもよい。   The tank body 22 is formed of resin (in this embodiment, a thermoplastic resin). Specifically, the tank main body 22 includes a resin layer and a barrier layer having a lower fuel permeability than the resin layer (a fuel is difficult to permeate). For example, high density polyethylene (HDPE) may be used as the resin constituting the resin layer, and ethylene vinyl alcohol (EVOH) may be used as a material for forming the barrier layer.

タンク本体２２には、配管を接続するための開口部が形成されているが、開口部については図示省略している。   The tank body 22 is formed with an opening for connecting a pipe, but the opening is not shown.

また、タンク本体２２は、上下に分割された２つのタンク本体２２Ａ、２２Ｂの外周縁部を接合（溶着）することで箱形状とされている。なお、タンク本体２２Ａは全体として上に凸（図１図示状態）、タンク本体２２Ｂは全体として下に凸（図１図示状態）とされている。   The tank body 22 has a box shape by joining (welding) the outer peripheral edges of the two tank bodies 22A and 22B divided in the vertical direction. The tank body 22A is generally convex upward (as shown in FIG. 1), and the tank body 22B is generally convex downward (as shown in FIG. 1).

図１及び図２に示されるように、タンク本体２２（タンク本体２２Ｂ）の底部には、肉厚方向（板厚方向）に突出する突起２４が形成されている。具体的には、突起２４は、タンク本体２２の内側に向かって突出している。この突起２４は、内部が中空で且つ頂部２４Ａが閉塞された円筒状とされている。   As shown in FIGS. 1 and 2, a protrusion 24 is formed on the bottom of the tank body 22 (tank body 22B) so as to protrude in the thickness direction (plate thickness direction). Specifically, the protrusion 24 protrudes toward the inside of the tank body 22. The protrusion 24 has a hollow cylindrical shape and a closed top 24A.

図２に示されるように、突起２４は、燃料タンク２０の内部に取り付けられる取付部品２６（内蔵部品）の板状の締結座２８に形成された取付孔３０に挿入されている。また、突起２４の外周面２４Ｂは、取付孔３０の孔壁面３０Ａに密着している。なお、取付部品２６には、例えば、燃料タンク２０の他の内蔵部品が直接又は他の部材を介して間接的に取り付けられる。   As shown in FIG. 2, the protrusion 24 is inserted into an attachment hole 30 formed in a plate-like fastening seat 28 of an attachment part 26 (built-in part) attached to the inside of the fuel tank 20. The outer peripheral surface 24 </ b> B of the protrusion 24 is in close contact with the hole wall surface 30 </ b> A of the attachment hole 30. For example, another built-in component of the fuel tank 20 is attached to the attachment component 26 directly or indirectly via another member.

突起２４の頂部２４Ａ側には、外周側（突起２４の半径方向外側と同じ）に張り出す張出部３２が形成されている。この張出部３２は、突起２４の外周に沿って一周分形成され、一般部２２Ｃとの間で締結座２８を挟持している。具体的には、張出部３２は締結座２８の一方の面２８Ａ（図２では上面）に密着し、一般部２２Ｃは他方の面２８Ｂ（図２では下面）に密着している。これにより、張出部３２と一般部２２Ｃとの間で締結座２８が挟まれて固定（締結）されている。言い換えると、張出部３２と一般部２２Ｃによって締結座２８がカシメられている。   On the top 24 </ b> A side of the protrusion 24, an overhanging portion 32 is formed to project to the outer peripheral side (same as the radially outer side of the protrusion 24). The overhang portion 32 is formed for one turn along the outer periphery of the protrusion 24 and sandwiches the fastening seat 28 with the general portion 22C. Specifically, the overhang portion 32 is in close contact with one surface 28A (upper surface in FIG. 2) of the fastening seat 28, and the general portion 22C is in close contact with the other surface 28B (lower surface in FIG. 2). Thus, the fastening seat 28 is sandwiched and fixed (fastened) between the overhang portion 32 and the general portion 22C. In other words, the fastening seat 28 is crimped by the overhang portion 32 and the general portion 22C.

また、突起２４の取付孔３０に挿入された部分（以下、「挿入部２４Ｃ」と記載する。）の肉厚Ｔ１及び張出部３２の肉厚Ｔ２は、タンク本体２２の一般部２２Ｃの肉厚Ｔ０以上とされている。   Further, the thickness T1 of the portion inserted into the mounting hole 30 of the protrusion 24 (hereinafter referred to as “insertion portion 24C”) and the thickness T2 of the overhang portion 32 are the thickness of the general portion 22C of the tank body 22. The thickness is set to T0 or more.

次に、本実施形態の燃料タンク２０のタンク本体２２Ｂを成形する成形装置４０について説明する。図３、図６及び図９に示されるように、成形装置４０は、成形型４２、可動部材４４及び加圧部材４６などの各種構成部材を備えている。   Next, the shaping | molding apparatus 40 which shape | molds the tank main body 22B of the fuel tank 20 of this embodiment is demonstrated. As shown in FIGS. 3, 6, and 9, the molding apparatus 40 includes various components such as a molding die 42, a movable member 44, and a pressure member 46.

図３に示されるように、成形型４２は、シート状の溶融樹脂（以下、「溶融樹脂シート３４」と記載する）をタンク本体２２Ｂに成形するための金型であり、タンク本体２２Ｂの形状に合わせたキャビティ４８を備えている。   As shown in FIG. 3, the molding die 42 is a mold for molding a sheet-like molten resin (hereinafter referred to as “molten resin sheet 34”) into the tank body 22 </ b> B, and the shape of the tank body 22 </ b> B. The cavity 48 is provided.

成形型４２の内部には、可動部材４４及びこの可動部材４４を可動（移動）させるためのアクチュエータ５０が配置されている。   Inside the mold 42, a movable member 44 and an actuator 50 for moving (moving) the movable member 44 are arranged.

可動部材４４は、略円柱状の金属棒であり、アクチュエータ５０によってキャビティ面４８Ａの底部４８Ｂと直交する方向に移動可能に構成されている。アクチュエータ５０は、可動部材４４を移動させてキャビティ面４８Ａから突出させたり、成形型４２内に収容させたりすることができるように構成されている。   The movable member 44 is a substantially cylindrical metal rod, and is configured to be movable in a direction orthogonal to the bottom 48B of the cavity surface 48A by the actuator 50. The actuator 50 is configured so that the movable member 44 can be moved so as to protrude from the cavity surface 48 </ b> A or accommodated in the molding die 42.

本実施形態のアクチュエータ５０は、一例として複動型のエアシリンダを用いている。このアクチュエータ５０を動作させるための動作回路５２（図９参照）については後述する。また、本実施形態では、エアシリンダの往復動部分に可動部材４４が接続されている。なお、本実施形態では、アクチュエータ５０としてエアシリンダを用いているが、本発明はこの構成に限定されず、例えば、油圧シリンダやサーボモータなどを用いてもよい。サーボモータを用いた場合には、可動部材４４のキャビティ面４８Ａからの突出高さの精度を向上できる。また、可動部材４４の移動速度を精度よく調整できる。   As an example, the actuator 50 of the present embodiment uses a double-action air cylinder. An operation circuit 52 (see FIG. 9) for operating the actuator 50 will be described later. In the present embodiment, the movable member 44 is connected to the reciprocating portion of the air cylinder. In the present embodiment, an air cylinder is used as the actuator 50. However, the present invention is not limited to this configuration, and for example, a hydraulic cylinder or a servo motor may be used. When the servo motor is used, the accuracy of the protrusion height of the movable member 44 from the cavity surface 48A can be improved. Further, the moving speed of the movable member 44 can be adjusted with high accuracy.

また、可動部材４４は、ヒータ５４によって加熱される。本実施形態のヒータ５４は、可動部材４４の外周に巻き付けられた電熱線５４Ａと電源５４Ｂ（図９参照）とで構成されている。なお、可動部材４４の外周に電熱線５４Ａを巻き付ける代わりに、可動部材４４の内部に棒状の電熱部材（電熱材料で形成された部材）を埋設する構成としてもよい。   The movable member 44 is heated by the heater 54. The heater 54 of the present embodiment includes a heating wire 54A and a power source 54B (see FIG. 9) wound around the outer periphery of the movable member 44. Instead of winding the heating wire 54 </ b> A around the outer periphery of the movable member 44, a rod-shaped electric heating member (a member formed of an electric heating material) may be embedded in the movable member 44.

図３に示されるように、成形型４２には、成形型４２内を通り、キャビティ面４８Ａに開口する気体流路５６が設けられている。この気体流路５６は、図示しない空圧回路に接続されている。この空圧回路は、加圧気体生成装置（図示省略）及び負圧生成装置（図示省略）に接続されており、気体流路５６を通じてキャビティ４８周辺に加圧気体を供給する、又はキャビティ４８周辺の気体を吸引することができるように構成されている。なお、本実施形態では、加圧気体生成装置の一例として正圧ポンプ、負圧生成装置の一例として負圧ポンプを用いている。   As shown in FIG. 3, the molding die 42 is provided with a gas flow path 56 that passes through the molding die 42 and opens to the cavity surface 48A. The gas flow path 56 is connected to a pneumatic circuit (not shown). This pneumatic circuit is connected to a pressurized gas generating device (not shown) and a negative pressure generating device (not shown), and supplies pressurized gas to the periphery of the cavity 48 through the gas flow path 56, or around the cavity 48. The gas can be sucked. In the present embodiment, a positive pressure pump is used as an example of a pressurized gas generation device, and a negative pressure pump is used as an example of a negative pressure generation device.

成形型４２のキャビティ面４８Ａの周辺部４２Ａには、成形型４２内に導入された溶融樹脂シート３４の外周縁部３４Ａが押圧機５８によって押し付けられるようになっている。この押圧機５８は、溶融樹脂シート３４の外周縁部３４Ａ全体を成形型４２の周辺部４２Ａに押し付けられるように構成されている。この押圧機５８を用いて成形型４２内に溶融樹脂シート３４をセット（配置）すると、溶融樹脂シート３４とキャビティ面４８Ａとの間の空間が密閉状態となる（すなわち、密閉空間６０が形成される）。なお、上述の空圧回路を用いることで、密閉空間６０内に加圧気体（本実施形態では、加圧空気）を供給して密閉空間６０内を加圧する、又は密閉空間６０内から気体を吸引して密閉空間６０を減圧することができる。   The outer peripheral edge 34A of the molten resin sheet 34 introduced into the mold 42 is pressed against the peripheral part 42A of the cavity surface 48A of the mold 42 by a pressing machine 58. The pressing machine 58 is configured to press the entire outer peripheral edge 34 </ b> A of the molten resin sheet 34 against the peripheral part 42 </ b> A of the molding die 42. When the molten resin sheet 34 is set (arranged) in the mold 42 using the pressing machine 58, the space between the molten resin sheet 34 and the cavity surface 48A is in a sealed state (that is, the sealed space 60 is formed). ) In addition, by using the above-mentioned pneumatic circuit, pressurized gas (in this embodiment, pressurized air) is supplied into the sealed space 60 to pressurize the sealed space 60, or gas is supplied from the sealed space 60. The sealed space 60 can be decompressed by suction.

図９に示されるように、アクチュエータ５０の動作回路５２中には、電磁弁６２が設けられている。この電磁弁６２を切り替えることで、可動部材４４の押し出し、引き戻し、中立状態を切り替えることができる。また、動作回路５２には、気体供給源（コンプレッサー）６６が接続されている。なお、可動部材４４を戻すための戻し側回路に絞り弁を設けてもよい。   As shown in FIG. 9, an electromagnetic valve 62 is provided in the operation circuit 52 of the actuator 50. By switching the electromagnetic valve 62, the movable member 44 can be pushed out, pulled back, and switched to the neutral state. In addition, a gas supply source (compressor) 66 is connected to the operation circuit 52. A throttle valve may be provided in the return side circuit for returning the movable member 44.

図６に示されるように、成形型４２に対向して加工装置６８が設けられている。この加工装置６８は、キャビティ面４８Ａの底部に対して直交する方向に移動可能で且つ成形型４２上から退避移動可能に構成されている。   As shown in FIG. 6, a processing device 68 is provided to face the mold 42. The processing device 68 is configured to be movable in a direction orthogonal to the bottom of the cavity surface 48A and to be retractable from the mold 42.

加工装置６８は、後述する溶融樹脂突起３６を内部に収容する円筒状型７０を備えている。溶融樹脂突起３６は加圧されることで円筒状型７０の内面形状と同じ形状に成形される。また、円筒状型７０の周壁７０Ａには、円筒状型７０を加熱するための電熱部材７２Ａが内蔵されている。この電熱部材７２Ａは図示しない電源に接続されてヒータ７２を構成している。また、円筒状型７０は、先端部で締結座２８の取付孔３０の周辺部を成形型４２側へ押さえつけられるように構成されている。なお、本実施形態の円筒状型７０は、本発明の可動型の一例である。   The processing device 68 includes a cylindrical mold 70 that accommodates a molten resin protrusion 36 to be described later. The molten resin protrusion 36 is molded into the same shape as the inner surface shape of the cylindrical mold 70 by being pressurized. In addition, an electric heating member 72A for heating the cylindrical mold 70 is built in the peripheral wall 70A of the cylindrical mold 70. The electric heating member 72A is connected to a power source (not shown) to constitute a heater 72. The cylindrical mold 70 is configured so that the peripheral portion of the attachment hole 30 of the fastening seat 28 can be pressed to the mold 42 side at the tip. In addition, the cylindrical mold | type 70 of this embodiment is an example of the movable mold | type of this invention.

また、円筒状型７０の内部には、加圧部材４６が配置されている。この加圧部材４６は、略円柱状の金属棒４６Ａと、この金属棒４６Ａの先端部に設けられた金属製の円板部４６Ｂとを含んで構成されている。この円板部４６Ｂの外周面４６Ｃは、円筒状型７０の内周面７０Ｂに接している。   A pressure member 46 is disposed inside the cylindrical mold 70. The pressing member 46 includes a substantially cylindrical metal rod 46A and a metal disc portion 46B provided at the tip of the metal rod 46A. The outer peripheral surface 46C of the disc portion 46B is in contact with the inner peripheral surface 70B of the cylindrical mold 70.

また、加圧部材４６は、アクチュエータ７４によって円筒状型７０の軸方向に沿って移動可能に構成されている。なお、円筒状型７０は、軸方向が可動部材４４の移動方向と同じ方向となるように加工装置６８に設置されている。   The pressure member 46 is configured to be movable along the axial direction of the cylindrical mold 70 by an actuator 74. The cylindrical mold 70 is installed in the processing device 68 so that the axial direction is the same as the moving direction of the movable member 44.

本実施形態のアクチュエータ７４は、一例として複動型のエアシリンダを用いている。このアクチュエータ７４を動作させるための動作回路７８（図９参照）については後述する。また、本実施形態では、エアシリンダの往復動部分に加圧部材４６が接続されている。なお、本実施形態では、アクチュエータ７４としてエアシリンダを用いているが、本発明はこの構成に限定されず、例えば、油圧シリンダやサーボモータなど用いてもよい。サーボモータを用いた場合には、加圧部材４６の円筒状型７０内での位置決め精度を向上できる。また、加圧部材４６の移動速度を精度よく調整できる。   As an example, the actuator 74 of the present embodiment uses a double-action air cylinder. An operation circuit 78 (see FIG. 9) for operating the actuator 74 will be described later. In the present embodiment, the pressurizing member 46 is connected to the reciprocating portion of the air cylinder. In this embodiment, an air cylinder is used as the actuator 74, but the present invention is not limited to this configuration, and for example, a hydraulic cylinder, a servo motor, or the like may be used. When the servo motor is used, the positioning accuracy of the pressure member 46 in the cylindrical mold 70 can be improved. Further, the moving speed of the pressing member 46 can be adjusted with high accuracy.

また、加圧部材４６は、ヒータ７６によって加熱される。本実施形態のヒータ７６は、金属棒４６Ａの外周に巻き付けられた電熱線７６Ａと電源７６Ｂ（図９参照）とで構成されている。この電熱線７６Ａからの熱は金属棒４６Ａを介して円板部４６Ｂに伝達されるようになっている。なお、加圧部材４６の外周に電熱線７６Ａを巻き付ける代わりに、加圧部材４６の内部に棒状の電熱部材（電熱材料で形成された部材）を埋設する構成としてもよい。   The pressure member 46 is heated by the heater 76. The heater 76 of this embodiment includes a heating wire 76A and a power source 76B (see FIG. 9) wound around the outer periphery of the metal rod 46A. Heat from the heating wire 76A is transmitted to the disc portion 46B through the metal rod 46A. Instead of winding the heating wire 76 </ b> A around the outer periphery of the pressing member 46, a rod-shaped heating member (a member formed of an electrically heated material) may be embedded in the pressing member 46.

図９に示されるように、アクチュエータ７４の動作回路７８中には、電磁弁８０が設けられている。この電磁弁８０を切り替えることで、加圧部材４６の押し出し、引き戻し、中立状態を切り替えることができる。また、動作回路７８には、気体供給源（コンプレッサー）８４が接続されている。動作回路５２と動作回路７８に接続される気体供給源は同一のものでも構わない。なお、加圧部材４６を押し出すための押し出し側回路に絞り弁を設けてもよい。   As shown in FIG. 9, an electromagnetic valve 80 is provided in the operation circuit 78 of the actuator 74. By switching the electromagnetic valve 80, the pressing member 46 can be pushed out, pulled back, and switched to the neutral state. A gas supply source (compressor) 84 is connected to the operation circuit 78. The gas supply sources connected to the operation circuit 52 and the operation circuit 78 may be the same. It should be noted that a throttle valve may be provided in the extrusion side circuit for extruding the pressure member 46.

また、円筒状型７０の内部には、先端側（成形型４２側）に加圧部材４６の円板部４６Ｂの直径よりも内径が大きい成形部７０Ｃが形成されている。この成形部７０Ｃによって突起２４から張り出す張出部３２が成形されるようになっている。なお、加圧部材４６は、円板部４６Ｂが円筒状型７０の成形部７０Ｃ近傍に至るまで移動できるように調整されている。   Further, inside the cylindrical mold 70, a molded part 70 </ b> C having a larger inner diameter than the diameter of the disk part 46 </ b> B of the pressure member 46 is formed on the distal end side (molding mold 42 side). The overhanging portion 32 protruding from the protrusion 24 is formed by the forming portion 70C. The pressing member 46 is adjusted so that the disk portion 46B can move to the vicinity of the forming portion 70C of the cylindrical mold 70.

図９に示されるように、成形装置４０は、成形装置４０に用いられる電気機器を制御する制御装置８６を備えている。この制御装置８６は、一例として電磁弁６２及び電磁弁８０の切り替え及びヒータ５４、ヒータ７２、ヒータ７６の起動を制御している。   As shown in FIG. 9, the molding apparatus 40 includes a control device 86 that controls electrical equipment used in the molding apparatus 40. As an example, the control device 86 controls switching of the electromagnetic valve 62 and the electromagnetic valve 80 and activation of the heater 54, the heater 72, and the heater 76.

なお、本実施形態の成形装置４０では、可動部材４４が成形型４２からタンク本体２２Ｂを離型させるイジェクトピンの機能も兼用している。   In the molding apparatus 40 of this embodiment, the movable member 44 also functions as an eject pin that releases the tank body 22B from the molding die 42.

次に、本実施形態の燃料タンク２０の製造方法について説明する。   Next, the manufacturing method of the fuel tank 20 of this embodiment is demonstrated.

（セット工程）
まず、燃料タンク２０のタンク本体２２Ｂとなる溶融樹脂シート３４を製造し、この溶融樹脂シート３４を成形装置４０の成形型４２内に導入する。そして、図３に示されるように、押圧機５８で溶融樹脂シート３４の外周縁部３４Ａを成形型４２の周辺部４２Ａに押し付けて溶融樹脂シート３４を成形型４２にセットする。 (Set process)
First, the molten resin sheet 34 to be the tank body 22 </ b> B of the fuel tank 20 is manufactured, and the molten resin sheet 34 is introduced into the molding die 42 of the molding apparatus 40. Then, as shown in FIG. 3, the outer peripheral edge portion 34 </ b> A of the molten resin sheet 34 is pressed against the peripheral portion 42 </ b> A of the molding die 42 by the pressing device 58 and the molten resin sheet 34 is set on the molding die 42.

（伸張工程）
次に、図４に示されるように、溶融樹脂シート３４とキャビティ面４８Ａとの間に形成された密閉空間６０へ空圧回路から気体流路５６を通じて気体を供給し、密閉空間６０内を加圧して、溶融樹脂シート３４を風船状に膨らませて伸張させる。これにより、溶融樹脂シート３４の膨らんだ部分の肉厚が均一化する。また、溶融樹脂シート３４がキャビティ面４８Ａに対して余長分を得る。なお、密閉空間６０内の圧力を調整することで、溶融樹脂シート３４の余長分を変化させられる。溶融樹脂シート３４の余長分は、後述する溶融樹脂突起３６に必要な樹脂量分得る（生成する）ことが好ましい。 (Extension process)
Next, as shown in FIG. 4, gas is supplied from the pneumatic circuit to the sealed space 60 formed between the molten resin sheet 34 and the cavity surface 48 </ b> A through the gas flow path 56, and the inside of the sealed space 60 is added. The molten resin sheet 34 is inflated into a balloon shape and stretched. Thereby, the thickness of the swollen part of the molten resin sheet 34 is made uniform. Further, the molten resin sheet 34 obtains an extra length with respect to the cavity surface 48A. In addition, by adjusting the pressure in the sealed space 60, the extra length of the molten resin sheet 34 can be changed. The extra length of the molten resin sheet 34 is preferably obtained (generated) by the amount of resin necessary for the molten resin protrusion 36 described later.

また、溶融樹脂シート３４の伸張時に、可動部材４４のキャビティ面４８Ａからの突出高さを調整する。なお、可動部材４４の突出高さの調整は、伸張した溶融樹脂シート３４（余長分を有する（得た）溶融樹脂シート３４）を後述する賦形工程でキャビティ面４８Ａに沿って配置する前であれば、どのタイミングで実施しても構わない。   Further, when the molten resin sheet 34 is stretched, the protruding height of the movable member 44 from the cavity surface 48A is adjusted. The protrusion height of the movable member 44 is adjusted before the expanded molten resin sheet 34 (the molten resin sheet 34 having (obtained) extra length) is arranged along the cavity surface 48A in the shaping step described later. Any timing may be used.

（賦形工程）
次に、図５に示されるように、気体流路５６を通じて密閉空間６０から空気を吸引して密閉空間６０内を減圧し、伸張した溶融樹脂シート３４をキャビティ面４８Ａに密着させる。これにより、伸張した溶融樹脂シート３４がキャビティ面４８Ａに沿って配置される。このとき、可動部材４４がキャビティ面４８Ａから突出しているため、伸張した溶融樹脂シート３４の可動部材４４に当接した部分が肉厚方向に突出して溶融樹脂突起３６が形成される。なお、伸張した溶融樹脂シート３４の余長分は、可動部材４４周りに集約されて溶融樹脂突起３６を形成する。このようにして、伸張した溶融樹脂シート３４がタンク本体２２Ｂの形状に賦形される。 (Shaping process)
Next, as shown in FIG. 5, air is sucked from the sealed space 60 through the gas flow path 56 to depressurize the sealed space 60, and the expanded molten resin sheet 34 is brought into close contact with the cavity surface 48 </ b> A. Thereby, the expanded molten resin sheet 34 is disposed along the cavity surface 48A. At this time, since the movable member 44 protrudes from the cavity surface 48A, the portion of the expanded molten resin sheet 34 in contact with the movable member 44 protrudes in the thickness direction to form the molten resin protrusion 36. The extra length of the expanded molten resin sheet 34 is gathered around the movable member 44 to form a molten resin protrusion 36. In this way, the expanded molten resin sheet 34 is shaped into the shape of the tank body 22B.

（配置工程）
次に、図６に示されるように、取付部品２６の締結座２８に形成された取付孔３０に溶融樹脂突起３６を挿入し、締結座２８を伸張した溶融樹脂シート３４上に配置する。 (Arrangement process)
Next, as shown in FIG. 6, the molten resin protrusion 36 is inserted into the attachment hole 30 formed in the fastening seat 28 of the attachment component 26, and the fastening seat 28 is disposed on the expanded molten resin sheet 34.

（加工工程）
次に、可動部材４４を溶融樹脂突起３６の突出方向と反対方向に移動させた後で、加圧部材４６で溶融樹脂突起３６を頂部３６Ａ側から突出方向と反対方向に加圧して変形させる。具体的には、本実施形態では、電磁弁６２を切り変えて可動部材４４を引き戻し、その後、電磁弁８０を切り変えて加圧部材４６を押し出して溶融樹脂突起３６を加圧して変形させる。なお、本発明は上記構成に限定されず、例えば、可動部材４４を、溶融樹脂突起３６の突出方向と反対方向に移動させながら加圧部材４６で溶融樹脂突起３６を突出方向と反対方向に加圧してもよい。 (Processing process)
Next, after the movable member 44 is moved in the direction opposite to the protruding direction of the molten resin protrusion 36, the molten resin protrusion 36 is pressed by the pressing member 46 in the direction opposite to the protruding direction from the top portion 36 </ b> A and deformed. Specifically, in the present embodiment, the electromagnetic valve 62 is switched and the movable member 44 is pulled back, and then the electromagnetic valve 80 is switched and the pressure member 46 is pushed out to pressurize and deform the molten resin protrusion 36. The present invention is not limited to the above configuration. For example, while the movable member 44 is moved in the direction opposite to the protruding direction of the molten resin protrusion 36, the pressing member 46 adds the molten resin protrusion 36 in the opposite direction to the protruding direction. You may press.

なお、加工工程では、制御装置８６がヒータ５４、ヒータ７２及びヒータ７６を起動させている。また、ヒータ５４は、賦形工程及び加工工程で起動させてもよい。   In the processing step, the control device 86 activates the heater 54, the heater 72, and the heater 76. Further, the heater 54 may be activated in the shaping process and the machining process.

図７に示されるように、加圧部材４６で加圧された溶融樹脂突起３６は、周壁部３６Ｂが２重に折り畳まれるように変形し、この折り畳まれた部分が円筒状型７０の成形部７０Ｃと締結座２８との間の空間に入り込み、外周側に張り出した張出部３６Ｃが溶融樹脂突起３６に形成される。また、加圧部材４６からの加圧によって溶融樹脂突起３６を形成する溶融樹脂は、円筒状型７０の成形部７０Ｃと締結座２８との間の空間や、溶融樹脂突起３６と取付孔３０の孔壁面３０Ａとの間の隙間に流れ込む。これにより、張出部３６Ｃと締結座２８の一方の面２８Ａが密着し、伸張した溶融樹脂シート３４と締結座２８の他方の面２８Ｂが密着する。さらに、溶融樹脂突起３６と孔壁面３０Ａが密着する。これにより、張出部３６Ｃと伸張した溶融樹脂シート３４の一般部３４Ｂとの間で取付部品２６の締結座２８が挟まれる。なお、本実施形態の一般部３４Ｂは、伸張した溶融樹脂シート３４の締結座２８と接する部分を指している。   As shown in FIG. 7, the molten resin protrusion 36 pressed by the pressing member 46 is deformed so that the peripheral wall portion 36 </ b> B is double-folded, and the folded portion is a molded portion of the cylindrical mold 70. An overhanging portion 36 </ b> C that enters the space between 70 </ b> C and the fastening seat 28 and projects outward is formed on the molten resin protrusion 36. Further, the molten resin that forms the molten resin protrusion 36 by the pressure from the pressure member 46 is the space between the molded portion 70 </ b> C of the cylindrical mold 70 and the fastening seat 28, or between the molten resin protrusion 36 and the mounting hole 30. It flows into the gap between the hole wall surface 30A. Thus, the overhang portion 36C and the one surface 28A of the fastening seat 28 are in close contact with each other, and the expanded molten resin sheet 34 and the other surface 28B of the fastening seat 28 are in close contact with each other. Further, the molten resin protrusion 36 and the hole wall surface 30A are in close contact with each other. As a result, the fastening seat 28 of the attachment component 26 is sandwiched between the overhanging portion 36 </ b> C and the general portion 34 </ b> B of the expanded molten resin sheet 34. In addition, the general part 34B of this embodiment has pointed out the part which contact | connects the fastening seat 28 of the expanded molten resin sheet 34. FIG.

そして、ヒータ５４、ヒータ７２及びヒータ７６を停止し、締結座２８を張出部３６Ｃと伸張した溶融樹脂シート３４の一般部３４Ｂで挟んだ状態で溶融樹脂を冷却固化させる。これにより、図８に示されるように、燃料タンクに取付部品を取り付けるための取付部３８（突起２４及び張出部３２によって構成される）がタンク本体２２Ｂに形成される。この取付部３８により、取付部品２６がタンク本体２２Ｂに固定（締結）される。   Then, the heater 54, the heater 72, and the heater 76 are stopped, and the molten resin is cooled and solidified in a state where the fastening seat 28 is sandwiched between the extended portion 36C and the general portion 34B of the molten resin sheet 34 that is extended. As a result, as shown in FIG. 8, an attachment portion 38 (configured by the protrusion 24 and the overhang portion 32) for attaching the attachment component to the fuel tank is formed in the tank body 22B. The attachment part 26 is fixed (fastened) to the tank body 22B by the attachment portion 38.

次に、可動部材４４を突出させて成形型４２からタンク本体２２Ｂを離型させる。そして、図示しない成形型を用いて成形したタンク本体２２Ａの外周縁部と、タンク本体２２Ｂの外周縁部とを重ねて接合（溶着）することで、タンク本体２２が完成する。   Next, the movable member 44 is projected to release the tank body 22B from the mold 42. The tank body 22 is completed by overlapping (joining) the outer peripheral edge portion of the tank main body 22A formed using a molding die (not shown) and the outer peripheral edge portion of the tank main body 22B.

次に、本実施形態の燃料タンク２０及び燃料タンク２０の製造方法の作用効果について説明する。   Next, the effects of the fuel tank 20 and the method for manufacturing the fuel tank 20 according to the present embodiment will be described.

燃料タンク２０の製造方法によれば、燃料タンク２０の取付部３８となる溶融樹脂突起３６は、成形型４２のキャビティ面４８Ａに対して余長分を有する溶融樹脂シート３４（本実施形態では、伸張した溶融樹脂シート３４）に形成されることから、例えば、余長分を有さない溶融樹脂シートに形成されるものと比べて、必要な樹脂量を確保することができる。これにより、燃料タンク２０の取付部３８の強度が確保される。なお、キャビティ面４８Ａに対して余長分を有する（得る）とは、キャビティ面４８Ａの面積（表面積）に対して溶融樹脂シート３４の成形面の面積を広くして余り部分を有する（得る）ことを意味する。   According to the manufacturing method of the fuel tank 20, the molten resin protrusion 36 that becomes the mounting portion 38 of the fuel tank 20 has a molten resin sheet 34 (in this embodiment, an extra length with respect to the cavity surface 48 </ b> A of the mold 42. Since it is formed on the stretched molten resin sheet 34), for example, a necessary amount of resin can be ensured as compared with that formed on the molten resin sheet having no extra length. Thereby, the strength of the mounting portion 38 of the fuel tank 20 is ensured. Note that “having (obtain) the surplus length with respect to the cavity surface 48A” means that the area of the molding surface of the molten resin sheet 34 is widened (obtained) with respect to the area (surface area) of the cavity surface 48A. Means that.

燃料タンク２０の製造方法では、伸張工程において、溶融樹脂シート３４を伸張させて余長分を得ることから、溶融樹脂シート３４の樹脂量が変化しないため、タンク本体２２の重量増加を抑制することができる。   In the method of manufacturing the fuel tank 20, since the molten resin sheet 34 is stretched to obtain an extra length in the stretching step, the amount of the resin in the molten resin sheet 34 does not change, so that an increase in the weight of the tank body 22 is suppressed. Can do.

また、溶融樹脂シート３４と成形型４２との間の密閉空間６０を加圧して溶融樹脂シート３４を伸張させるため、製造工程が複雑化する、或いは製造装置が複雑化又は大型化するのを抑止できる。また、溶融樹脂シート３４を均一に加圧して伸張させることができる。これにより、伸張した溶融樹脂シート３４の肉厚が略均一となる（ただし、外周縁部３４Ａ除く）。   Further, since the sealed space 60 between the molten resin sheet 34 and the molding die 42 is pressurized to extend the molten resin sheet 34, the manufacturing process is complicated, or the manufacturing apparatus is prevented from becoming complicated or large. it can. Further, the molten resin sheet 34 can be uniformly pressed and stretched. Thereby, the thickness of the expanded molten resin sheet 34 becomes substantially uniform (except for the outer peripheral edge portion 34A).

また、燃料タンク２０の製造方法では、賦形工程において、可動部材４４を伸張した溶融樹脂シート３４に当接させて溶融樹脂突起３６を形成することから、溶融樹脂突起３６を加圧し、冷却固化させて形成される突起２４の内部が可動部材４４の引き抜きによって中空となる。ここで、突起２４の内部が中空となるため、取付部３８を形成するのに必要な樹脂量を抑えることができる。   Further, in the manufacturing method of the fuel tank 20, since the molten resin protrusion 36 is formed by bringing the movable member 44 into contact with the expanded molten resin sheet 34 in the shaping step, the molten resin protrusion 36 is pressurized and cooled and solidified. The inside of the projection 24 thus formed becomes hollow by pulling out the movable member 44. Here, since the inside of the protrusion 24 is hollow, the amount of resin required to form the attachment portion 38 can be suppressed.

さらに、燃料タンク２０の製造方法では、加工工程において、可動部材４４を溶融樹脂突起３６の突出方向と反対方向に移動させた後で溶融樹脂突起３６を突出方向と反対方向に加圧することから、溶融樹脂突起３６が突出方向と反対方向に均等に圧縮される（押し潰される）。これにより、溶融樹脂突起３６の周壁部３６Ｂが２重に折り畳まれて外周側に張り出すため、取付部３８の張出部３２を肉厚にできる。なお、可動部材４４を溶融樹脂突起３６の突出方向と反対方向に移動させながら溶融樹脂突起３６を突出方向と反対方向に加圧した場合も同様の作用効果を得られる。   Furthermore, in the manufacturing method of the fuel tank 20, since the movable member 44 is moved in the direction opposite to the protruding direction of the molten resin protrusion 36 in the processing step, the molten resin protrusion 36 is pressurized in the direction opposite to the protruding direction. The molten resin protrusion 36 is evenly compressed (squeezed) in the direction opposite to the protruding direction. Thereby, since the surrounding wall part 36B of the molten resin protrusion 36 is double-folded and protrudes to the outer peripheral side, the protruding part 32 of the attachment part 38 can be thickened. The same effect can be obtained when the molten resin protrusion 36 is pressurized in the direction opposite to the protruding direction while moving the movable member 44 in the direction opposite to the protruding direction of the molten resin protrusion 36.

また、円筒状型７０内に溶融樹脂突起３６を挿入した状態で溶融樹脂突起３６を加圧することから、溶融樹脂突起３６が円筒状型７０の内面形状に成形される。ここで、円筒状型７０内が取付孔３０の直径よりも内径が大きい成形部７０Ｃを備えているため、取付部品２６が取付部３８によって確実に燃料タンク２０に取り付けられる。また、円筒状型７０によって取付部品２６を押さえながら、溶融樹脂突起３６を加圧するため、加圧時の円筒状型７０の位置ずれを抑制できる。   Further, since the molten resin protrusion 36 is pressed in a state where the molten resin protrusion 36 is inserted into the cylindrical mold 70, the molten resin protrusion 36 is formed into the inner surface shape of the cylindrical mold 70. Here, since the inside of the cylindrical mold 70 includes the molding portion 70 </ b> C having an inner diameter larger than the diameter of the attachment hole 30, the attachment component 26 is reliably attached to the fuel tank 20 by the attachment portion 38. Moreover, since the molten resin protrusion 36 is pressurized while pressing the attachment part 26 by the cylindrical mold 70, the positional deviation of the cylindrical mold 70 at the time of pressurization can be suppressed.

上記製造方法で製造された燃料タンク２０では、突起２４の内部を中空としていることから、取付部３８を形成するために必要な樹脂量が抑えられる。これにより、燃料タンク２０の重量を低減することができる。また、突起２４の内部を中空としているが、突起２４の挿入部２４Ｃの肉厚Ｔ１をタンク本体２２の一般部２２Ｃの肉厚Ｔ０以上としていることから、突起２４の断面二次モーメントが確保されるため、突起２４の強度が確保される。さらに、張出部３２の肉厚Ｔ２も一般部２２Ｃの肉厚Ｔ０以上としていることから、張出部３２の強度が確保される。これにより、突起２４及び張出部３２で構成される取付部３８の強度を確保することができる。加えて、取付部３８による取付部品２６の固定強度も確保することができる。   In the fuel tank 20 manufactured by the above manufacturing method, since the inside of the protrusion 24 is hollow, the amount of resin necessary for forming the attachment portion 38 can be suppressed. Thereby, the weight of the fuel tank 20 can be reduced. Further, although the inside of the protrusion 24 is hollow, since the thickness T1 of the insertion portion 24C of the protrusion 24 is equal to or greater than the thickness T0 of the general portion 22C of the tank body 22, a secondary moment of section of the protrusion 24 is ensured. Therefore, the strength of the protrusion 24 is ensured. Furthermore, since the wall thickness T2 of the overhang portion 32 is equal to or greater than the wall thickness T0 of the general portion 22C, the strength of the overhang portion 32 is ensured. Thereby, the strength of the attachment portion 38 constituted by the protrusion 24 and the overhang portion 32 can be ensured. In addition, the fixing strength of the attachment component 26 by the attachment portion 38 can be ensured.

前述の実施形態の製造方法では、賦形工程において、密閉空間６０内を加圧し、溶融樹脂シート３４を風船状に膨らませて伸張させることで、溶融樹脂シート３４がキャビティ面４８Ａに対して余長を得ているが、本発明はこの構成に限定されない。例えば、セット工程において、キャビティ面４８Ａに対して余長分を有するように押出機で押し出した溶融樹脂シート３４を、成形型４２内にセットしてもよい。この構成の場合には、溶融樹脂シート３４を風船状に膨らませて伸張させなくてもよいため、製造工程が複雑化する、或いは製造装置が複雑化又は大型化するのを抑止できる。   In the manufacturing method according to the above-described embodiment, in the shaping process, the inside of the sealed space 60 is pressurized, and the molten resin sheet 34 is expanded in a balloon shape so as to be stretched, so that the molten resin sheet 34 has an extra length with respect to the cavity surface 48A. However, the present invention is not limited to this configuration. For example, in the setting step, the molten resin sheet 34 extruded with an extruder so as to have an extra length with respect to the cavity surface 48 </ b> A may be set in the molding die 42. In the case of this configuration, the molten resin sheet 34 does not have to be inflated and expanded in a balloon shape, so that it is possible to prevent the manufacturing process from becoming complicated, or the manufacturing apparatus from becoming complicated or enlarged.

また、前述の実施形態の製造方法では、賦形工程において、密閉空間６０の加圧により、溶融樹脂シート３４を伸張させ、密閉空間６０の減圧により、伸張した溶融樹脂シート３４をキャビティ面４８Ａに沿って配置しているが、本発明はこの構成に限定されない。図１０、図１１に示されるように、成形型４２と圧空成形型９２を型合わせして圧空成形型９２と溶融樹脂シート３４との間の空間を密閉状態として（すなわち、密閉空間９４を形成して）、この密閉空間９４内を加圧する、又は減圧することで、溶融樹脂シート３４を伸張させる、または、伸張した溶融樹脂シート３４をキャビティ面４８Ａに沿って配置（密着）させる構成としてもよい。   In the manufacturing method of the above-described embodiment, in the shaping step, the molten resin sheet 34 is expanded by pressurizing the sealed space 60, and the expanded molten resin sheet 34 is applied to the cavity surface 48A by depressurizing the sealed space 60. However, the present invention is not limited to this configuration. As shown in FIGS. 10 and 11, the molding die 42 and the pressure forming die 92 are combined to make the space between the pressure forming die 92 and the molten resin sheet 34 sealed (that is, a sealed space 94 is formed). Further, by pressing or depressurizing the inside of the sealed space 94, the molten resin sheet 34 may be expanded, or the expanded molten resin sheet 34 may be disposed (contacted) along the cavity surface 48A. Good.

またさらに、前述の実施形態の製造方法では、タンク本体２２Ａとタンク本体２２Ｂを別々の成形装置で形成し、その後接合してタンク本体２２を形成する構成としているが、本発明はこの構成に限定されない。例えば、タンク本体２２Ａ用の成形型と、成形型４２とを備え、タンク本体２２Ａとタンク本体２２Ｂとをそれぞれ離型する前に、型合わせしてタンク本体２２Ａとタンク本体２２Ｂを接合できる成形装置を用いてタンク本体２２を形成する構成としてもよい。   Furthermore, in the manufacturing method of the above-described embodiment, the tank body 22A and the tank body 22B are formed by separate molding apparatuses, and then joined to form the tank body 22. However, the present invention is limited to this structure. Not. For example, a molding apparatus that includes a molding die for the tank main body 22A and a molding die 42, and can mold and match the tank main body 22A and the tank main body 22B before separating the tank main body 22A and the tank main body 22B from each other. It is good also as a structure which forms the tank main body 22 using.

前述の実施形態の製造方法では、配置工程において、締結座２８の他方の面２８Ｂを平坦状とした取付部品２６を伸張した溶融樹脂シート３４上に配置しているが、本発明はこの構成に限定されない。例えば、図１４に示されるように、締結座２８の他方の面２８Ｂに取付孔３０を中心にした環状の凸部９８及び環状の凹部１００を設けた取付部品２６を伸張した溶融樹脂シート３４上に配置してもよい。これにより、配置工程において、締結座２８の他方の面２８Ｂが伸張した溶融樹脂シート３４に融着するため、伸張した溶融樹脂シート３４に取付部品２６を仮固定することができる。また、凸部９８を凹部１００よりも取付孔３０の近くに配置することで、加圧時に溶融樹脂突起３６を構成する溶融樹脂が伸張した溶融樹脂シート３４の一般部３４Ｂへ流れ出すのを抑制することができる。さらに、凹部１００で、伸張した溶融樹脂シート３４の締結座２８とキャビティ面４８Ａとで挟まれる部分の溶融樹脂を受けることで、溶融樹脂が締結座２８の外側へ流れ出すのを抑制することができる。なお、締結座２８の他方の面２８Ｂに凸部９８のみを設ける、又は、凹部１００のみを設ける構成としてもよい。   In the manufacturing method of the above-described embodiment, in the arranging step, the mounting part 26 having the other surface 28B of the fastening seat 28 in a flat shape is arranged on the expanded molten resin sheet 34, but the present invention has this configuration. It is not limited. For example, as shown in FIG. 14, on the molten resin sheet 34 obtained by extending the attachment component 26 provided with the annular protrusion 98 and the annular recess 100 around the attachment hole 30 on the other surface 28 </ b> B of the fastening seat 28. You may arrange in. Thereby, in the arrangement step, the other surface 28 </ b> B of the fastening seat 28 is fused to the expanded molten resin sheet 34, so that the attachment component 26 can be temporarily fixed to the expanded molten resin sheet 34. Further, by disposing the convex portion 98 closer to the attachment hole 30 than the concave portion 100, the molten resin constituting the molten resin protrusion 36 is prevented from flowing out to the general portion 34B of the molten resin sheet 34 that is stretched during pressurization. be able to. Furthermore, by receiving the molten resin in a portion sandwiched between the fastening seat 28 of the stretched molten resin sheet 34 and the cavity surface 48 </ b> A by the recess 100, it is possible to suppress the molten resin from flowing out of the fastening seat 28. . In addition, it is good also as a structure which provides only the convex part 98 in the other surface 28B of the fastening seat 28, or provides only the recessed part 100. FIG.

前述の実施形態の燃料タンク２０では、張出部３２が突起２４の外周に沿って一周分形成される構成としているが、本発明はこの構成に限定されない。例えば、張出部３２を突起２４の外周に沿って複数に分割してもよい。言い換えると、図１２及び図１３に示されるように、突起２４の外周に沿って一つ又は複数の張出部９６を形成してもよい。このように構成することで、取付部３８の形成に必要な樹脂量を減らすことができる。   In the fuel tank 20 of the above-described embodiment, the overhang portion 32 is formed along the outer periphery of the protrusion 24, but the present invention is not limited to this configuration. For example, the overhang portion 32 may be divided into a plurality along the outer periphery of the protrusion 24. In other words, as shown in FIGS. 12 and 13, one or a plurality of overhang portions 96 may be formed along the outer periphery of the protrusion 24. By comprising in this way, the amount of resin required for formation of the attaching part 38 can be reduced.

また前述の実施形態の燃料タンク２０では、突起２４の張出部３２と一般部２２Ｃとの間で締結座２８を挟んで固定（締結）しているが、本発明はこの構成に限定されない。例えば、張出部３２と締結座２８との間に隙間が形成されてもよい。この構成でも突起２４が締結座２８から抜け出るのを張出部３２が防止できるため、燃料タンク２０と取付部品２６の取付状態を維持することができる。   In the fuel tank 20 of the above-described embodiment, the fastening seat 28 is sandwiched and fixed (fastened) between the protruding portion 32 of the protrusion 24 and the general portion 22C, but the present invention is not limited to this configuration. For example, a gap may be formed between the overhang portion 32 and the fastening seat 28. Even in this configuration, the protruding portion 32 can prevent the protrusion 24 from coming out of the fastening seat 28, so that the mounting state of the fuel tank 20 and the mounting part 26 can be maintained.

以上、本発明の一実施形態について説明したが、本発明は、上記に限定されるものでなく、その主旨を逸脱しない範囲内において上記以外にも種々変形して実施することが可能であることは勿論である。   Although one embodiment of the present invention has been described above, the present invention is not limited to the above, and various modifications other than the above can be implemented without departing from the spirit of the present invention. Of course.

２０ 燃料タンク
２２ タンク本体
２２Ｃ 一般部
２４ 突起
２４Ａ 頂部
２４Ｃ 挿入部（取付孔に挿入された部分）
２６ 取付部品
３０ 取付孔
３２ 張出部
３４ 溶融樹脂シート
３６ 溶融樹脂突起
３６Ｃ 張出部（張り出した部分）
４２ 成形型
４４ 可動部材
４８Ａ キャビティ面（型面）
６０ 密閉空間
７０ 円筒状型（可動型）
９４ 密閉空間
９６ 張出部
９８ 凸部
１００ 凹部
９２ 圧空成形型
９６ 張出部
９８ 凸部
１００ 凹部
Ｔ０ タンク本体の一般部の肉厚
Ｔ１ 突起の挿入部の肉厚（取付孔に挿入された部分の肉厚） 20 Fuel tank 22 Tank body 22C General part 24 Projection 24A Top part 24C Insertion part (part inserted into the mounting hole)
26 Mounting parts 30 Mounting holes 32 Overhanging portion 34 Molten resin sheet 36 Molten resin protrusion 36C Overhanging portion (overhanging portion)
42 Mold 44 Moving member 48A Cavity surface (mold surface)
60 Sealed space 70 Cylindrical type (movable type)
94 Sealed space 96 Overhanging part 98 Convex part 100 Concave part 92 Pressure forming mold 96 Overhang part 98 Convex part 100 Concave part T0 Thickness of the general part of the tank body T1 Thickness of the insertion part of the protrusion (the part inserted into the mounting hole) Thickness)

Claims (10)

タンク本体を成形するための成形型の型面に対して余長分を有する溶融樹脂シートに前記成形型内で肉厚方向に突出する溶融樹脂突起を形成する賦形工程と、
取付部品に設けられた取付孔に前記溶融樹脂突起を挿入して前記溶融樹脂シート上に前記取付部品を配置する配置工程と、
前記取付孔に挿入された前記溶融樹脂突起を加圧して、前記溶融樹脂突起の一部を外周側に張り出させる加工工程と、
を備える燃料タンクの製造方法。 A forming step of forming a molten resin protrusion protruding in the thickness direction in the mold on the molten resin sheet having an extra length with respect to the mold surface of the mold for forming the tank body;
An arrangement step of inserting the molten resin protrusion into an attachment hole provided in the attachment component and arranging the attachment component on the molten resin sheet;
A processing step of pressurizing the molten resin protrusion inserted into the mounting hole and projecting a part of the molten resin protrusion outward.
A method for manufacturing a fuel tank comprising: 前記賦形工程の前に、溶融樹脂シートを前記成形型内にセットするセット工程と、前記セットされた溶融樹脂シートを伸張させて前記型面に対して余長分を得る伸張工程と、を備える請求項１に記載に燃料タンクの製造方法。   Before the shaping step, a setting step of setting a molten resin sheet in the mold, and an extension step of extending the set molten resin sheet to obtain an extra length with respect to the mold surface, The manufacturing method of a fuel tank according to claim 1 provided. 前記伸張工程では、前記セットされた溶融樹脂シートと前記成形型との間の空間を加圧し、又は前記セットされた溶融樹脂シートと前記成形型に合わされた圧空成形型との間の空間を減圧して前記セットされた溶融樹脂シートを膨らませ、伸張させる、請求項２に記載の燃料タンクの製造方法。   In the extension step, the space between the set molten resin sheet and the mold is pressurized, or the space between the set molten resin sheet and the compressed air mold fitted to the mold is depressurized. The method for producing a fuel tank according to claim 2, wherein the set molten resin sheet is expanded and expanded. 前記伸張工程では、前記セットされた溶融樹脂シートと前記成形型との間の空間を密閉状態にして加圧し、又は前記セットされた溶融樹脂シートと前記成形型に合わされた圧空成形型との間の空間を密閉状態にして減圧する、請求項３に記載の燃料タンクの製造方法。   In the extension step, the space between the set molten resin sheet and the mold is sealed and pressed, or between the set molten resin sheet and the compressed air mold fitted to the mold The method for producing a fuel tank according to claim 3, wherein the space is sealed and the pressure is reduced. 前記賦形工程の前に、前記型面に対して余長分を有する溶融樹脂シートを前記成形型内にセットするセット工程を備える請求項１に記載に燃料タンクの製造方法。   The method for manufacturing a fuel tank according to claim 1, further comprising a setting step of setting a molten resin sheet having a surplus length with respect to the mold surface in the mold before the shaping step. 前記賦形工程では、前記成形型と前記余長分を有する溶融樹脂シートとの間の空間を減圧し、又は前記成形型に合わされた圧空成形型と前記余長分を有する溶融樹脂シートとの間の空間を加圧して前記余長分を有する溶融樹脂シートを前記型面に沿って配置させると共に、前記余長分を有する溶融樹脂シートに前記成形型に設けられた可動部材を当接させて前記溶融樹脂突起を形成する、請求項１〜５のいずれか１項に記載の燃料タンクの製造方法。   In the shaping step, the space between the molding die and the molten resin sheet having the extra length is depressurized, or the compressed air molding die fitted to the molding die and the molten resin sheet having the extra length The molten resin sheet having the extra length is arranged along the mold surface by pressurizing the space therebetween, and the movable member provided in the mold is brought into contact with the molten resin sheet having the extra length. The method for manufacturing a fuel tank according to claim 1, wherein the molten resin protrusion is formed. 前記加工工程では、前記可動部材を前記溶融樹脂突起の突出方向と反対方向に移動させながら、又は移動させた後で、前記溶融樹脂突起を前記反対方向に加圧する、請求項６に記載の燃料タンクの製造方法。   The fuel according to claim 6, wherein in the processing step, the molten resin protrusion is pressurized in the opposite direction while moving the movable member in a direction opposite to a protruding direction of the molten resin protrusion or after the movement. Tank manufacturing method. 前記加工工程では、前記取付部品の前記取付孔よりも部分的に内径が大きい可動型で前記取付部品を押さえ且つ前記可動型内に前記溶融樹脂突起をセットした状態で前記溶融樹脂突起を加圧して、前記溶融樹脂突起に少なくとも前記取付孔の周辺部まで張り出す張出部を形成する、請求項１〜７のいずれか１項に記載の燃料タンクの製造方法。 The processing in the step, the mounting part wherein the mounting hole the molten resin protrusion is pressurized at setting the molten resin protrusion to the fitting of the retainer and the movable mold in a partially having a larger inner diameter steerable than the The method for manufacturing a fuel tank according to any one of claims 1 to 7, wherein an overhang portion is formed on the molten resin protrusion so as to project at least to a peripheral portion of the attachment hole. 前記配置工程では、前記溶融樹脂シートとの接触面に凸部及び凹部の一方又は両方が設けられた前記取付部品を前記溶融樹脂シートに配置する、請求項１〜８のいずれか１項に記載の燃料タンクの製造方法。   In the said arrangement | positioning process, the said attachment components by which the one or both of the convex part and the recessed part were provided in the contact surface with the said molten resin sheet are arrange | positioned in the said molten resin sheet. Fuel tank manufacturing method. 樹脂で形成され、燃料を収容可能なタンク本体と、
前記タンク本体に形成され、肉厚方向に突出し、内部が中空で且つ頂部が閉塞された筒状とされ、取付部品に設けられた取付孔に挿入され、前記取付孔に挿入された部分の肉厚が前記タンク本体の一般部の肉厚以上とされた突起と、
前記突起に形成され、前記突起の外周側に張り出し、前記取付部品の取付孔周辺部を前記一般部との間で挟んで前記取付部品を前記タンク本体に取り付ける張出部と、
を備える燃料タンク。 A tank body made of resin and capable of containing fuel;
It is formed in the tank body, protrudes in the thickness direction, has a cylindrical shape with a hollow inside and a closed top, and is inserted into a mounting hole provided in a mounting part, and the portion of the wall inserted into the mounting hole A protrusion whose thickness is equal to or greater than the thickness of the general portion of the tank body;
An overhanging portion that is formed on the protrusion, protrudes to the outer peripheral side of the protrusion, and attaches the attachment component to the tank body with the attachment hole peripheral portion of the attachment component sandwiched between the general portion;
With fuel tank.
JP2013228745A 2013-11-01 2013-11-01 Fuel tank manufacturing method and fuel tank Active JP5895922B2 (en)

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JP5929875B2 (en) 2013-11-06 2016-06-08 トヨタ自動車株式会社 Manufacturing method of fuel tank
JP6064949B2 (en) * 2014-07-15 2017-01-25 トヨタ自動車株式会社 Fuel tank manufacturing method and fuel tank
JP6296010B2 (en) * 2015-07-06 2018-03-20 トヨタ自動車株式会社 Molding device for internal parts fixing part of fuel tank
JP6350440B2 (en) * 2015-08-06 2018-07-04 トヨタ自動車株式会社 Built-in component fixing structure of resin tank

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US5308427A (en) * 1992-09-28 1994-05-03 Ford Motor Company Method for fastening plastic articles
FR2873321B1 (en) * 2004-07-23 2008-05-09 Inergy Automotive Systems Res METHOD FOR FIXING AN ACCESSORY IN A FUEL TANK OF PLASTIC MATERIAL
FR2918595B1 (en) * 2007-07-11 2009-10-09 Inergy Automotive Systems Res METHOD FOR FIXING AN ACCESSORY IN A PLASTIC RESERVOIR
FR2934806A1 (en) * 2008-08-07 2010-02-12 Inergy Automotive Systems Res METHOD FOR ATTACHING AN ACCESSORY IN A HOLLOW BODY OF PLASTIC MATERIAL
FR3008641B1 (en) * 2013-07-22 2015-12-11 Inergy Automotive Systems Res METHOD FOR ATTACHING AN ACCESSORY TO THE WALL OF A TANK

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