US20010051236A1 - Resin container and a manufacturing method thereof - Google Patents

Resin container and a manufacturing method thereof Download PDF

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Publication number
US20010051236A1
US20010051236A1 US09/035,750 US3575098A US2001051236A1 US 20010051236 A1 US20010051236 A1 US 20010051236A1 US 3575098 A US3575098 A US 3575098A US 2001051236 A1 US2001051236 A1 US 2001051236A1
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US
United States
Prior art keywords
resin
gas barrier
manufacturing
intermediate molded
melt
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US09/035,750
Other languages
English (en)
Inventor
Katsuyuki Kido
Hirokazu Ishimaru
Masaki Terada
Yoichi Serino
Makoto Kito
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Toyota Motor Corp
Original Assignee
Individual
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Filing date
Publication date
Application filed by Individual filed Critical Individual
Assigned to TOYOTA JIDOSHA KABUSHIKI KAISHA reassignment TOYOTA JIDOSHA KABUSHIKI KAISHA ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ISHIMARU, HIROKAZU, KIDO, KATSUYUKI, KITO, MAKOTO, SERINO, YOICHI, TERADA, MASAKI
Assigned to TOYOTA JIDOSHA KABUSHIKI KAISHA reassignment TOYOTA JIDOSHA KABUSHIKI KAISHA ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ISHIMARU, HIROKAZU, KIDO, KATSUYUKI, KITO, MAKOTO, SERINO, YOICHI, TERADA, MASAKI
Priority to US09/940,799 priority Critical patent/US6616788B2/en
Publication of US20010051236A1 publication Critical patent/US20010051236A1/en
Abandoned legal-status Critical Current

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    • 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
    • B60K15/03177—Fuel tanks made of non-metallic material, e.g. plastics, or of a combination of non-metallic and metallic material
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0053—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping
    • B29C45/006—Joining parts moulded in separate cavities
    • 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
    • B29C51/266—Auxiliary operations after the thermoforming operation
    • B29C51/267—Two sheets being thermoformed in separate mould parts and joined together while still in the mould
    • 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
    • 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"
    • B29C65/2007—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" characterised by the type of welding mirror
    • B29C65/2023—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" characterised by the type of welding mirror said welding mirror comprising several sectors
    • 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"
    • B29C65/2007—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" characterised by the type of welding mirror
    • B29C65/203—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" characterised by the type of welding mirror being several single mirrors, e.g. not mounted on the same tool
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B29C65/58—Snap connection
    • 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
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt joints
    • 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
    • B29C66/01—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
    • B29C66/14—Particular design of joint configurations particular design of the joint cross-sections the joint having the same thickness as the thickness 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
    • B29C66/50—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
    • B29C66/50—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
    • B29C66/542—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 joining hollow covers or hollow bottoms to open ends of container bodies
    • 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
    • B29C66/543—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 joining more than two hollow-preforms to form said hollow 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
    • B29C66/50—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
    • B29C66/545—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 one hollow-preform being placed inside the other
    • 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
    • B29C66/72341—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 for gases
    • 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
    • B29C66/814—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 design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—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 design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81427—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 design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
    • 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
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    • B29C66/818—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 cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps
    • B29C66/8182—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 cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the thermal insulating constructional aspects
    • B29C66/81821—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 cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the thermal insulating constructional aspects of the welding jaws
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/81411—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 design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat
    • B29C66/81415—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 design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being bevelled
    • B29C66/81419—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 design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being bevelled and flat
    • 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
    • B29C66/814—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 design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—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 design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81411—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 design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat
    • B29C66/81421—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 design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave
    • B29C66/81422—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 design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave being convex
    • 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
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products
    • 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
    • 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
    • B60K2015/03467—Arrangements or special measures related to fuel tanks or fuel handling for fixing or mounting parts of the fuel tank together by clip or snap fit fittings
    • 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
    • B60K15/077—Fuel tanks with means modifying or controlling distribution or motion of fuel, e.g. to prevent noise, surge, splash or fuel starvation
    • B60K2015/0777—Fuel tanks with means modifying or controlling distribution or motion of fuel, e.g. to prevent noise, surge, splash or fuel starvation in-tank reservoirs or baffles integrally manufactured with the fuel Tank
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]

Definitions

  • JP-A Japanese Patent Application Laid-Open
  • 5-229015 for resin containers such as fuel tanks and the like mounted in automotive vehicles and methods for manufacturing the same have been known.
  • a molten resin 122 in a high temperature state is extruded onto a convex metal mold 146 so as to conform to the measurements of the metal mold.
  • a vacuum is created in the suction holes 134 provided on an inner wall 132 of a concave metal mold 130 which corresponds to the shape of the convex metal mold 146 by a vacuum apparatus 140 , and a film (a sheet member) 142 made of the same material as that of the resin 122 and having a gas barrier layer which prevents gasoline from permeating through is heated so as to adhere to the innerwall 132 of the concave metal mold 130 .
  • the convex metal mold 146 and the concave metal mold 130 are die matched and heat compressed, and thereafter the molds are opened.
  • the concave metal mold 130 holding an intermediate concave molded product formed in the above manner and kept in a high temperature state, and the other metal mold holding an intermediate concave molded product formed in the same manner and kept in a high temperature state are combined with each other and then are thermally compressed. Accordingly, the joint portions of the intermediate products adhere to each other in the high temperature state, so that the bonding strength is improved.
  • the related art concerning the present invention includes Japanese Patent Application Laid-Open (JP-A) No. 63-260424 which discloses a fuel tank having a multi-layered resin structure, Japanese Patent Application Laid-Open (JP-A) Nos. 6-278223 and 6-278224 which disclose a fuel tank in which the peripheral portions of two concave resin containers is subjected to melt-adhesion, and Japanese Patent Application Laid-Open (JP-A) No. 58-202112 which discloses a fuel tank in which the peripheral portions of two containers comprising a resin layer and a metal foil are melted to adhere to each other.
  • the present invention takes the above facts into consideration and an object of the present invention is to provide a resin container and a method for manufacturing the same which can improve the gas permeation preventing performance in the bonding portions of intermediate molded products.
  • the present invention provides a resin container formed by superposing peripheral edge portions of at least two intermediate molded products, each of the intermediate molded products comprising at least two layers including a sheet member and a resin layer, in which the sheet members of the at least two intermediate molded products are melted and adhered to each other and the resin layers of the intermediate molded products are melted and adhered to each other. Accordingly, since the sheet members are securely adhered to each other in the bonding portion in which the peripheral edge portions of two intermediate molded products are superposed on each other, the gas permeation preventing performance in the bonding portion between the intermediate molded products can be improved.
  • the present invention comprises an intermediate molded product forming step of forming concave intermediate molded products, each of the intermediate molded products comprising at least two layers including a sheet member and a resin layer, a sheet material melt-adhering step of superposing the peripheral edge portions of the intermediate formed products to melt and adhere the sheet members to each other, and a resin layer melt-adhering step of melt-adhering the resin layers of the intermediate molded products to each other. Accordingly, the resin container in which the gas permeation preventing performance in the bonding portion between the intermediate molded products is improved.
  • FIG. 1A is a cross sectional view of an apparatus and a container which shows one step of a method for manufacturing a resin container in accordance with a first embodiment of the present invention.
  • FIG. 1B is a cross sectional view of an apparatus and a container which shows one step of a method for manufacturing a resin container in accordance with a first embodiment of the present invention.
  • FIG. 1C is a cross sectional view of an apparatus and a container which shows one step of a method for manufacturing a resin container in accordance with a first embodiment of the present invention.
  • FIG. 1D is a cross sectional view of an apparatus and a container which shows one step of a method for manufacturing a resin container in accordance with a first embodiment of the present invention.
  • FIG. 1E is a cross sectional view of an apparatus and a container which shows one step of a method for manufacturing a resin container in accordance with a first embodiment of the present invention.
  • FIG. 1F is a cross sectional view of an apparatus and a container which shows one step of a method for manufacturing a resin container in accordance with a first embodiment of the present invention.
  • FIG. 2 is a cross sectional view of an apparatus and a container in cases where the pressure inside a saccate gas barrier sheet is reduced by a resin layer welding process of a method for manufacturing a resin container in accordance with a first embodiment of the present invention.
  • FIG. 3 is an enlarged partial cross sectional view of a gas barrier sheet used in a method for manufacturing a resin container in accordance with a first embodiment of the present invention.
  • FIG. 4 is an enlarged cross sectional view of an attached part (a cut off valve) in a method for manufacturing a resin container in accordance with a first embodiment of the present invention.
  • FIG. 5 is an enlarged cross sectional view of an attached part (a pipe) in a method for manufacturing a resin container in accordance with a first embodiment of the present invention.
  • FIG. 6 is an enlarged partial cross sectional view of a gas barrier sheet and a resin layer in a state where the gas barrier sheet and the resin layer are welded together in a method for manufacturing a resin container in accordance with a first embodiment of the present invention.
  • FIG. 7 is an enlarged cross sectional view of a bonded portion of a heat plate, a gas barrier sheet, and a resin layer near the heat plate in a method for manufacturing a resin container in accordance with a first embodiment of the present invention.
  • FIG. 8 is a perspective view of a resin container manufactured by a method for manufacturing a resin container in accordance with a first embodiment of the present invention.
  • FIG. 9 is a cross sectional view of an apparatus and a container which shows a gas discharge process of a method for manufacturing a resin container in accordance with a second embodiment of the present invention.
  • FIG. 10 is a cross sectional view of an apparatus and a container which shows a state after a gas discharge step is completed in a method for manufacturing a resin container in accordance with a second embodiment of the present invention.
  • FIG. 11 is a schematical cross sectional view of a container manufactured by a method for manufacturing a resin container in accordance with a second embodiment of the present invention.
  • FIG. 12 is an enlarged cross sectional view of a bonded portion of a heat plate, a gas barrier sheet, and a resin layer near the heat plate in a method for manufacturing a resin container in accordance with a third embodiment of the present invention.
  • FIG. 13 is an enlarged cross sectional view of a bonded portion of a heat plate, a gas barrier sheet, and a resin layer near the heat plate in a method for manufacturing a resin container in accordance with a modified embodiment of the third embodiment of the present invention.
  • FIG. 14A is an enlarged cross sectional view which shows a state before sheet member engaging portions are engaged in a method for manufacturing a resin container in accordance with a fourth embodiment of the present invention.
  • FIG. 14B is an enlarged cross sectional view which shows a state after sheet member engaging portions are engaged in a method for manufacturing a resin container in accordance with a fourth embodiment of the present invention.
  • FIG. 15 is an exploded perspective view of a container manufactured by a method for manufacturing a resin container in accordance with a fourth embodiment of the present invention.
  • FIG. 16A is an enlarged cross sectional view which shows a state before sheet member engaging portions are engaged in a method for manufacturing a resin container in accordance with a modified embodiment of the fourth embodiment of the present invention.
  • FIG. 16B is an enlarged cross sectional view which shows a state after sheet member engaging portions are engaged in a method for manufacturing a resin container in accordance with a modified embodiment of the fourth embodiment of the present invention.
  • FIG. 17A is an enlarged cross sectional view which shows a state before sheet member engaging portions are engaged in a method for manufacturing a resin container in accordance with a further modified embodiment of the fourth embodiment of the present invention.
  • FIG. 17B is an enlarged cross sectional view which shows a state after sheet member engaging portions are engaged in a method for manufacturing a resin container in accordance with a further modified embodiment of the fourth embodiment of the present invention.
  • FIG. 18 is a cross sectional view of an apparatus and a container which shows one step of a method for manufacturing a resin container in accordance with a fifth embodiment of the present invention.
  • FIG. 19 is an enlarged partial cross sectional view of a bonded portion of a gas barrier sheet and a resin layer in a method for manufacturing a resin container in accordance with a sixth embodiment of the present invention.
  • FIG. 20A is a cross sectional view of an apparatus and a container which shows one step of a method for manufacturing a resin container in accordance with a sixth embodiment of the present invention.
  • FIG. 20B is a cross sectional view of an apparatus and a container which shows one step of a method for manufacturing a resin container in accordance with a sixth embodiment of the present invention.
  • FIG. 21A is an enlarged cross sectional view which shows a state before a bonding portion of a gas barrier sheet is welded in a method for manufacturing a resin container in accordance with a sixth embodiment of the present invention.
  • FIG. 21B is an enlarged cross sectional view which shows a state after a bonding portion of a gas barrier sheet is welded in a method for manufacturing a resin container in accordance with a sixth embodiment of the present invention.
  • FIG. 22 is a schematical cross sectional view which shows a container manufactured by a method for manufacturing a resin container in accordance with a sixth embodiment of the present invention.
  • FIG. 23A is a schematical cross sectional view which shows a heat plate used for a method for manufacturing a resin container in accordance with a modified embodiment of the sixth embodiment of the present invention.
  • FIG. 23B is a schematical cross sectional view which shows a heat plate used for a method for manufacturing a resin container in accordance with a further modified embodiment of the sixth embodiment of the present invention.
  • FIG. 24 is an enlarged cross sectional view of a bonded portion of a heat plate, a gas barrier sheet, and a resin layer near the heat plate in a method for manufacturing a resin container in accordance with a seventh embodiment of the present invention.
  • FIG. 25 is a cross sectional view along a line 25 - 25 in FIG. 24.
  • FIG. 26 is a cross sectional view of an apparatus and a container which shows a portion near a resin injecting heat plate in a method for manufacturing a resin container in accordance with an eighth embodiment of the present invention.
  • FIG. 27 is a cross sectional view of an apparatus and a container which shows a part engaging portion in a method for manufacturing a resin container in accordance with a ninth embodiment of the present invention.
  • FIG. 28 is a partial cross sectional view of a jig and a container which shows a shape correcting step of a method for manufacturing a resin container in accordance with a modified embodiment of the present invention.
  • FIG. 29 is a partial cross sectional view of a jig and a container which shows a shape correcting step of a method for manufacturing a resin container in accordance with a modified embodiment of the present invention.
  • FIG. 30 is a cross sectional view of an apparatus and a container which shows a gas barrier layer forming step of a method for manufacturing a resin container in accordance with a modified embodiment of the present invention.
  • FIG. 31 is a cross sectional view of an apparatus and a container which shows a resin layer forming step of a method for manufacturing a resin container in accordance with a modified embodiment of the present invention.
  • FIG. 32 is a cross sectional view of an apparatus and a container which shows an attachment part forming step of a method for manufacturing a resin container in accordance with a modified embodiment of the present invention.
  • FIG. 33 is a cross sectional view of an apparatus and a container which shows a resin layer forming step of a method for manufacturing a resin container in accordance with a modified embodiment of the present invention.
  • FIG. 34A is an enlarged cross sectional view which shows a state before bonding portions of a resin layer and a gas barrier sheet are welded in a method for manufacturing a resin container in accordance with a modified embodiment of the present invention.
  • FIG. 34B is an enlarged cross sectional view which shows a state after bonding portions of a resin layer and a gas barrier sheet are welded in a method for manufacturing a resin container in accordance with a modified embodiment of the present invention.
  • FIG. 35A is an enlarged cross sectional view which shows a state before bonding portions of a resin layer and a gas barrier sheet are welded in a method for manufacturing a resin container in accordance with a modified embodiment of the present invention.
  • FIG. 35B is an enlarged cross sectional view which shows a state after bonding portions of a resin layer and a gas barrier sheet are welded in a method for manufacturing a resin container in accordance with a modified embodiment of the present invention.
  • FIG. 36 is a schematic cross sectional view which shows a part of a method for manufacturing a resin container in accordance with a conventional embodiment.
  • a first embodiment of a method for manufacturing a resin container for example, a fuel tank for an automotive vehicle
  • a resin container for example, a fuel tank for an automotive vehicle
  • the gas barrier sheet 10 is structured so that a gas barrier layer 10 A having a gas permeation preventing properties is held between resin layers 10 B made of the same resin as that of a base resin.
  • the gas barrier layer 10 A is also called as an anti-gas permeation layer and is made of an ethylene vinyl alcohol (EVOH) layer or a nylon (TRADE MARK) layer.
  • the resin layer 10 B is made of a high density polyethylene (HDPE) which is the same type of resin (for example, polyethylene resin) as that of the base resin.
  • HDPE high density polyethylene
  • Examples of the gas barrier sheet 10 having the above structure include DAIAMILON MF, manufactured by Mitsubishi Plastics, Inc., and examples of the HDPE include F6040V manufactured by Nihon Poly olefin Inc.
  • the anti-gas permeability of the gas barrier sheet 10 is improved by the gas barrier layer 10 A, and the adhesiveness between the gas barrier sheet 10 and the base resin is improved by the resin layer 10 B.
  • the gas barrier sheet 10 covering the outer side (the outer side of the container once it has been formed into a container shape) of attachment parts such as a cut off valve 16
  • the gas barrier sheet 10 and the attachment parts such as the cut off valve 16 and the like are set on a base resin (hereinafter, referred to as resin layer 36 ) forming lower mold 18 .
  • resin layer 36 a base resin
  • the gas barrier sheet 10 can be easily adhered to the surface of the lower mold 18 by reducing the pressure between the lower mold 18 and the gas barrier sheet 10 .
  • an upper mold 20 is set onto the lower mold 18 in such a way that a cavity 22 is formed between the gas barrier sheet 10 and the inner surface of the upper mold 20 .
  • the cut off valve 16 is a pipe for expelling the gas which builds up in the top of the inside of the fuel tank when fuel is fed through an inlet pipe 30 into the fuel tank which is a resin container 28 comprising a lower part 24 and an upper part 26 .
  • This pipe closes when the fuel fills up to the valve position and remains open when the fuel level is below the valve position.
  • the gas expelled from the cut off valve 16 is expelled to the outside through a pipe 33 passing through a fuel pump mounting opening 32 .
  • the structure is made in such a way that the gas barrier sheet 10 covers parts such as the cut off valve 16 and the like, no hole is pierced on the barrier sheet 10 , and the gas permeation preventing performance is improved in regions where parts such as the cut off valve 16 and the like are disposed.
  • a resin layer 36 is injection molded onto the outer side of the gas barrier sheet 10 .
  • the resin layer 36 is molded by pouring a molten resin into the cavity 22 through a hole 40 in the upper mold 20 and then cooling and solidifying it.
  • the pressing plate 14 is removed and an intermediate molded product 38 having a concave shape and open peripheral edges is formed (intermediate molded product molding process).
  • a heated base resin sheet is disposed on the gas barrier sheet, and a resin layer is formed by stamping with a press.
  • a sub tank 44 and a separator 46 attachment parts are integrally formed on the fuel tank lower part 24 . Since the sub tank 44 and the separator 46 are made of HDPE and do not include EVOH, they are integrally formed with the resin layer 36 when the resin layer 36 is formed.
  • the intermediate molded product 38 is combined with at least one other intermediate molded product 38 able to be combined therewith in a state where the peripheral edges of the opening thereof and the peripheral edges of the gas barrier sheet 10 (sheet member melt-adhering step) are aligned.
  • the pressing plate 14 has already been removed from the intermediate molded product 38 in this state.
  • the combined intermediate molded products 38 are pressed together by moving a pair of molds, 50 (upper mold) and 52 (lower mold), of the welding press adjacent to each other so as to weld the peripheral edges of the resin layers 36 of the combined intermediate molded products 38 to each other (resin welding step).
  • the heat plate 12 is constructed in such a manner as to be able to be separated in several peripheral directions so as to be pulled apart in at least two directions (for example, four directions) with respect to the intermediate molded product 38 .
  • a fixed cutter 12 A for cutting the portions of the gas barrier sheets 10 between the heat plates 12 away from the bag portion is formed on the inner peripheral end of the heat plate 12 (refer to FIG. 7), and is structured so that when the gas barrier sheet 10 is held between the pair of heat plates 12 , the portions of the gas barrier sheets 10 between the opposing fixed cutters 12 A are constricted so that the gas barrier sheets 10 can be easily cut by pulling out the heat plates 12 at the constricted portion.
  • the gas barrier sheets 10 of each of the intermediate molded products 38 are put under higher pressure where the fixed cutters 12 A are positioned than in other regions, the molten resin layer 10 B between the gas barrier layers 10 A flows out and the two gas barrier layers 10 cut through to join each other.
  • the molecules of the two gas barrier layers 10 are thus linked together in a chain and the gas barrier layers 10 A are sealed to each other in an air tight manner. Accordingly, as the gas barrier sheets 10 are sealed to each other in an air tight manner, a bag-like gas barrier sheet 10 is formed.
  • the pressure reduction pipe used at this time can be an attachment pipe of the resin container (the fuel tank) 28 , and this is passed through one of the openings necessarily formed in the resin container such as the fuel pump mounting opening 32 , the inlet pipe opening 30 , and the like so as to lead to the outside of the container.
  • the pressure reduction pump is connected to this, and the pressure inside the container can be reduced.
  • the attachment part 16 is covered on the outside by the gas permeation preventing gas barrier sheet 10 . Accordingly, it is not necessary to pierce a hole in the gas barrier sheet 10 and the resin layer 36 in the location of the attachment part 16 as is done in the conventional art. As a result of this, the gas permeation preventing performance and the reliability of the container in the region of the attachment part 16 is greatly improved. Further, since the resin container 28 manufactured by the method mentioned above is structured so that the resin layers 36 and the gas barrier sheets 10 of each of two intermediate formed products 38 are respectively melt-adhered to each other, the gas barrier sheets 10 do not peel apart from each other and the gas permeation preventing performance and the reliability thereof is high. Further, since there is no hole piercing process and no melt-adhering step process between the attachment part and the container as in the conventional manufacturing method, the number of steps and the consequent manufacturing costs can be correspondingly reduced.
  • the bonding portions of the gas barrier sheets 10 and the resin layers 36 are in close contact with the heat plate 12 , the heat transfer between the heat plate 12 and the gas barrier sheets 10 and resin layers 36 can be efficiently performed, so that the reliability of the bonding strength and the air tightness is increased when welding the intermediate molded products 38 to each other. Further, since the melt-adhesion is performed by holding the gas barrier sheets 10 of the respective intermediate molded products 38 between the high rigid heat plates 18 , warps and deformities in the bonded portion are restricted, so that the reliability of the bonding strength and the air tightness when welding the gas barrier sheets 10 of the respective intermediate molded products 38 is increased.
  • the resin layers 36 of the intermediate molded products 38 can be securely melt-adhered to each other and the adhering strength and the adhering reliability of the resin layer 36 can be improved.
  • the thickness and quality of the material of the gas barrier layer 10 A of the gas barrier sheet 10 in the upper section 26 of the resin container 28 may be more moldable in comparison with the thickness or quality of the material of the gas barrier layer 10 A of the gas barrier sheet 10 in the lower section 24 of the resin container 28 .
  • the thickness and quality of the material of the gas barrier layer 10 A of the gas barrier sheet 10 in the upper section 26 of the resin container 28 may be inferior in gas permeation preventing properties in comparison with the thickness and material of the gas barrier layer 10 A of the gas barrier sheet 10 in the lower section 24 of the resin container 28 . Accordingly, the moldability of the upper section 26 of the resin container 28 which has larger protuberances can be improved and together with this, the gas permeation of the lower section 24 of the resin container 28 , in which the gas permeation is easily increased, can be restricted.
  • a pipe 54 serving as a connecting passage for connecting the inside to the outside of the resin layer 36 is provided in the joint of the resin layer 36 .
  • the gas barrier sheet 10 can be melt-adhered to the resin layer 38 by the temperature of the resin layer 38 .
  • the pipe 54 for exhausting the gas is closed, the portion of the pipe 54 projecting from the resin container (the fuel tank) 28 is cut and removed by a cutter and the like, and as shown in FIG. 11, the resin container (the fuel tank) 28 is removed from the pair of molds 50 (uppermold) and 52 (lower mold) of the melt-adhering press.
  • the gas barrier sheet 10 since in the gas exhausting process (refer to FIG. 9) the gas barrier sheet 10 is melt-adhered to the resin layer 38 by the temperature of the resin layer 38 , the gas barrier sheet 10 can be securely held. Further, since it is not necessary to independently heat either the gas barrier sheet 10 or the resin layer 38 , productivity is improved.
  • a cooling portion 64 is provided in the portion which is brought into contact with the peripheral edge of the resin layer 36 of the upper mold 20 used for the intermediate molded product molding process, and a heat insulating material 66 is provided between the cooling portion 64 and the upper mold 20 .
  • the cooling portion 64 is constructed, for example, from a pipe through which a cooling water passes.
  • the gas barrier sheet 10 can be bent in the non-melt-adhered portion 68 . Accordingly, since the gas barrier sheet 10 is not affected by the influence of the heat, localized elongation of the gas barrier sheet 10 can be restricted. As a result of this, the reliability of the gas barrier sheet 10 can be improved.
  • the reliability of the gas barrier sheet 10 can be improved. Further, since the non-melt-adhered portion 68 between the resin layer 36 and the gas barrier sheet 10 is formed along the peripheral edge of the resin layer 36 , the gas barrier sheet 10 can be bent in the non-melt-adhered portion 68 at the same time as the slack of the gas barrier sheet 10 is pushed inside the resin container (fuel tank) 28 . Accordingly, since the gas barrier sheet 10 is not affected by the influence of the heat, localized elongation of the gas barrier sheet 10 is restricted and the reliability of the gas barrier sheet 10 can be improved.
  • a structure wherein a piece of Teflon tape may be preliminarily disposed on the peripheral edge portion of the gas barrier sheet 10 as a member which is not melt-adhered with the resin layer 36 may be utilized.
  • Teflon tape 70 is in contact with the peripheral edge portion of the resin layer 36 , it is able not only to inhibit the temperature of the peripheral edge of the barrier sheet 10 from increasing but also to allow the elongation of the gas barrier sheet 10 to be restricted due to non-melt-adhered portions in the peripheral edges portions of the resin layer 36 and the gas barrier sheet 10 through the Teflon tape 70 .
  • the process for injection molding is shown, however, the present invention can be applied to injection press molding, hot flow stamping molding, and sheet flow stamping molding.
  • hook shaped engaging concave 74 and convex 76 portions are integrally formed in advance by press molding or the like at predetermined intervals on the connecting sections 10 C of the peripheral edges of both gas barrier sheets 10 to act as engagers, as is also shown in FIG. 15. After these concave 74 and convex 76 engaging portions have engaged with each other the connecting sections 10 C of the peripheral edges of both gas barrier sheets 10 are melt-adhered together (sheet member melt-adhering step), as is shown in FIG. 14B.
  • engaging concave portions 74 and engaging convex portions 76 are respectively formed in the peripheral edges of the gas barrier sheets 10 at predetermined intervals.
  • the shape of the engaging concave portions 74 and the engaging convex parts 76 may be made in other shapes such as an arrow head shape and the like.
  • the structure may be made so that the engaging concave portion 74 and the engaging convex portion 76 are respectively inserted or fixed to the connecting portions 10 C of the peripheral edge portions of each of the gas barrier sheets 10 as independent members.
  • a poly-amide resin (PA) layer 78 serving as a reinforcing layer is formed on the gas barrier sheet 10 .
  • the poly-amide resin layer 78 is formed in advance on the portion 10 A of the gas barrier sheet 10 which is opposite the resin injecting hole 40 provided in the upper mold 20 and an area surrounding the portion 10 A.
  • the gas barrier sheet 10 can be prevented from melting by the poly-amide resin layer 78 which is not melted by the injected resin and is disposed on the portion 10 A of the gas barrier sheet 10 and the area surrounding this portion opposite the resin injecting hole 40 . As a result of this, the reliability of the gas barrier sheet 10 can be improved.
  • the reinforcing layer is not limited to the poly-amide layer 78 and the other members such as metal foil and the like which are not melted by the injected resin may be used. Further, the reinforcing layer may be formed on the entire surface of the gas barrier sheet 10 .
  • a length L 1 and a length L 2 of the peripheral edges portions of the gas barrier sheets 10 of the combined intermediate molded products 38 are different from each other.
  • the convex portion 10 A is formed on the gas barrier sheet 10 , when the resin layer 36 is formed on the outside of the gas barrier sheet 10 by injection molding, an engaging portion 39 between the convex portion 10 A of the gas barrier sheet 10 and the concave portion 36 A of the resin layer 36 is formed near the portion held between the heat plate 12 and the pressing plate 14 of the gas barrier sheet 10 , that is, in the end portion of the bonding portion between the resin layer 36 and the gas barrier sheet 10 .
  • the cross sectional shape of the heat plate 12 is formed as a wedge shape. Accordingly, when the peripheral edge of the gas barrier sheet 10 is thermally melt-adhered, as shown in FIG. 21B, the resin layer 15 held between the respective gas barrier layers 13 can be pressed out so that the respective gas barrier layers 13 are melt-adhered to each other. As a result of this, since the structure advantageous for preventing gas permeation, that is, the gas barrier layer 13 , can be made into a seamless bag shape, the level of gas permeation can be minimized.
  • the engaging portion 39 between the convex portion 10 A of the gas barrier sheet 10 and the concave portion 36 A of the resin layer 36 is formed in an end portion 80 A of a bonded portion 80 between the resin layer 36 and the gas barrier sheet 10 , when the pressure inside the bag-shaped gas barrier sheet 10 is reduced so as to pull in the gas barrier sheet 10 , the stress generated in the gas barrier sheet 10 acts as a tensile force (arrow F 1 of FIG. 19) on the gas barrier sheet 10 at the engaging portion 39 , but does not act as a peeling force (arrow F 2 of FIG. 19) on the bonding portion 80 between the resin layer 36 and the gas barrier sheet 10 . Accordingly, the gas barrier sheet 10 can be prevented from peeling away from the resin layer 36 or becoming liable to peel away, so that the reliability of the gas barrier sheet 10 can be improved.
  • the portion 82 may be previously made as a non-melt-adhered portion so that the peeling force does not act on the bonded portion 80 between the resin layer 36 and the gas barrier sheet 10 .
  • the engaging portion 39 engaging the convex portion 10 A of the gas barrier sheet 10 and the concave portion 36 A of the resin layer 36 is formed in the end portion of the bonding portion between the resin layer 36 and the gas barrier sheet 10 .
  • the engaging portion 39 engaging the convex portion 10 A of the gas barrier sheet 10 and the concave portion 36 A of the resin layer 36 is formed on the end portion 80 A of the bonding portion 80 between the resin layer 36 and the gas barrier sheet 10 , during the manufacturing process, when the pressure inside the bag-shaped gas barrier sheet 10 is reduced and the gas barrier sheet 10 is pulled in, the stress generated in the gas barrier sheet 10 acts as a tensile force (arrow F 1 of FIG. 19) on the gas barrier sheet 10 at the engaging portion 39 , but does not act as a peeling force on the bonding portion 80 between the resin layer 36 and the gas barrier sheet 10 . Accordingly, the reliability of the gas barrier sheet 10 can be improved.
  • the length L 1 and L 2 of the peripheral edge portions of the gas barrier sheets 10 of the combined intermediate molded products 38 are different from each other. Accordingly, as shown in FIG. 19, since the position of the joint 10 B between the gas barrier sheets 10 and the position of the bend 10 C in the gas barrier sheet 10 generated when the sheet is pulled in, do not match each other, the stress generated when the sheet is pulled in is not concentrated on the joint 10 B, so that the reliability of the gas barrier sheet 10 can be further improved.
  • the cross sectional shape of the heat plate 12 is made wedge shaped, however, the cross sectional shape of the heat plate 12 is not limited to this, and can be made as other convex shapes
  • FIG. 23A and FIG. 23B show examples of a cross sectional shape having a circular convex portion 12 A so that the resin layer held between the respective gas barrier layers can be pressed out by the convex portion 12 A.
  • the process for injection molding is shown, however, the present invention can be applied to injection press molding, hot flow stamping molding, and sheet flow stamping molding. Further, high frequency welding can be applied as the film welding method.
  • a notch 100 is formed in the edge portion of the heat plate 12 opposed to the gas barrier sheet 10 along the gas barrier sheet 10 , and the opening 100 A of the notch 100 disposed on the opposite side to the bonding portion 10 C on the gas barrier sheet 10 is made with a small diameter. Further, as shown in FIG. 25, the cross section of the notch 100 is made in a half circular shape.
  • an extension portion 36 B is formed extending from a point 36 C where a portion of the resin layer 36 bonds with the other intermediate molded product to the bonding portion 10 C of the gas barrier sheet 10 .
  • the extended portion 36 B of the resin layer 36 imparts tension to the bonding portion 10 C of the gas barrier sheet 10 in the intermediate molded product molding step, the creases in the connecting portion 10 C of the gas barrier sheet 10 can be restricted. Further, when the bonding portions 36 C of the resin layers 36 are melt-adhered to each other, the extension portion 36 B is easily broken at the neck portion 37 formed by the opening portion 100 A of the notch 100 and is drawn into the container together with the gas barrier sheet 10 .
  • a gap H 1 within the cavity 22 near the resin injecting hole 40 of the upper mold 20 is wider than a gap H 2 of the other portions.
  • the portion 10 A of the gas barrier sheet 10 opposite the resin injecting hole 40 and the area surrounding the portion 10 A are affected by the influence of the heat of the molten resin which is increased by the shear force imparted by the resin injecting hole 40 and the friction force from the molten resin.
  • the gap H 1 inside the cavity 22 near the resin injecting hole 40 on the gas barrier sheet 10 is wider than the gap H 2 of the other portions, the flow speed of the molten resin can be restricted. As a result of this, the gas barrier sheet 10 can be prevented from being melted and the reliability of the gas barrier sheet 10 can be improved.
  • the engaging portion 110 A of the attachment part is formed as a concave shape. Accordingly, in the intermediate molded product molding process, when the attachment part such as the cut off valve 16 or the like is covered by the gas barrier sheet 10 , the engaging portion 110 A of the attachment part is formed as a concave shape and the engaging portion 110 A of the gas barrier sheet 10 is formed as a convex shape.
  • the engaging portion 110 A of the attachment part such a cut off valve 16 is formed as a concave shape in the engaging portion 110 , which is different from in case that the engaging portion of the attachment part such a cut off valve 16 is formed as a convex shape as shown in FIG. 1B, in the intermediate molded product molding process, the engaging portion 100 can reduce the heat and the friction force imparted by the molten resin (the arrow in FIG. 27 shows the flow of the molten resin). As a result of this, fusion due to accumulated heat between the attachment part and the gas barrier sheet 10 is not generated in the engaging portion 100 , so that the reliability of the gas barrier sheet 10 can be improved.
  • the present invention has been explained with respect to the specified embodiments, however, the present invention is not limited to the above embodiments, and it will be clear to those skilled in the art that other various embodiments are possible within the scope of the present invention.
  • a fuel tank for an automotive vehicle is used as an example of a resin container 22
  • the resin container 22 is not limited to fuel tanks for automotive vehicles.
  • the material of the gas barrier sheet 10 and the material of the resin layer 36 are not limited to those explained above.
  • the resin layer 36 may be set to a jig 112 so as to correct the shape of the bonding portion (the peripheral edge portion) 36 C.
  • the resin layer 36 may be set to a jig 112 so as to correct the shape of the bonding portion (the peripheral edge portion) 36 C.
  • FIG. 29 by using a vacuum shape correcting machine 114 and the like, external force maybe applied to the resin layer 36 .
  • the external force is given during the melt-adhering of the peripheral edges of the resin layers 36 of the combined intermediate molded products 38 (resin melt-adhering step), it is more effective.
  • the gas barrier layer 10 A may be formed between the lower mold 18 and an upper mold 116 by injection molding (the arrow in FIG. 30 shows the flow of the molten resin), thereafter, as shown in FIG. 31, the upper mold 116 may be replaced by the upper mold 20 , and the resin layer 36 may be formed between the upper mold 20 and the gas barrier layer 10 A by injection molding (the arrow in FIG. 31 shows the flow of the molten resin). Accordingly, productivity and moldability is improved. Further, since the thickness and the quality of the material of the gas barrier layer 10 A can be changed in the upper portion and the lower portion or the front portion and the rear portion, or the like of the resin container, the optimum gas permeation preventing performance, strength and formability can be guaranteed.
  • a resin container with a seamless gas barrier layer 10 A can be efficiently produced.
  • a resin injecting port 118 is provided in the lower mold 18 , a resin 122 is poured into the cavity of a middle mold 120 from the resin injecting port 118 (the arrow in FIG. 32 shows the flow of the molten metal), so that the inner structural portions such as the sub tank 44 , the separator 46 , and the like bonded to the gas barrier layer 10 A may be formed.
  • the inner structural portions such as the separator 46 and the like set on the lower mold 18 , and a clamp 124 and the like set on the upper mold 20 may be simultaneously melt-adhered.
  • the inner structural portions such as the separator 46 and the like which are melt-adhered to the gas barrier layer 10 A, breakage of the gas barrier layer during melt-adhering can be prevented.
  • the gas barrier sheets 10 may be melt-adhered to each other by the heat from the resin layer 36 .
  • the resin container and the method for manufacturing the same in accordance with the present invention are effective for fuel tanks for automotive vehicles and the manufacturing thereof, and in particular, for improving the gas permeation preventing performance in the area where the intermediate formed products of a fuel tank for an automotive vehicle are bonded to each other.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Containers Having Bodies Formed In One Piece (AREA)
  • Rigid Containers With Two Or More Constituent Elements (AREA)
US09/035,750 1996-07-09 1998-03-06 Resin container and a manufacturing method thereof Abandoned US20010051236A1 (en)

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US09/940,799 US6616788B2 (en) 1996-07-09 2001-08-29 Manufacturing method for a resin container

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JP8-178379 1996-07-09
JP17837996 1996-07-09
JP3797497 1997-02-21
JP3797797 1997-02-21
JP3797697 1997-02-21
JP4422997 1997-02-27
JP10201497 1997-04-18
JP10450397 1997-04-22
PCT/JP1997/002329 WO1998001287A1 (en) 1996-07-09 1997-07-04 Hollow resin container and method of manufacturing same

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US09/940,799 Division US6616788B2 (en) 1996-07-09 2001-08-29 Manufacturing method for a resin container

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US09/940,799 Expired - Fee Related US6616788B2 (en) 1996-07-09 2001-08-29 Manufacturing method for a resin container

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US (2) US20010051236A1 (ko)
EP (1) EP0888867B1 (ko)
JP (1) JP3301083B2 (ko)
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CN (1) CN1080185C (ko)
DE (1) DE69721514T2 (ko)
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US20050284872A1 (en) * 2000-04-03 2005-12-29 Inergy Automotive Systems Research (Societe Anonyme) Method of manufacturing a tank of thermoplastic material including a portion in relief for mounting an attachment, and a tank manufactured thereby
US20130103078A1 (en) * 2010-07-08 2013-04-25 Maurizio Longo Suture thread
KR20130087524A (ko) * 2010-07-08 2013-08-06 어슈트 유로페 에스.피.에이. 봉합 실
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EP0888867B1 (en) 2003-05-02
DE69721514T2 (de) 2004-04-08
WO1998001287A1 (en) 1998-01-15
EP0888867A1 (en) 1999-01-07
CN1200694A (zh) 1998-12-02
KR100276187B1 (ko) 2000-12-15
EP0888867A4 (ko) 1999-01-07
CN1080185C (zh) 2002-03-06
US6616788B2 (en) 2003-09-09
DE69721514D1 (de) 2003-06-05
JP3301083B2 (ja) 2002-07-15
KR19990044496A (ko) 1999-06-25
US20020025393A1 (en) 2002-02-28

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