US20100304943A1 - Fuel tank of thermoplastic material with functional installation fitments for air intake and venting, for fuel take-off and the like - Google Patents
Fuel tank of thermoplastic material with functional installation fitments for air intake and venting, for fuel take-off and the like Download PDFInfo
- Publication number
- US20100304943A1 US20100304943A1 US12/855,102 US85510210A US2010304943A1 US 20100304943 A1 US20100304943 A1 US 20100304943A1 US 85510210 A US85510210 A US 85510210A US 2010304943 A1 US2010304943 A1 US 2010304943A1
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- Prior art keywords
- container
- inside wall
- wall
- set forth
- surge
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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
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/20—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
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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
- B29C51/26—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
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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
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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
- B60K15/077—Fuel tanks with means modifying or controlling distribution or motion of fuel, e.g. to prevent noise, surge, splash or fuel starvation
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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
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/20—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
- B29C2049/2008—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements inside the article
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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
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/20—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
- B29C2049/2021—Inserts characterised by the material or type
- B29C2049/206—Inserts characterised by the material or type being constructed in such a way that the joining between the insert and the preform or parison is avoided
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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
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/20—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
- B29C2049/2073—Means for feeding the inserts into the mould, preform or parison, e.g. grippers
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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
- B29C2791/00—Shaping characteristics in general
- B29C2791/004—Shaping under special conditions
- B29C2791/006—Using vacuum
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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
- B29C2791/00—Shaping characteristics in general
- B29C2791/004—Shaping under special conditions
- B29C2791/007—Using fluid under pressure
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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
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
- B29C49/04—Extrusion blow-moulding
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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
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
- B29C49/06905—Using combined techniques for making the preform
- B29C49/0691—Using combined techniques for making the preform using sheet like material, e.g. sheet blow-moulding from joined 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
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
- B29C49/06905—Using combined techniques for making the preform
- B29C49/0691—Using combined techniques for making the preform using sheet like material, e.g. sheet blow-moulding from joined sheets
- B29C49/06914—Using combined techniques for making the preform using sheet like material, e.g. sheet blow-moulding from joined sheets using parallel sheets as a preform
-
- 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
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/22—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor using multilayered preforms or parisons
-
- 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
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- 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
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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
- B60K15/01—Arrangement of fuel conduits
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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
- B60K2015/03105—Fuel tanks with supplementary interior tanks inside the fuel tank
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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
- B60K2015/03111—Swirl pots
Definitions
- the invention concerns a fuel tank of thermoplastic material with functional installation fitments for air intake and venting, for fuel take-off or the like.
- the invention concerns in particular an extrusion blow molded fuel tank of thermoplastic material.
- Such tanks are usually produced in one piece from one or more tubular preforms which are applied against the wall of a multi-part molding tool by means of gas pressure or are expanded in the tool.
- installation fitments are introduced into the tank either after it is finished through one or more mounting openings and fixed therein or the functional components are already introduced into the tank during the operation of shaping it.
- the diameter of the preform is generally such that it can be extruded over an installation fitment holder with installation fitments carried thereon.
- thermoplastic material which are equipped with installation fitments or installation components which are joined to the tank wall in manufacture in the first heat.
- the object of the invention is to provide a fuel tank of thermoplastic material having functional installation fitments for air intake and venting, for fuel take-off or the like, in which the functional components are connected to the container wall and in which the functional components were connected to the tank during shaping thereof in the first heat, the aim being that the tank should not involve the above-mentioned disadvantages.
- a fuel tank of thermoplastic material of the kind set forth in the opening part of this specification which is distinguished in that at least one functional installation fitment is connected to the inside wall of the container in material-bonded relationship in such a way that the functional component defines with the container wall a volume separated from the filling volume of the container in such a way that the inside wall of the container serves directly as a boundary wall of said volume.
- the invention can be summarised to the effect that there are introduced into the fuel tank those functional components which acquire full functionality only in a condition of co-operation with the inside wall of the container, so that the inside wall of the container takes over a part of the functionality of the component in question and also acts as a boundary wall of the functional component.
- functional installation fitments it is possible to provide for example profile portions which are welded to the inside wall of the container in such a way that, with the inside wall of the container, they form volumes or passages which are closed at least in portion-wise manner.
- profile portions can be of semicircular, U-shaped or V-shaped configuration in cross-section.
- At least one surge container for a fuel pump which surge container is open on its side towards the inside wall of the tank in the installation position and the boundary wall thereof being connected therearound to the inside wall of the tank in material-bonded relationship. That eliminates an accumulation of material at the inside wall of the tank, which occurs by virtue of the bottom of the surge container bearing over its full surface area against the inside wall of the fuel tank.
- the fuel tank itself forms the bottom of the surge container.
- a surge container which is at least partially closed on it's side remote from the inside wall of the tank.
- Such a surge container can be for example in the form of a plastic component produced in one piece by injection molding. The possibility of being able to produce the surge container as an integral component or in one piece is afforded in particular by virtue of the fact that the surge container is closed by the wall of the fuel tank upon being mounted or connected to the inside wall of the fuel tank.
- the boundary wall of the surge container is provided with a peripherally extending fixing flange at the side that is towards the inside wall of the tank in the installation position.
- the joining surface of the fixing flange can be of a profiled configuration.
- the joining surface of the fixing flange can be provided with melting projections and/or melting extension portions. That is used to denote thin material projections or material extension portions, ribs or limbs which have a comparatively slight thermal capacity and which, when the parts in question of the joining surface come into contact with the inside wall of the tank which is still hot, melt because of their slight thermal capacity and thus contribute to forming a reliable welded connection.
- the boundary wall of the surge container can be of a flexible nature at least in region-wise manner and at least portion-wise in relation to the periphery of the surge container.
- the boundary wall of the surge container may have a peripherally extending film hinge or the like so that the angle between the fixing flange and the container wall is variable. It is thus possible advantageously to compensate for unevenness and irregularities in the inside wall of the tank.
- components which are just extrusion blow molded involve slight tolerances in respect of wall thickness, which are to be taken into consideration when designing installation fitments to be welded to the tank wall, at least in relation to those installation fitments which must be welded peripherally in sealing relationship with the inside wall of the tank, as must be the case for example with a surge container.
- profile portions for forming passages or receiving means for lines are to be provided as the installation fitment, it is possible for those installation fitments to be so designed overall in terms of their wall thickness that tolerances in wall thickness of the inside wall of the tank can be compensated for, when joining the installation fitments.
- FIG. 1 shows a view in section through a fuel tank according to the invention
- FIG. 2 shows an enlarged sectional view of the detail II in FIG. 1 ,
- FIG. 3 shows an alternative configuration of the fixing flange shown in FIG. 2 of the surge container fixed in the fuel tank
- FIG. 4 shows a further configuration of the surge container in the region of its fixing to the inside wall of the tank
- FIG. 5 shows a fourth variant of the surge container in the region of its fixing to the inside wall of the fuel tank
- FIG. 6 shows a fifth embodiment according to the invention
- FIG. 7 shows a sixth embodiment according to the invention
- FIG. 8 shows a partial section through the surge container of the fuel tank according to the invention, in which a non-flat support and fixing surface on the inside wall of the container is shown on an exaggerated scale
- FIGS. 9 and 10 show a seventh embodiment according to the invention.
- FIGS. 11 and 12 show an eighth embodiment according to the invention.
- FIG. 1 shows a simplified sectional view of a fuel tank 1 according to the invention.
- the fuel tank 1 is in the form of an extrusion blow molded plastic hollow body. It was produced by extrusion blowing of an overall six-layer co-extrudate of thermoplastic material with at least one barrier layer for hydrocarbons. In that case, two preforms in web form of thermoplastic material were extruded between the opened parts of a blow molding tool having a total of three parts.
- the blow molding tool for the production of such a fuel tank 1 includes at least two outer molds and a central mold, wherein each of the outer molds forms a cavity portion which defines a respective half of the hollow body to be produced.
- a first step in the method the respective preforms in web form are extruded or arranged between an outer mold and the central mold respectively. In that position the outer molds are closed against the central mold. That results in the formation of a closed mold cavity, wherein the preforms are each drawn into the respective cavity portion at the respective outer mold by means of gas pressurisation of the central mold and/or evacuation of the outer molds.
- Component carriers with components disposed thereon are preferably provided in the central mold on a displaceable frame.
- the component carriers are arranged displaceably in the central mold by way of for example hydraulically or pneumatically actuable cylinders.
- functional components are placed within the tank in such a way that they are fitted for example into suitable receiving means at the inside wall of the tank.
- a fuel tank as is described in detail hereinafter can also be obtained by deep drawing or thermoforming, in which respect also functional components can be welded to the inside wall of the tank in such a process.
- the container shown in FIG. 1 is in the form of a fuel tank 1 .
- the principle described herein can however be readily applied to other closed containers of plastic material with functional components to be provided therein.
- the fuel tank 1 is shown in greatly simplified form. It may include the usual air intake and venting lines as well as at least one filling connection and lines for fuel take-off to an internal combustion engine of a motor vehicle (not shown).
- the fuel is conveyed by way of a plurality of suction jet pumps from various sub-volumes of the fuel tank 1 which is shown here for reasons of simplification only with one single volume into a surge container 2 which is arranged in the fuel tank 1 .
- a surge container 2 Arranged in known manner within the surge container 2 which is also referred to as a roll pot is at least one electric fuel delivery pump which conveys fuel from the volume of the surge container to the engine of the internal combustion machine.
- the fuel pump is also not shown here for reasons of simplification.
- the surge container 2 serves to ensure that the fuel pump is supplied with fuel during all travel conditions of the vehicle, that is to say in acceleration, deceleration and when negotiating bends.
- the surge container 2 is connected to the inside wall 3 of the fuel tank 1 in such a way that it defines a volume which is separate from the filling volume of the fuel tank 1 , wherein the inside wall 3 of the container serves directly as the boundary wall of the volume.
- the surge container 2 in the embodiment described here does not have a bottom.
- the bottom is formed by the inside wall 3 of the fuel tank 1 , wherein the surge container 2 is provided on its side towards the inside wall 3 with a fixing flange 4 which is peripherally welded in sealing relationship to the inside wall 3 of the fuel tank 1 . That makes it possible for the surge container 2 to be in the form of a one-piece injection-molded component on which all essential elements are molded.
- the surge container 2 may be connected to the inside wall 3 in material-bonded relationship therewith during the procedure for shaping the fuel tank 1 . More specifically, as already mentioned in the opening part of this specification, this may be done in such a way that the inside wall 3 forms a boundary wall of the surge container 2 .
- the boundary wall 5 of the surge container 2 in the region of the fixing flange 4 can be of an L- or T-shaped profile with a joining surface 6 which faces towards the inside wall 3 .
- the joining surface 6 of the fixing flange 4 is of a fully peripherally extending configuration so that it can be welded at the edge side in sealing relationship to the inside wall 3 of the fuel tank 1 .
- the joining surface 6 is provided with welding ribs or welding protrusions 7 (See FIGS. 3-6 ) whose thermal capacity is such that, upon coming into contact with the wall 3 of the fuel tank 1 when it is still hot and plastic during the procedure for shaping the fuel tank, the ribs or protrusions 7 melt and thus form an intimate material-bonded connection between the inside wall 3 on the one hand and the joining surface 6 on the other hand.
- the boundary wall 5 may be of a flexible configuration, as shown in FIGS. 4 through 8 , in such a way that the fixing flange 4 may be flexible or movable within certain limits and can assume for example the angled (not right-angled) position with respect to the boundary wall 5 of the surge container 2 , which is shown in FIG. 8 on the right-hand side.
- the flexibility of the fixing flange 4 in relation to the boundary wall 5 can be achieved in various ways, for example by the provision of a peripherally extending film hinge having a curved ( FIG. 5 ) or thinned ( FIGS. 4 , 6 and 8 - 12 ) cross-section.
- the surge container can have been produced from various plastic materials, in which case for example plastic materials of varying hardness can be provided over the height of the boundary wall 5 (hard-soft-hard for example). That may permit height compensation in respect of any projections in the inside wall 3 of the fuel tank 1 .
- load relief slots can be provided therein to avoid unacceptable stresses, caused by the circular ring shape of the joining surface 6 .
- profile portions 9 as installation fitments in accordance with the invention.
- the profile portions 9 were welded to the inside wall 3 of the fuel tank 1 during the shaping thereof, in such a way that they form either closed passages for air and/or fuel or for receiving lines which are of round cross-section. In the latter case the profile portions 9 a, b embrace and hold lines accommodated therein, only in region-wise manner.
- the profile portion 9 a shown in FIG. 1 is of a V-shaped cross-section while the profile portion identified at 9 b in FIG. 1 is in the form of a U-shaped cross-section.
- Other geometries are readily conceivable within the scope of the invention.
- the profile portions 9 a, b make use of the underlying idea of the invention, of using the inside wall 3 of the container as a boundary wall of a volume to be separated from the container. That saves on clamping or latching retaining fixings for lines.
- the inside wall 3 of the fuel tank can be provided with inwardly projecting ribs 10 or the like, which co-operate with corresponding grooves 10 a of the surge container 2 and which facilitate immovable fixing thereof on the inside wall 3 of the fuel tank 1 .
- FIGS. 11 and 12 show a variant of the surge container which comprises a plastic material which is not compatible with the inside wall 3 of the fuel tank 1 , in the sense of being weldable thereto.
- a hot melt adhesive 11 or another suitable bonding agent which in contact with the hot inside wall 3 of the fuel tank 1 produces a connection involving a material-bonded relationship.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Sustainable Development (AREA)
- Sustainable Energy (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Transportation (AREA)
- Manufacturing & Machinery (AREA)
- Cooling, Air Intake And Gas Exhaust, And Fuel Tank Arrangements In Propulsion Units (AREA)
Abstract
The invention concerns a fuel tank of thermoplastic material, comprising functional installation fitments for air intake and venting, for fuel take-off or the like, which is distinguished in that at least one functional installation fitment is connected to the inside wall of the container in material-bonded relationship in such a way that the functional installation fitment defines with the container wall a volume separated from the filling volume of the container in such a way that the inside wall of the container serves directly as a boundary wall of said volume.
Description
- This application is a continuation of U.S. application Ser. No. 11/957,792, filed Dec. 17, 2007 which claims the benefit of U.S. Provisional Application 60/870,231 filed Dec. 15, 2006.
- The invention concerns a fuel tank of thermoplastic material with functional installation fitments for air intake and venting, for fuel take-off or the like.
- The invention concerns in particular an extrusion blow molded fuel tank of thermoplastic material. Such tanks are usually produced in one piece from one or more tubular preforms which are applied against the wall of a multi-part molding tool by means of gas pressure or are expanded in the tool. Depending on how the operation of shaping the tank in the tool is effected, installation fitments are introduced into the tank either after it is finished through one or more mounting openings and fixed therein or the functional components are already introduced into the tank during the operation of shaping it. If the tank is blow molded from a tubular preform, the diameter of the preform is generally such that it can be extruded over an installation fitment holder with installation fitments carried thereon.
- Welding installation fitments to the inside wall of the tank in the first heat when shaping the tank has proven to be disadvantageous in particular when dealing with relatively large installation fitments such as surge containers or the like as cooling of the container wall after the article is finished is impeded in the regions in which weld surfaces are provided on the inside wall of the container. If for example in the fuel tank a surge container is welded with its bottom support surface over a large area to the inside wall of the fuel tank, cooling of the tank wall when cooling down the article is hindered over a large area. In particular internal cooling of the finished article by gas/air flushing is adversely effected. The accumulation of material at the inside wall of the container, being greater in region-wise manner, possibly causes shrinkage distortion of the material which is visible externally on the tank.
- In principle however, for reasons of production engineering simplification, it would be desirable to provide one-piece tanks made from thermoplastic material, which are equipped with installation fitments or installation components which are joined to the tank wall in manufacture in the first heat.
- Therefore the object of the invention is to provide a fuel tank of thermoplastic material having functional installation fitments for air intake and venting, for fuel take-off or the like, in which the functional components are connected to the container wall and in which the functional components were connected to the tank during shaping thereof in the first heat, the aim being that the tank should not involve the above-mentioned disadvantages.
- That object is attained by a fuel tank of thermoplastic material of the kind set forth in the opening part of this specification, which is distinguished in that at least one functional installation fitment is connected to the inside wall of the container in material-bonded relationship in such a way that the functional component defines with the container wall a volume separated from the filling volume of the container in such a way that the inside wall of the container serves directly as a boundary wall of said volume.
- The invention can be summarised to the effect that there are introduced into the fuel tank those functional components which acquire full functionality only in a condition of co-operation with the inside wall of the container, so that the inside wall of the container takes over a part of the functionality of the component in question and also acts as a boundary wall of the functional component. As functional installation fitments, it is possible to provide for example profile portions which are welded to the inside wall of the container in such a way that, with the inside wall of the container, they form volumes or passages which are closed at least in portion-wise manner.
- By way of example the profile portions can be of semicircular, U-shaped or V-shaped configuration in cross-section.
- In a particularly preferred variant of the invention there is provided at least one surge container for a fuel pump, which surge container is open on its side towards the inside wall of the tank in the installation position and the boundary wall thereof being connected therearound to the inside wall of the tank in material-bonded relationship. That eliminates an accumulation of material at the inside wall of the tank, which occurs by virtue of the bottom of the surge container bearing over its full surface area against the inside wall of the fuel tank. In the variant according to the invention the fuel tank itself forms the bottom of the surge container. In that way, it is advantageously possible to use a surge container which is at least partially closed on it's side remote from the inside wall of the tank. Such a surge container can be for example in the form of a plastic component produced in one piece by injection molding. The possibility of being able to produce the surge container as an integral component or in one piece is afforded in particular by virtue of the fact that the surge container is closed by the wall of the fuel tank upon being mounted or connected to the inside wall of the fuel tank.
- It will be appreciated that the fact that the side of the surge container that is remote from the inside wall of the tank is to be of a closed configuration is to be interpreted as meaning that the surge container can have connections, nipples or apertures for lines which are to pass into or out of the surge container.
- Desirably the boundary wall of the surge container is provided with a peripherally extending fixing flange at the side that is towards the inside wall of the tank in the installation position.
- In order to achieve a peripherally extending connection which is as good as possible, involving a material-bonded relationship, between the fixing flange on the one hand and the inside wall of the tank on the other hand, the joining surface of the fixing flange can be of a profiled configuration. Alternatively the joining surface of the fixing flange can be provided with melting projections and/or melting extension portions. That is used to denote thin material projections or material extension portions, ribs or limbs which have a comparatively slight thermal capacity and which, when the parts in question of the joining surface come into contact with the inside wall of the tank which is still hot, melt because of their slight thermal capacity and thus contribute to forming a reliable welded connection.
- The boundary wall of the surge container can be of a flexible nature at least in region-wise manner and at least portion-wise in relation to the periphery of the surge container. By way of example the boundary wall of the surge container may have a peripherally extending film hinge or the like so that the angle between the fixing flange and the container wall is variable. It is thus possible advantageously to compensate for unevenness and irregularities in the inside wall of the tank. As is known, components which are just extrusion blow molded involve slight tolerances in respect of wall thickness, which are to be taken into consideration when designing installation fitments to be welded to the tank wall, at least in relation to those installation fitments which must be welded peripherally in sealing relationship with the inside wall of the tank, as must be the case for example with a surge container.
- If profile portions for forming passages or receiving means for lines are to be provided as the installation fitment, it is possible for those installation fitments to be so designed overall in terms of their wall thickness that tolerances in wall thickness of the inside wall of the tank can be compensated for, when joining the installation fitments.
- The invention is described hereinafter by means of an embodiment by way of example which is illustrated in the drawing in which:
-
FIG. 1 shows a view in section through a fuel tank according to the invention, -
FIG. 2 shows an enlarged sectional view of the detail II inFIG. 1 , -
FIG. 3 shows an alternative configuration of the fixing flange shown inFIG. 2 of the surge container fixed in the fuel tank, -
FIG. 4 shows a further configuration of the surge container in the region of its fixing to the inside wall of the tank, -
FIG. 5 shows a fourth variant of the surge container in the region of its fixing to the inside wall of the fuel tank, -
FIG. 6 shows a fifth embodiment according to the invention, -
FIG. 7 shows a sixth embodiment according to the invention, -
FIG. 8 shows a partial section through the surge container of the fuel tank according to the invention, in which a non-flat support and fixing surface on the inside wall of the container is shown on an exaggerated scale, -
FIGS. 9 and 10 show a seventh embodiment according to the invention, and -
FIGS. 11 and 12 show an eighth embodiment according to the invention. -
FIG. 1 shows a simplified sectional view of afuel tank 1 according to the invention. Thefuel tank 1 is in the form of an extrusion blow molded plastic hollow body. It was produced by extrusion blowing of an overall six-layer co-extrudate of thermoplastic material with at least one barrier layer for hydrocarbons. In that case, two preforms in web form of thermoplastic material were extruded between the opened parts of a blow molding tool having a total of three parts. The blow molding tool for the production of such afuel tank 1 includes at least two outer molds and a central mold, wherein each of the outer molds forms a cavity portion which defines a respective half of the hollow body to be produced. In a first step in the method the respective preforms in web form are extruded or arranged between an outer mold and the central mold respectively. In that position the outer molds are closed against the central mold. That results in the formation of a closed mold cavity, wherein the preforms are each drawn into the respective cavity portion at the respective outer mold by means of gas pressurisation of the central mold and/or evacuation of the outer molds. Component carriers with components disposed thereon are preferably provided in the central mold on a displaceable frame. The component carriers are arranged displaceably in the central mold by way of for example hydraulically or pneumatically actuable cylinders. By means of the component carriers functional components are placed within the tank in such a way that they are fitted for example into suitable receiving means at the inside wall of the tank. - Alternatively it is possible in that way for functional components of plastic material to be welded to the inside wall of the tank, while that wall is still plastic, during the operation of shaping the tank.
- It will be appreciated that a fuel tank as is described in detail hereinafter can also be obtained by deep drawing or thermoforming, in which respect also functional components can be welded to the inside wall of the tank in such a process.
- The container shown in
FIG. 1 is in the form of afuel tank 1. The principle described herein can however be readily applied to other closed containers of plastic material with functional components to be provided therein. - The
fuel tank 1 is shown in greatly simplified form. It may include the usual air intake and venting lines as well as at least one filling connection and lines for fuel take-off to an internal combustion engine of a motor vehicle (not shown). Usually the fuel is conveyed by way of a plurality of suction jet pumps from various sub-volumes of thefuel tank 1 which is shown here for reasons of simplification only with one single volume into asurge container 2 which is arranged in thefuel tank 1. Arranged in known manner within thesurge container 2 which is also referred to as a roll pot is at least one electric fuel delivery pump which conveys fuel from the volume of the surge container to the engine of the internal combustion machine. The fuel pump is also not shown here for reasons of simplification. Thesurge container 2 serves to ensure that the fuel pump is supplied with fuel during all travel conditions of the vehicle, that is to say in acceleration, deceleration and when negotiating bends. - In accordance with the invention it is provided that for example the
surge container 2 is connected to theinside wall 3 of thefuel tank 1 in such a way that it defines a volume which is separate from the filling volume of thefuel tank 1, wherein theinside wall 3 of the container serves directly as the boundary wall of the volume. In other words, thesurge container 2 in the embodiment described here does not have a bottom. The bottom is formed by theinside wall 3 of thefuel tank 1, wherein thesurge container 2 is provided on its side towards theinside wall 3 with a fixing flange 4 which is peripherally welded in sealing relationship to theinside wall 3 of thefuel tank 1. That makes it possible for thesurge container 2 to be in the form of a one-piece injection-molded component on which all essential elements are molded. In the case of a conventionally designedsurge container 2 with a bottom, it is necessary for it possibly to be provided with a cover fastener which is then latched to thesurge container 2. That is necessary in order to pre-assemble the fuel pump and possibly a fuel level sender or the like in thesurge container 2 before it is introduced into thefuel tank 1. - According to the invention it is provided that the
surge container 2 may be connected to theinside wall 3 in material-bonded relationship therewith during the procedure for shaping thefuel tank 1. More specifically, as already mentioned in the opening part of this specification, this may be done in such a way that theinside wall 3 forms a boundary wall of thesurge container 2. - As can be seen from
FIGS. 2 through 7 , theboundary wall 5 of thesurge container 2 in the region of the fixing flange 4 can be of an L- or T-shaped profile with a joiningsurface 6 which faces towards theinside wall 3. In the case of thesurge container 2 which is desirably of a round configuration in cross-section, the joiningsurface 6 of the fixing flange 4 is of a fully peripherally extending configuration so that it can be welded at the edge side in sealing relationship to theinside wall 3 of thefuel tank 1. - For that purpose the joining
surface 6 is provided with welding ribs or welding protrusions 7 (SeeFIGS. 3-6 ) whose thermal capacity is such that, upon coming into contact with thewall 3 of thefuel tank 1 when it is still hot and plastic during the procedure for shaping the fuel tank, the ribs orprotrusions 7 melt and thus form an intimate material-bonded connection between theinside wall 3 on the one hand and the joiningsurface 6 on the other hand. - In order to be able to compensate for wall thickness tolerances in the container wall or indeed unevenness and irregularities of the inside wall, the
boundary wall 5 may be of a flexible configuration, as shown inFIGS. 4 through 8 , in such a way that the fixing flange 4 may be flexible or movable within certain limits and can assume for example the angled (not right-angled) position with respect to theboundary wall 5 of thesurge container 2, which is shown inFIG. 8 on the right-hand side. The flexibility of the fixing flange 4 in relation to theboundary wall 5 can be achieved in various ways, for example by the provision of a peripherally extending film hinge having a curved (FIG. 5 ) or thinned (FIGS. 4 , 6 and 8-12) cross-section. Alternatively, the surge container can have been produced from various plastic materials, in which case for example plastic materials of varying hardness can be provided over the height of the boundary wall 5 (hard-soft-hard for example). That may permit height compensation in respect of any projections in theinside wall 3 of thefuel tank 1. Depending on the respective width and configuration of the fixing flange 4 load relief slots can be provided therein to avoid unacceptable stresses, caused by the circular ring shape of the joiningsurface 6. - The invention has been described hereinbefore with reference to a
surge container 2. - As is also shown in
FIG. 1 , it is also possible to provide profile portions 9 as installation fitments in accordance with the invention. The profile portions 9 were welded to theinside wall 3 of thefuel tank 1 during the shaping thereof, in such a way that they form either closed passages for air and/or fuel or for receiving lines which are of round cross-section. In the latter case theprofile portions 9 a, b embrace and hold lines accommodated therein, only in region-wise manner. - The
profile portion 9 a shown inFIG. 1 is of a V-shaped cross-section while the profile portion identified at 9 b inFIG. 1 is in the form of a U-shaped cross-section. Other geometries are readily conceivable within the scope of the invention. Theprofile portions 9 a, b make use of the underlying idea of the invention, of using theinside wall 3 of the container as a boundary wall of a volume to be separated from the container. That saves on clamping or latching retaining fixings for lines. - As shown in
FIGS. 9 and 10 , theinside wall 3 of the fuel tank can be provided with inwardly projectingribs 10 or the like, which co-operate withcorresponding grooves 10 a of thesurge container 2 and which facilitate immovable fixing thereof on theinside wall 3 of thefuel tank 1. - It will be appreciated that, instead of the
ribs 10 on theinside wall 3 of thefuel tank 1, it is also possible to provide there grooves which co-operate with corresponding ribs on thesurge container 2. -
FIGS. 11 and 12 show a variant of the surge container which comprises a plastic material which is not compatible with theinside wall 3 of thefuel tank 1, in the sense of being weldable thereto. In that case, provided between the joiningsurface 6 of theboundary wall 5 and theinside wall 3 of thefuel tank 1 is a hot melt adhesive 11 or another suitable bonding agent which in contact with the hot insidewall 3 of thefuel tank 1 produces a connection involving a material-bonded relationship. -
- 1 fuel tank
- 2 surge container
- 3 inside wall
- 4 fixing flange
- 5 boundary wall
- 6 joining surface
- 7 welding protrusions
- 8 relief slots
- 9 a, b profile portions
- 10 ribs
- 10 a grooves
- 11 hot melt adhesive
Claims (14)
1. A method for forming a container of thermoplastic material, having an inside wall and a filling volume, and including functional installation fitments, comprising:
connecting one functional installation fitment to said inside wall of the container by melt-bonding in such a way that the functional installation fitment defines with the container wall a second volume separated from the filling volume of the container in such a way that the inside wall of the container serves directly as a boundary wall of said second volume,
wherein said melt-bonding of said at least one installation fitment to said inside wall of said container occurs while said container wall is still plastic and during the operation of shaping the tank.
2. The method as set forth in claim 1 wherein profile portions are provided as functional installation fitments, being melt-bonded to the inside wall of the container in such a way that they form volumes or passages which are closed at least in portion-wise manner therewith, wherein said melt-bonding of said profile portions to said inside wall of said container occurs while said container wall is still plastic and during the operation of shaping the tank.
3. The method as set forth in claim 2 wherein said profile portions are of semicircular, U-shaped or V-shaped cross-section.
4. The method as set forth in claim 1 wherein said at least one functional installation fitment comprises a surge container for a fuel pump, said surge container including a boundary wall and at least one side and is open on the side that in the installation position faces towards the inside wall of the container and said boundary wall is peripherally connected in melt-bonded relationship to the inside wall of the container during the shaping of the tank.
5. The method as set forth in claim 4 wherein the surge container is at least partially closed on the side remote from the inside wall of the container.
6. The method as set forth in claim 4 wherein the boundary wall of the surge container has a peripherally extending fixing flange at the side facing towards the inside wall of the container in the installation position.
7. The method as set forth in claim 6 wherein the joining surface of the fixing flange is profiled.
8. The method as set forth in claim 7 wherein the joining surface of the fixing flange is provided with melting projections and/or melting extension portions which melt to form said connection.
9. The method as set forth in claim 6 wherein the boundary wall of the surge container is flexible at least in region-wise manner and at least portion-wise with respect to the periphery of the surge container.
10. The method as set forth in claim 9 wherein the angle between the fixing flange and the boundary wall is variable.
11. The method as set forth in claim 4 wherein said surge container includes one or more of connections, nipples and apertures for lines which are to pass into or out of said surge container.
12. The method as set forth in claim 6 wherein said inside wall is provided with one or more inwardly projecting ribs which cooperate with one or more grooves in said joining surface.
13. The method as set forth in claim 6 wherein said inside wall is provided with one or more grooves which cooperate with one or more inwardly projecting ribs on said joining surface.
14. The method as set forth in claim 1 wherein said connection in melt-bonded relationship of said is at least one functional installation fitment to said inside wall of the container requires no additional thermal energy.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/855,102 US20100304943A1 (en) | 2006-12-15 | 2010-08-12 | Fuel tank of thermoplastic material with functional installation fitments for air intake and venting, for fuel take-off and the like |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US87023106P | 2006-12-15 | 2006-12-15 | |
US11/957,792 US7861885B2 (en) | 2006-12-15 | 2007-12-17 | Fuel tank of thermoplastic material with functional installation fitments for air intake and venting, for fuel take-off or the like |
US12/855,102 US20100304943A1 (en) | 2006-12-15 | 2010-08-12 | Fuel tank of thermoplastic material with functional installation fitments for air intake and venting, for fuel take-off and the like |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/957,792 Continuation US7861885B2 (en) | 2006-12-15 | 2007-12-17 | Fuel tank of thermoplastic material with functional installation fitments for air intake and venting, for fuel take-off or the like |
Publications (1)
Publication Number | Publication Date |
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US20100304943A1 true US20100304943A1 (en) | 2010-12-02 |
Family
ID=39541380
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/957,792 Expired - Fee Related US7861885B2 (en) | 2006-12-15 | 2007-12-17 | Fuel tank of thermoplastic material with functional installation fitments for air intake and venting, for fuel take-off or the like |
US12/855,102 Abandoned US20100304943A1 (en) | 2006-12-15 | 2010-08-12 | Fuel tank of thermoplastic material with functional installation fitments for air intake and venting, for fuel take-off and the like |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
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US11/957,792 Expired - Fee Related US7861885B2 (en) | 2006-12-15 | 2007-12-17 | Fuel tank of thermoplastic material with functional installation fitments for air intake and venting, for fuel take-off or the like |
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US (2) | US7861885B2 (en) |
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EP2711224B1 (en) | 2012-09-20 | 2017-11-22 | Veritas Ag | Liquid tank with a connection element |
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US9023264B2 (en) * | 2006-07-03 | 2015-05-05 | Kautex Textron Gmbh & Co. Kg | Method for producing a container of thermoplastic material |
DE102008027830B4 (en) * | 2008-06-11 | 2014-11-06 | Kautex Textron Gmbh & Co. Kg | Fuel tank and method of servicing a fuel tank |
FR2934804A1 (en) * | 2008-08-07 | 2010-02-12 | Inergy Automotive Systems Res | PROCESS FOR THE MANUFACTURE OF A FUEL TANK OF PLASTIC MATERIAL. |
FR2934806A1 (en) * | 2008-08-07 | 2010-02-12 | Inergy Automotive Systems Res | METHOD FOR ATTACHING AN ACCESSORY IN A HOLLOW BODY OF PLASTIC MATERIAL |
FR2934805A1 (en) * | 2008-08-07 | 2010-02-12 | Inergy Automotive Systems Res | METHOD FOR ATTACHING AN ACCESSORY TO A HOLLOW BODY OF PLASTIC MATERIAL DURING MOLDING |
FR2935289B1 (en) * | 2008-09-01 | 2013-02-22 | Inergy Automotive Systems Res | PROCESS FOR THE MANUFACTURE OF A FUEL TANK OF PLASTIC PLASTIC MATERIAL WITH PUMP. |
DE102009005826A1 (en) | 2009-01-22 | 2010-07-29 | Magna Steyr Fuel Systems Gmbh | Fuel tank with built-in additional tank |
US9321347B2 (en) * | 2010-06-14 | 2016-04-26 | Ford Global Technologies, Llc | Compliance structure for a distensible fuel tank |
FR2961738B1 (en) * | 2010-06-23 | 2014-02-28 | Inergy Automotive Systems Res | PROCESS FOR MANUFACTURING A FUEL TANK WITH A BAFFLE |
DE102010032931A1 (en) * | 2010-07-30 | 2012-02-02 | Kautex Textron Gmbh & Co. Kg | Container made of thermoplastic material |
EP2990356B1 (en) | 2010-12-03 | 2019-08-28 | Salflex Polymers Ltd. | Deployable fuel tank baffle and fuel tank system |
JP2014024370A (en) * | 2012-07-24 | 2014-02-06 | Yachiyo Industry Co Ltd | Hollow container and hollow container manufacturing apparatus |
DE102012023035B4 (en) * | 2012-11-26 | 2017-02-16 | Kautex Textron Gmbh & Co. Kg | Process for producing a hollow body of thermoplastic material |
FR3011761A1 (en) * | 2013-10-16 | 2015-04-17 | Inergy Automotive Systems Res | FOOT FOR AN ACCESSORY AND ACCESSORY FOR A MOTOR VEHICLE TANK, METHOD OF MANUFACTURING SUCH A TANK. |
JP6669550B2 (en) * | 2016-03-25 | 2020-03-18 | キョーラク株式会社 | Manufacturing method of laminated structure |
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Also Published As
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US20080149642A1 (en) | 2008-06-26 |
US7861885B2 (en) | 2011-01-04 |
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