CN102802914B - 容器制造 - Google Patents

容器制造 Download PDF

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Publication number
CN102802914B
CN102802914B CN201080037837.3A CN201080037837A CN102802914B CN 102802914 B CN102802914 B CN 102802914B CN 201080037837 A CN201080037837 A CN 201080037837A CN 102802914 B CN102802914 B CN 102802914B
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China
Prior art keywords
parison
mould
product
film
partly
Prior art date
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CN201080037837.3A
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English (en)
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CN102802914A (zh
Inventor
A.J.贝克
A.W.多布迈尔
A.埃勒
P.格明德
P.格劳尔
M.豪亚拉
M.B.奥尔布里奇
P.E.德尔巴勒
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TI Automotive Technology Center GmbH
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TI Automotive Technology Center GmbH
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Priority claimed from US12/491,964 external-priority patent/US9073245B2/en
Application filed by TI Automotive Technology Center GmbH filed Critical TI Automotive Technology Center GmbH
Publication of CN102802914A publication Critical patent/CN102802914A/zh
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Classifications

    • 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
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/92—Measuring, controlling or regulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/42—Component parts, details or accessories; Auxiliary operations
    • B29C49/4205—Handling means, e.g. transfer, loading or discharging means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • 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
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    • 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
    • B29C65/022—Particular heating or welding methods not otherwise provided for
    • B29C65/028—Particular heating or welding methods not otherwise provided for making use of inherent heat, i.e. the heat for the joining comes from the moulding process of one of the parts to be joined
    • 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
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5057—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like positioned between the surfaces to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
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    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt joints
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • 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
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/82—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps
    • B29C66/824—Actuating mechanisms
    • B29C66/8242—Pneumatic or hydraulic drives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • B29C66/83221—Joining or pressing tools reciprocating along one axis cooperating reciprocating tools, each tool reciprocating along one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • 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
    • 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
    • B29C49/42—Component parts, details or accessories; Auxiliary operations
    • B29C49/78—Measuring, controlling or regulating
    • B29C49/783—Measuring, controlling or regulating blowing pressure
    • B29C2049/7831—Measuring, controlling or regulating blowing pressure characterised by pressure values or ranges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
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    • B29C49/78—Measuring, controlling or regulating
    • B29C49/783—Measuring, controlling or regulating blowing pressure
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/0081—Shaping techniques involving a cutting or machining operation before shaping
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C2948/92—Measuring, controlling or regulating
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    • B29C2948/92—Measuring, controlling or regulating
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C2948/92—Measuring, controlling or regulating
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0017—Combinations of extrusion moulding with other shaping operations combined with blow-moulding or thermoforming
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
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    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
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    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
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    • 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
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    • B29C66/72321—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 non-plastics layer consisting of metals or their alloys
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    • 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
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    • 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
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    • B29K2995/0069—Permeability to liquids; Adsorption non-permeable
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Abstract

一种制造产品的方法，包括挤压一型坯；通过切割部分膨胀的型坯或将纵向弱化的型坯拉开而将所述型坯分成型坯半；以及抵靠相应的模具半形成所述型坯半。所述方法还可以包括抵靠所述型坯半和/或所述模具半施加膜；以及抵靠所述模具半形成所述膜和型坯半以生产多层产品半。还公开了执行所述方法的设备。

Description

容器制造
技术领域
本发明整体上涉及一种生产塑料容器的方法，更具体地涉及一种塑料产品的模制工艺。
背景技术
吹塑成型是生产多种塑料产品，特别是容器或包括燃料箱、贮存器等的中空器皿的一种熟知的方法。一般而言，多层燃料箱的典型吹塑工艺包括将一多层管状型坯围绕扩张器杆和吹气杆挤压在打开的模具中。扩张器杆展开以使热型坯沿径向朝模具半伸展。模具半围绕伸展的型坯闭合在一起，并且吹气杆向型坯内部喷射加压气体，以使型坯与模具半的内部表面相一致。同时，托架和各种燃料***构件，如燃料量传感器、通风装置、燃料泵、燃料过滤器等可以由吹气杆承载并被模制在适当位置。但是，在吹塑形成期间在燃料箱中安置所述构件可能是困难的，因为只有在模具闭合且型坯抵靠模具半成形之后所述构件才附接至模制的燃料箱的内侧表面。
同样，燃料箱经常通过吹塑可以包括多个结构阻挡件和粘结层的挤压的多层型坯而生产。但是，挤压通常需要生产固定尺寸和固定构形的固定数量型坯层的专用挤压设备。因此，生产具有不同数量、尺寸和构形的层的燃料箱的灵活性受到了限制。
发明内容
在目前制造产品的优选方法的一个实施例中，型坯被挤压并定位在具有模具半的模具中，所述型坯的上、下部分塌陷以限定所述型坯的密封的内部。此外，所述模具部分闭合以在所述模具半之间留有间隙，加压气体呗引入所述型坯的密封内部以部分膨胀所述型坯。同样，所述部分膨胀的型坯沿所述模具半之间的间隙被切成两半。
根据又一实施例，产品的制造方法包括挤压一型坯以包括纵向延伸的弱化部分，利用在弱化部分的相对侧上的对置的夹具来夹持所述型坯，以及缩回所述对置的夹具以将所述型坯撕开以限定型坯半。
根据又一实施例，产品的制造方法包括挤压一型坯，将所述型坯分成两半，以及将所述型坯半放置在模具的模具半之间。所述方法还包括抵靠所述型坯半或模具半的至少一个施加膜，以及抵靠所述模具半形成膜和型坯半，以生产多层燃料箱半。
根据又一实施例，产品的制造设备包括挤压型坯的挤压机；具有模具半的模具；使所述型坯上、下部分塌陷以限定所述型坯的密封的内部的钳子。所述设备还包括将所述型坯放置在所述模具中的夹具，其中所述模具部分地闭合以在所述模具半之间留出间隙，以及加压气体被引入所述型坯的密封的内部以使所述型坯膨胀。所述设备还包括将膨胀的型坯沿所述模具半之间的间隙切割成两半的切割工具。
根据又一实施例，产品的制造设备包括挤压机，其挤压一型坯以包括纵向弱化的部分；以及对置的夹具，其前进以在所述弱化的部分的相对侧上夹持所述型坯，并且缩回以将所述型坯撕开以限定型坯半。
附图说明
下面将参照附图对示例性实施例以及最佳方式进行详细地说明，图中：
图1是吹塑成型设备的示例性实施例的纵向剖面图；
图2是沿图1的线2-2截取的剖面图，其以虚线描述出未膨胀的型坯，以实线描述出部分膨胀的型坯；
图3是图1的吹塑成型设备一部分的放大片断图，其描述出上、下型坯夹具夹持型坯闭合的上、下部分；
图4是图1的吹塑成型设备的剖面图，其描述出完全膨胀的型坯、吹针、以及用于将型坯切割成两半的型坯切割工具；
图4A是图4中所示设备的一部分的放大片断图；
图5是图1的吹塑成型设备的剖面图，其描述出定位在燃料***构件和打开的模具半之间的托架；
图6是图5中所示吹塑成型设备的横向剖面图，其描述出模具半围绕燃料***构件和托架闭合在一起；
图6A是图1的设备的纵向剖面图，其描述出模具半被分开以打开模具并去除模制产品的余料；
图7是吹塑成型设备另一示例性实施例的俯视图，其示出挤压的型坯和保持所述型坯的夹具；
图8是图7的设备一部分的放大图；
图9是图7的设备的俯视图，其描述出型坯被分成两半并由夹具朝相应的模具半拉动；
图10是图9中所示设备的剖面图，其描述出分开的型坯与所述模具半形成接触；
图11是图10中所示设备的剖面图，其示出模具半闭合在一起以将所述型坯半相互粘合一起；
图12是吹塑成型设备又一示例性实施例的俯视图，其描述出挤压型坯的分开的两半以及将材料膜放置在模具半之间的附加夹具组；
图13是图12中所示的设备的剖面图，其描述出所述分开的型坯半与所述模具半形成接触，以及相应的膜与所述型坯半在所述型坯半的内侧形成接触；
图14是图13中所示设备的剖面图，其描述出所述模具半闭合在一起以将所述膜相互粘合；
图15是图13所示设备的一可替换构型的剖面图，其描述出膜与所述模具半在所述型坯半的模具侧形成接触；
图16是图15所示设备的剖面图，其描述出所述模具半闭合在一起以将所述型坯半相互粘合；
图17是图13所示设备的一可替换构型的剖面图，其描述出内部膜在所述型坯半的内侧接触所述型坯半，以及内膜与所述模具半在所述型坯半的模具侧形成接触；以及
图18是图15中所示设备的剖面图，其描述出所述模具半闭合在一起以将所述内膜相互粘合。
具体实施方式
更详细地参见附图，图1描述出模具成型设备20的示例性实施例，其可以用于实施本公开的制造单层或多层塑料产品（例如塑料燃料箱）的方法，在所述产品的制造期间可将一个或多个构件引入所述产品。下面的设备说明仅提供一个示例性设备的简要概述，但是这里没有示出的其它设备同样可以支持当前公开的方法。
一般而言，设备20可以包括用于生产型坯24的挤压机22，以及吹塑成型和/或深拉伸机的模具26以使型坯24形成产品，例如燃料箱（未示出），且所述模具包括大体上相对的模具半26a, 26b。如这里所用，术语“模具半”可以包括单一的构件或多构件组件。换句话说，每个模具半26a,26b可以包括构成形成表面的多个模具构件。挤压机22可以直接设置在模具26上方，或如果需要的话可以与模具26横向间隔开。同样，机器人（未单独示出）可以定位在挤压机22和模具26附近，并且可以包括上和/或下夹具28a,28b以夹持型坯24并自挤压机22向模具26运送型坯24。夹具28a,28b可以是真空夹具。设备20还可以包括用于将加压气体引入型坯24的吹杆30，以及用于使型坯24径向向外伸展的扩张器32。一般而言，挤压机、模制或拉伸机、夹具、扩张器以及吹杆都是其结构和功能均为本领域普通技术人员所熟知的设备，因而这里不作详细讨论以将注意力集中于本公开。本公开方法的一个示例性实施例可以通过采用任何适当的设备，如设备20来实施。
型坯可以通过挤压或共挤压以任何已知的方式生产，并且所述型坯可以由夹具运送至模具。例如，挤压机22可以挤压型坯24，并且上和/或下夹具28a,28b可以将型坯24运送至模具26。型坯24可以由热塑性塑料，如高密度聚乙烯（HDPE），或聚酯纤维构成，或可以由热固塑料构成。型坯24可以构成为具有或不具有一个或多个例如乙烯醇共聚物（EVOH）或聚酰胺阻挡层，阻挡燃料蒸汽扩散通过要形成的燃料箱。如这里所用，术语“型坯”可以包括柔软的热的成型工件，其具有至少一层由挤压或共挤压机挤压出来的塑料材料。如这里所用，术语“挤压”包括单层型坯的挤压或多层型坯的共挤压。
挤压的型坯24可以被引入或定位在模具26中，并且可以通过可***型坯24内部的扩张器32相对型坯24的纵轴横向伸展或扩展，如图2所示。例如，在型坯24被放置在模具26内之后，扩张器32可以自下面引入型坯24。该扩张器32可以包括固定的中心部分和两个或更多横向可移动的扩张指。移动扩张指使之分开，该移动可以将型坯24拉成细长的椭圆形。固定的中心部分可以包括吹杆30，该中心部分可以用于阻止型坯24的相对壁部分的中心区域相互接触并熔合在一起。如果需要的话，在形成过程中扩张指可以保持在型坯24中。如果需要的话，邻近扩张指的材料后来可以与形成的燃料箱分开并循环使用。
可以例如用钳子通过挤压或夹紧型坯24的上、下部分而使所述上、下部分塌陷。例如，钳子可以是夹具28a,28b本身，如图3所述。在另一实施例中，钳子可以包括其他成组的夹具、臂、叶片、或任何其它挤压或夹紧所述型坯部分的合适设备。型坯24的塌陷部分可以限定型坯24的密封的内部。
同样，如图2中所示，型坯24可以部分地膨胀，如通过将加压气体经由扩张器32中心部分中的吹杆30引入型坯24的密封内部。型坯24可以部分地膨胀至其最终体积的一部分，例如其最终体积的大致20%至40%。可以采取任何适当的正压来部分地膨胀型坯24，例如大约0至3巴（0-43磅/平方英寸），或根据更具体的实施例2至3巴。
如图2和图3所述，模具26可以部分地闭合或朝闭合位置移动但不完全闭合，以便在模具26完全闭合之前在模具半26a,26b之间保留如约20至70mm的间隙34。模具26可以在型坯24部分膨胀之前、之后或期间以任何适合的方法部分地闭合。例如，间隔块（未示出）可前进至模具半26a,26b、成型机压盘（未示出）、模具半26a,26b与所述压盘之间的模具支架或底座（未示出）等的面对的部分之间的位置。这种布置提供一种积极的“硬止动”以限定间隙34。可以采用任何其它适当的布置来限定所述间隙34，例如集成在成型机闭合装置（未示出）中的硬止动，或编程在成型机控制器中的“软止动”等。
仍然参见图2，设备20可以包括支撑在模具26外侧的护罩33以在型坯24部分膨胀期间当模具26仅部分闭合时防止型坯24经间隙34吹出。例如，护罩33可以包括相对的面板或板35a,35b沿模具半26a,26b的侧面被可滑动地支撑。相对的板35a,35b可以通过如致动器35c相对彼此前进或缩回。板35a,35b可以前进至相互结合或抵靠以闭合间隙34。可以采用任何适当的致动器35c，如液压、气压或机电致动器。如图2所示，护罩33可以沿模具26的纵向侧设置，但其它护罩出于相同或相似的目的也可以邻近模具26的顶部和/或底部设置。
参见图3，设备20还可以包括上和/或下切割工具29以去除型坯24的上和/或下部分。切割工具29可以包括例如刀片、刀、激光器和/或热金属丝，或其它适当的切割工具。同样，可以提供任何适当的致动器31以前进和缩回切割工具29，如液压、气压或机电致动器。型坯24的上和/或下部分可以在任何适当的时候去除，如在将型坏24成形为初步形成产品50期间或之后（图4）。
比如，如图4所示，部分膨胀的型坯24（图2和图3）可以在模具26中进一步成形，例如通过经由吹杆30、或吹针30’、或二者将加压气体引入型坯24的内部，和/或通过例如经由模具半26a,26b中的真空通道（未示出）对型坯24的外部施加真空。在一个实施例中，型坯24可以通过吹杆30以例如约3巴（43磅/平方英寸）的压力来膨胀，吹针30’可以通过吹塑模具半26a,26b中的一个被横向推动通过部分膨胀的型坯24的壁，并且膨胀的型坯24的内部可以以例如约1.5巴（21-22磅/平方英寸）的额外压力进一步膨胀。可以施加任何适当的压力，例如3至10巴（43-145磅/平方英寸）直到模具半26a,26b被型坯24形状配合地填满。这一压力至少在开始阶段可以保持适当的时长，如约15至25秒，以生产初步形成的产品50，但避免过度冷却初步形成的产品50，以便其内部表面保持热度和粘性。在一个示例中，可以采用两个吹针30’。
再参见图4，初步形成的产品50可以在模具半26a,26b之间的间隙34中被切割。例如，膨胀的型坯24的剩余部分或初步形成的产品50的突出到模具26结线（pinch line）之外的部分可以被例如刀片、刀、激光器和/或热金属丝，或任何其它适当的切割工具切割。可以使用任何适当的致动器37以沿模具26在护罩33的板35a,35b之间移动切割工具36。因此，护罩板35a,35b可以缩回以允许切割工具36进入模具半之间的间隙34。在另一实施例中，板35a,35b可以尽可能接近地前进，同时仍然允许切割工具36至少部分地在其间突出。在这一在后实施例中，可以在护罩33的相对的护罩半之间限定密封的室39，并且可以在室39中提供加压气体以防止型坯24经过板35a,35b之间吹出。在任何情况下，前进的板35a,35b的面对部分的接近程度可以足够以防止型坯24被吹动通过。切割操作可以在型坯24部分膨胀之后但完全膨胀之前进行，或在形成初步形成产品50期间的压力保持期间或之后进行。换句话说，所述切割操作可以在所述工艺的任何适当的时点进行。
如图5所示，可以打开模具26，其中膨胀的型坯24的型坯半24a,24b保持在其相应的模具半26a,26b中。在一个示例中，型坯半24a,24b可以通过夹具（未示出）保持在模具26中。在另一示例中，型坯半24a,24b可以通过型坯半24a,24b周围的底切或槽或销（未示出）保持在模具26中。在又一示例中，型坯半24a,24b可以通过经由定位在模具半26a,26b中或周围的真空孔（未示出）施加的真空保持在模具26中。
一般而言，构件可以被引入模具26以放置在完成的模制产品中。例如，一个或多个构件40、42、44、46可以集体设置在托架38上，引入到模具26中并连接至一个型坯半24a,24和/或另外一个。例如，采用机器人和夹具（未示出）可以将一个或多个构件放置成与一个或两个型坯半24a,24b的内侧表面或壁接触，使得所述构件附接至所述壁。在另一示例中，构件可以松散地定位，以便它们并不附接至型坯半24a,24b的壁。这样的构件可以包括燃料量传感器、通风装置、燃料泵、燃料过滤器，其中多个构件可以预安装在公用的托架38以及支撑元件48上，该支撑元件可达到燃料箱的间隔开的区域，如一个或多个角部区域。这类公用托架的一示例公开在2009年9月19日提交的名称为“燃料箱支架”的美国专利申请No.12/562,266（律师文件号为2681.3322.001）中，其被转让给本申请的受让人并以引用其整体的形式结合在本申请中。在一个或多个构件固定至燃料箱内侧之后，机器人可以移动离开模具26。
如图6所示，模具26可以闭合，以便仍然热的型坯半24a,24b沿其相应的边缘或边沿着结线相互熔合以限定模制产品150。如果需要的话，可以采用加热器（未示出）以增强这种边缘或边的熔合。
模制产品150的内部可以通过吹针30’加压以产生模制产品150的最终形状和/或适当冷却模制产品150。例如，产品150可以加压至约6至20巴（86-290磅/平方英寸）或，更具体地约8至10巴（115-145磅/平方英寸）。产品150的内部而后可以被通风，吹针30’缩回。
然后模具26可以打开，模制产品150可以从模具26移开，模制产品150可以同时或紧接着去除其余料（flash）151，之后传递至下游目的地。例如，燃料箱150可以通过任何适当的模具内去余料布置来自动去除余料，如图6A所示。因此，切割工具29和/或36与模具内去除余料一起可以提供无需进一步去除余料的成品。
整体上参见图7至图11，本公开方法的另一示例性实施例可通过采用任何适当的设备来实施，且在这里公开为结合一示例性设备220来实施。这一实施例在很多方面与图1至图6的实施例类似，且所述实施例之间相同的附图标记在所述几个附图中通常代表相同或相应的元件。因此，前述描述通过引用其整体结合在下面的描述中，相反亦然。此外，对于共同主题的描述在这里可能不再重复。
如图7和图8所示，型坯224可以通过挤压和共挤压来制造以形成两个纵向延伸的弱化部分225a,225b，其可以在直径方向上相对。在一个实施例中，弱化部分包括凹口或薄壁部分，其可以沿型坯224的整个长度纵向延伸。如图8最佳所示，弱化部分225a,225b可以沿内部表面、外部表面，或二者形成。例如，参见图1，挤压器22可以包括具有相应于凹状弱化部分225a,225b（图8）的凸状突出特征（未示出）的喷嘴23。在这一实施例的另一示例中，凸状突出特征可以设置在喷嘴23的下游，例如在安装于喷嘴23的环上。在另一实施例中（未示出），弱化部分可以是纵向延伸的孔，其可以通过挤压器喷嘴23处的辐条轮而形成。在又一实施例中（未示出），弱化部分可以是纵向延伸的部分切口，其并未刺穿型坯224的壁。这种部分切口可以通过在挤压器喷嘴23处的诸如比萨刀的旋转刀而形成。
在任何情况下，型坯224而后可以通过图1的运送夹具28a,28b运送至图7中的打开的模具226。但是在运送夹具28a,28b（图1）松开型坯224之前，如图7和图8所示，设置在模具226处的相对的成组夹具252a,252b可以前进以邻近弱化部分225a,225b在弱化部分225a,226b的相对侧上接合型坯224。夹具252a,252b可以是真空夹具，或任何其它适当类型的夹具。型坯224可以通过相对的成组夹具252a,252b被引入打开的模具226并定位于打开的模具半226a,226b之间。
相对的成组夹具252a, 252b可以缩回或彼此拉开，以将型坯224沿弱化部分225a,225b分开或撕成两半,以便例如分开的型坯的一半224a可以被至少一组夹具252a保持，而另一半224b被至少一组相对的夹具252b保持。可以采用任何适当数量、尺寸和构型的夹具。如这里所用，术语“夹具”包括将型坯224保持至足够程度以允许从整个型坯224分离型坯半224a,224b的任何构件。
参见图9，分开的型坯半224a,224b抵靠模具半226a,226b定位以在模具半226a,226b的相应外部上形成型坯半224a,224b的外部的密封配合。例如，夹具252a,252b可以继续缩回，以及可以或者移动以抵靠模具半226a,226b的打开表面定位型坯半224a,224b。如图10所示，型坯半224a,224b和模具半226a,226b之间的空间227a，227b而后可以被抽真空以抵靠模具半226a,226b的凹陷表面抽吸或真空形成两个燃料箱半228a,228b。
可以将一个或多个单个构件，或多个集体地设置在托架38上的构件40-46引入模具226并连接至新形成的燃料箱半228a,228b中的一个或两个上。如图11所示，模具226而后可以闭合以使燃料箱半228a,228b沿其相应的边缘相互熔合，而构件和/或托架保持在燃料箱半之间。模具226可以打开，而模制成形的燃料箱250可以移开。
整体上参见图12至图16，本公开方法的又一示例性实施例可以采用任何适当的设备实施，具体地可以与设备320一起并以上面所述的两个方法实施例实施。这一实施例在很多方面与图1至图11的实施例类似，且所述实施例之间相同的附图标记在所述几个附图中通常代表相同或相应的元件。因此，前述描述通过引用其整体结合在下面的描述中，相反亦然。此外，对于共同主题的描述在这里可能不再重复。
首先，如图12所述，膜352可以定位在模具326中位于模具半326a,326b之间。根据一示例，膜352可以包括膜片、喷涂膜、膜涂层等。例如，膜352的卷354可以设置在模具半326a,326b的上端的上方或其上，相对的成组膜夹具356a,356b可以夹持来自膜卷354的膜352的相应部分并将膜352向下拉至模具半326a,326b的下端处或下端下方的位置，以将膜352定位在每一个打开的模具半326a,326b前方。
在一实施例中，如图12所示，膜352可以定位在分开的型坯半324a,324b的内侧，且抵靠型坯半324a,324b内侧表面定位或放置。内型坯半324a,324b可以以任何适当的方式相互分开，例如切割或撕开。而后，型坯半324a,324b和模具半326a,326b之间的空间327a,327b 被抽真空以抵靠模具半326a,326b的凹陷表面抽吸或真空形成两个燃料箱半328a,328b，如图13所示。而后，模具320可以闭合以使新形成的燃料箱半328a,328b沿其相应的边缘相互熔合以形成燃料箱350，如图14所示。作为这一实施例的变体，膜可以是涂层，其可以是喷涂在型坯半324a,324b内侧表面上的。如这里所用，术语“施加”包括例如放置或喷涂。示例性的喷涂可以包括任何合适的聚乙烯醇、聚酰胺等。在另一实施例中，形成的燃料箱半328a,328b，不管有没有膜，可以在氟化化学反应中用氟气（fluoro-gas）进行处理以提供对渗透的阻挡或抵挡。
在另一实施例中，如图15所述，膜可以抵靠模具半326a,326b放置，并且根据这一实施例的一个方面，分开的型坯半324a,324b而后可以抵靠膜352的内侧表面放置。根据这一实施例的一未示出的不同的方面，型坯可以在部分打开的模具中膨胀成与膜接触，并且随后如在前相对于图4和图4A所述沿模具半之间的间隙切割。如图15所示，膜352和模具半之间的间隙被抽真空以抵靠模具半326a,326b的凹陷表面抽吸或真空形成两个燃料箱半428a,428b，如图15所示。随后，模具326可以闭合以使新形成的燃料箱半428a,428b沿其相应的边缘相互熔合以形成燃料箱450，如图16所示。
在图17所述的又一实施例中，膜352，353可以放置在型坯半524a,524b的内侧和外侧。例如，第一组膜352可以抵靠模具半326a,326b放置，而后型坯半524a,524b邻近第一组膜352放置，此后第二组膜353可以抵靠型坯半524a,524b的内侧表面放置，以将型坯半524a,524b夹在两组膜352，353之间。随后，模具326可以闭合以使新形成的燃料箱半528a,528b沿其相应的边缘相互熔合，以形成燃料箱550，如图18所示。在这一实施例中，第一和第二组膜可以具有不同的结构层构型和/或可以由不同的材料构成。下面将讨论不同的膜构型和材料。
可以提供任何适当数量和构型的层，包括一个或多个粘结层（a）、阻挡层(b)和/或结构层(c)。在一个实施例中，膜可以是五层或更多层膜，其具有以下基本构型：c/a/b/a/c。在又一实施例中，膜可以是三层或更多层膜，其具有以下基本构型：a/b/a。在又一实施例中，膜可以是两层或更多层膜，其具有以下基本构型：a/b，其中层a可以定向成与其相应的型坯半接触。膜可以具有任何适当数量的层并且可以包括这里未描述的附加层。
在一个示例性实施例中，膜352，353可以包括多层膜，其包括粘结层（a），该粘结层可定向成与两个燃料箱半中相应的一个接触，以便相对热的燃料箱半至少部分地熔化粘结层用以便于膜至燃料箱半的良好熔合。用于粘结层的示例性树脂可以包括马来酸酐接枝线性低密度聚乙烯。
同样，多层膜可以包括阻挡层（b），其可以由来自燃料箱半的热量熔化或不熔化以保护膜的结构整体性。用于阻挡层的示例性树脂可以包括乙烯醇共聚物（EVOH）、聚氧甲烯（POM）、可包括可以从特拉华州的杜邦公司购得的HYTREL牌热塑性聚酯纤维弹性体的热塑性聚酯纤维弹性体（TPE）、或任何其它适当的热塑性聚酯纤维弹性体。又一示例性阻挡层树脂可以包括任何数量的聚酰胺（PA）基材料，如PA12， 熔点为195℃至200℃的PA6/6-6共聚物、或熔点为220℃至225℃的PA6。又一PA材料可以包括MXD6，其是半芳香族PA，可以例如从苏威先进聚合物公司（Solvay Advanced Polymers）或三菱瓦斯化学株式会社购得。又一PA材料可以包括PA和聚乙烯混合，如混合物或合金，如可以从阿科玛（Arkema）公司购得的ORGALLOY牌聚合物,或可以从杜邦公司购得的ZYTEL牌聚合物。在又一实施例中，阻挡层可以包括任何适当的纳米复合材料，如纳米粘土材料或纳米管材料，以改善阻挡性能。在又一实施例中，阻挡层可以是EVOH和可从阿科玛公司购得的ORGALLOY® FT-104的组合。
此外，多层膜可以包括结构层（c）以增强膜的结构整体性。用于结构层的示例性树脂可以是与挤压型坯相同的合成物，如HDPE。用于内结构层的又一示例性树脂可以包括PE、PA、或任何其它聚合物，以及它们的导电形式，其可以通过例如将它们的基础树脂与导电填料或例如纳米管混合而获得。同样，结构层和/或一个或多个其它层可以作为新料或来自生产的重新研磨材料提供。
在一个实施例中，结构层(c)可以不是导电层，而是可以由例如HDPE构成，并且单独的导电材料能够以薄内层的形式存在。
在多层膜的结构层(c)的又一实施例中，结构层可以由一种材料构成，所述材料并不粘结至型坯半的材料以在结构层和型坯半之间留有空间。在这一实施例中，膜可以在形成的燃料箱的结线处熔合或以其他方式焊接在自身上。例如，可以使用加热的模具***物（未示出）在结线处提高材料的温度以将膜熔合在一起。尤其在这种情况下，如果加热的模具***物是感应型加热器，导电聚合物可能是理想的。
在与前一段相关的又一实施例中，膜可以提供为仅包括阻挡层的单一层膜。在这一实施例中，可以布置阻挡层以在阻挡层和型坯半之间留有空间。在这一实施例中，阻挡层单层膜可以在形成的燃料箱的结线处熔合或以其他方式焊接在其自身上。例如，可以使用加热的模具***物（未示出）在结线处提高材料的温度以将膜熔合在一起。尤其在这种情况下，如果加热的模具***物是感应型加热器，导电聚合物可能是理想的。
虽然示出并描述了优选的实施例，本领域普通技术人员很容易意识到前面的描述为说明而非为限制提出，且可以进行各种修改和替换而不偏离本发明的精神和范围。例如，虽然相对燃料箱进行了描述，本公开的方法和设备可以用于任何类型适当的容器。本发明由下面的权利要求限定。

Claims (30)

1.一种制造产品的方法，包括：
挤压一型坯以包括纵向弱化的部分；
利用相对的夹具在所述弱化部分的相对侧夹持所述型坯；以及
缩回所述相对的夹具以将所述型坯沿所述弱化部分撕开以限定型坯半。
2.权利要求1所述的方法，还包括：
利用所述相对的夹具抵靠模具的相应模具半将所述型坯半定位在所述模具中；
抽空所述型坯半和模具半之间的空间以真空形成所述产品的产品半；
将一个或多个构件引入所述模具半之间；以及
围绕所述一个或多个构件将所述模具半闭合在一起，以使所述型坯半沿相应的边缘相互熔合。
3.权利要求1所述的方法，还包括抵靠所述型坯半或模具半的至少一个施加膜。
4.一种制造产品的方法，包括：
挤压一型坯；
将所述型坯定位在具有模具半的模具之中；
使所述型坯的上、下部分塌陷以限定所述型坯的密封内部；
部分地闭合所述模具以在所述模具半之间留出间隙；
将加压气体引入所述型坯的所述密封内部以膨胀所述型坯；
在所述部分闭合的模具内抵靠所述模具半形成所述膨胀的型坯以初步形成所述产品；以及
将所述初步形成的产品沿所述模具半之间的间隙分成两半，
其中，所述方法还包括抵靠所述型坯半或模具半的至少一个施加膜。
5.权利要求4所述的方法，其中通过进一步引入升高压力的加压气体以抵靠所述模具半形成所述型坯。
6.权利要求5所述的方法，其中所述引入加压气体的步骤包括气体压力达到3巴，以及用于初步形成所述产品的所述升高压力达到6巴。
7.权利要求4所述的方法，还包括：
去除所述型坯的上部分或下部分的至少一个。
8.权利要求7所述的方法，所述去除步骤在抵靠所模具半形成所述膨胀的型坯的步骤期间实施。
9.权利要求4所述的方法，还包括：
打开所述部分闭合的模具；
在所述模具半之间引入一个或多个构件；
围绕所述一个或多个构件闭合所述模具，以使所述型坯半沿相应的边缘彼此熔合以形成熔合的产品；以及
对所述熔合的产品的内部加压。
10.权利要求9所述的方法，还包括在将所述型坯定位在所述模具中之后沿横向于所述型坯的挤压纵向的方向伸展所述型坯。
11.权利要求9所述的方法，其中所述一个或多个构件附接至一个或两个燃料箱半的内侧壁。
12.一种制造产品的方法，包括：
挤压一型坯；
将所述型坯分成型坯半；
将所述型坯半定位在模具的模具半之间；
抵靠所述型坯半或所述模具半的至少一个施加膜；以及
抵靠所述模具半形成所述膜和型坯半以生产多层产品半。
13.权利要求12所述的方法，其中所述产品半通过下述形成，抽空所述模具半和所述型坯半之间的空间以真空形成所述多层产品半，以及将所述模具半闭合在一起，以使所述多层产品半沿相应的边缘相互熔合。
14.权利要求12所述的方法，其中所述产品半通过下述形成，将所述模具半闭合在一起以使所述产品半沿相应的边缘相互熔合，以及将加压气体引入所述闭合的模具半。
15.权利要求12所述的方法，其中所述膜通过夹持并展开在所述模具半之间的膜片而定位。
16.权利要求12所述的方法，其中所述膜仅抵靠所述型坯半定位。
17.权利要求12所述的方法，其中所述膜仅定位在所述型坯半和模具半之间。
18.权利要求12所述的方法，其中所述膜定位成既抵靠所述型坯半又在所述型坯半和所述模具半之间。
19.权利要求12所述的方法，其中所述型坯通过以下步骤被分开：
使所述型坯的上下部分塌陷以限定所述型坯的密封内部；
部分地闭合所述模具在所述模具半之间留出间隙；
将加压气体引入所述型坯的所述密封内部以使所述型坯部分膨胀；以及
将所述部分膨胀的型坯沿所述模具半之间的间隙切割成两半。
20.权利要求12所述的方法，其中所述型坯通过以下步骤分开：
挤压一型坯以包括纵向弱化的部分；
利用相对的夹具在所述弱化部分的相对侧夹持所述型坯；以及
缩回所述相对的夹具以将所述型坯撕开以限定所述型坯半。
21.一种由权利要求12所述的方法制造的产品，其中所述膜构造成具有至少一个阻挡层和至少一个粘结层。
22.权利要求21所述的产品，其中所述至少一个阻挡层由下述材料中的至少一种构成：乙烯醇共聚物（EVOH）、聚酰胺（PA）基材料、或纳米复合材料。
23.权利要求22所述的产品，其中所述聚酰胺基材料包括PA12、PA6、PA6/6，6共聚物、MXD6，或PA和聚乙烯混合物或合金的至少一种。
24.权利要求21所述的产品，其中所述至少一个粘结层由马来酸酐接枝线性低密度聚乙烯构成。
25.权利要求21的所述产品，其中所述膜也构造成具有至少一个结构层。
26.权利要求25所述的产品，其中所述至少一个结构层由纯净或再研磨高密度聚乙烯材料构成。
27.权利要求25所述的产品，其中所述至少一个结构层由导电聚合物构成。
28.权利要求25所述的产品，其中所述至少一个结构层由一种材料构成，所述材料并不粘结至所述型坯半以在所述至少一个结构层和其相应的型坯半之间留有空间。
29.权利要求28所述的产品，其中所述膜在所述产品的结线处焊接到自身之上。
30.一种用于制造产品的设备，包括：
挤压机，其挤压一型坯以包括纵向弱化的部分；以及
相对的夹具，其前进以在所述弱化部分的相对侧夹持所述型坯，以及缩回以将所述型坯沿所述弱化部分撕开以限定型坯半。
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