JP5929875B2 - 燃料タンクの製造方法 - Google Patents
燃料タンクの製造方法 Download PDFInfo
- Publication number
- JP5929875B2 JP5929875B2 JP2013230685A JP2013230685A JP5929875B2 JP 5929875 B2 JP5929875 B2 JP 5929875B2 JP 2013230685 A JP2013230685 A JP 2013230685A JP 2013230685 A JP2013230685 A JP 2013230685A JP 5929875 B2 JP5929875 B2 JP 5929875B2
- Authority
- JP
- Japan
- Prior art keywords
- molten resin
- mold
- resin sheet
- fuel tank
- protrusion
- 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.)
- Expired - Fee Related
Links
- 239000002828 fuel tank Substances 0.000 title claims description 87
- 238000004519 manufacturing process Methods 0.000 title claims description 61
- 239000011347 resin Substances 0.000 claims description 249
- 229920005989 resin Polymers 0.000 claims description 249
- 238000007493 shaping process Methods 0.000 claims description 27
- 238000000034 method Methods 0.000 claims description 24
- 230000002093 peripheral effect Effects 0.000 claims description 21
- 238000003825 pressing Methods 0.000 claims description 18
- 230000008569 process Effects 0.000 claims description 5
- 238000000465 moulding Methods 0.000 description 34
- 230000000694 effects Effects 0.000 description 10
- 238000005485 electric heating Methods 0.000 description 6
- 238000010438 heat treatment Methods 0.000 description 6
- 239000002184 metal Substances 0.000 description 6
- 238000003780 insertion Methods 0.000 description 4
- 230000037431 insertion Effects 0.000 description 4
- 230000007935 neutral effect Effects 0.000 description 4
- 239000000446 fuel Substances 0.000 description 3
- 230000004927 fusion Effects 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 230000004888 barrier function Effects 0.000 description 2
- 229920001903 high density polyethylene Polymers 0.000 description 2
- 239000004700 high-density polyethylene Substances 0.000 description 2
- 238000005304 joining Methods 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 238000004804 winding Methods 0.000 description 2
- 230000004913 activation Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 239000004715 ethylene vinyl alcohol Substances 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- 239000012466 permeate Substances 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
Images
Classifications
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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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- 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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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/04—Combined thermoforming and prestretching, e.g. biaxial stretching
- B29C51/06—Combined thermoforming and prestretching, e.g. biaxial stretching using pressure difference for prestretching
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/10—Forming by pressure difference, e.g. vacuum
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- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/14—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C51/261—Handling means, e.g. transfer means, feeding means
- B29C51/262—Clamping means for the sheets, e.g. clamping frames
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- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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- B29C65/607—Riveting or staking the rivets being integral with one of the parts to be joined, i.e. staking the integral rivets being hollow
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
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- B29C66/05—Particular design of joint configurations
- B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
- B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
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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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- B29C66/53—Joining single elements to tubular articles, hollow articles or bars
- B29C66/532—Joining single elements to the wall of tubular articles, hollow articles or bars
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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
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- 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
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- 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
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- B29C66/8122—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the composition of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
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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
- B60K2015/03486—Fuel tanks characterised by the materials the tank or parts thereof are essentially made from
- B60K2015/03493—Fuel tanks characterised by the materials the tank or parts thereof are essentially made from made of plastics
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- Sustainable Development (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Transportation (AREA)
- Life Sciences & Earth Sciences (AREA)
- Cooling, Air Intake And Gas Exhaust, And Fuel Tank Arrangements In Propulsion Units (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
Description
また、加圧部材を低速且つ低荷重で動作させる場合には、燃料タンクの取付部を形成するために必要な樹脂量確保のために溶融樹脂シートを厚肉とする必要がない。このため、燃料タンクの樹脂量の増加を抑制することができる。
まず、燃料タンク20のタンク本体22Bとなる溶融樹脂シート34を製造し、この溶融樹脂シート34を成形装置40の成形型42内に導入する。そして、図3に示されるように、押圧機58で溶融樹脂シート34の外周縁部34Aを成形型42の周辺部42Aに押し付けて溶融樹脂シート34を成形型42にセットする。
次に、図4に示されるように、溶融樹脂シート34とキャビティ面48Aとの間に形成された密閉空間60へ空圧回路から気体流路56を通じて気体を供給し、密閉空間60内を加圧して、溶融樹脂シート34を風船状に膨らませて伸張させる。これにより、溶融樹脂シート34の肉厚が均一化する。また、溶融樹脂シート34がキャビティ面48Aに対して余長を確保できるように密閉空間60内の圧力を調整して、溶融樹脂シート34を伸張させる。なお、溶融樹脂シート34の余長は、後述する溶融樹脂突起36に必要な樹脂量分確保することが好ましい。
次に、図6に示されるように、取付部品26の締結座28に形成された取付孔30に溶融樹脂突起36を挿入し、締結座28を溶融樹脂シート34上に配置する。
次に、図7に示されるように、可動部材44を溶融樹脂突起36の突出方向と反対方向に(可動部材44を成形型42内に収容する方向)に移動させながら加圧部材46で溶融樹脂突起36を突出方向と反対方向に加圧して変形させる。具体的には、本実施形態では、電磁弁62を中立(排気)状態に切り変え、加圧部材46を低速低荷重(絞り弁82によって低速低荷重となる)で成形型42側へ移動させて、溶融樹脂突起36を介して可動部材44を押圧移動させながら、溶融樹脂突起36を加圧して変形させる。すなわち、加圧部材46が溶融樹脂突起36に当接すると、押圧された可動部材44が溶融樹脂突起36の突出方向と反対方向に移動を開始する。このとき、マグネット88とマグネット90との間に生じる斥力によって可動部材44と加圧部材46との間の間隔Lを一定に保つことができる。
また、加圧部材46を低速且つ低荷重で動作させる場合には、燃料タンク20の取付部38を形成するために必要な樹脂量確保のために溶融樹脂シート34を厚肉とする必要がない。このため、タンク本体22の樹脂量の増加を抑制することができる。
またさらに、溶融樹脂突起36の加圧時には、溶融樹脂突起36が可動部材44で支持されながら加圧変形するため、周壁部36Bの一部が二重に折り畳まれることなく外周側に張り出して張出部36Cが形成される。これにより、張出部36Cには、周壁部36Bの一部を二重に折り畳んだ場合の融着面が生じないため、取付部38の張出部32の強度を確保することができる。すなわち、取付部38の張出部32には、上記のように融着面が生じないため、融着面への応力集中を抑制することができる。
なお、アクチュエータ50及びアクチュエータ74をサーボモータとした場合には、加圧部材46が溶融樹脂突起36に当接すると可動部材44を溶融樹脂突起36の突出方向と反対方向に移動を開始する構成としてもよく、可動部材44と加圧部材46との間隔Lが予め設定された値(例えば、溶融樹脂シート34の一般部34Bの肉厚T0と同じ値)になると可動部材44が溶融樹脂突起36の突出方向と反対方向に移動を開始する構成としてもよい。また、アクチュエータ50及びアクチュエータ74のうち、一方をサーボモータ、他方をエアシリンダ(又は油圧シリンダ)としてもよい。
22 タンク本体
22C 一般部
24 突起
24A 頂部
24C 挿入部(取付孔に挿入された部分)
26 取付部品
30 取付孔
32 張出部
34 溶融樹脂シート
36 溶融樹脂突起
42 成形型
44 可動部材
46 加圧部材
48A キャビティ面(型面)
92 圧空成形型
T0 タンク本体の一般部の肉厚
T1 突起の頂部の肉厚
T2 突起の挿入部の肉厚(取付孔に挿入された部分の肉厚)
Claims (8)
- 樹脂で形成されたタンク本体となる溶融樹脂シートを成形型内に導入する導入工程と、
前記溶融樹脂シートに可動部材を当接させて前記溶融樹脂シートの肉厚方向に突出する溶融樹脂突起を形成する賦形工程と、
取付部品に設けられた取付孔に前記溶融樹脂突起を挿入して前記溶融樹脂シート上に前記取付部品を配置する配置工程と、
前記可動部材を前記溶融樹脂突起の突出方向と反対方向に移動させながら加圧部材で前記溶融樹脂突起を前記反対方向に加圧して、前記溶融樹脂突起の一部を外周側に張り出させる加工工程と、
を備え、前記加工工程では、前記溶融樹脂突起の加圧時に前記可動部材と前記加圧部材とが一定の間隔を保って移動する燃料タンクの製造方法。 - 前記加工工程では、前記加圧部材が前記溶融樹脂突起に当接すると前記可動部材が前記反対方向に移動を開始する、請求項1に記載の燃料タンクの製造方法。
- 前記加工工程では、前記可動部材と前記加圧部材との間隔が予め設定した値になると前記可動部材が前記反対方向に移動を開始する、請求項1に記載の燃料タンクの製造方法。
- 前記賦形工程では、前記成形型の型面から前記可動部材を突出させた状態で前記型面に沿って前記溶融樹脂シートを配置して前記溶融樹脂突起を形成する、請求項1〜3のいずれか1項に記載の燃料タンクの製造方法。
- 前記賦形工程では、前記溶融樹脂シートを前記成形型の型面に沿って配置した後で前記型面から前記可動部材を突出させて前記溶融樹脂突起を形成する、請求項1〜3のいずれか1項に記載の燃料タンクの製造方法。
- 前記賦形工程では、前記成形型と前記溶融樹脂シートとの間の空間を減圧し、又は前記成形型に合わされた圧空成形型と前記溶融樹脂シートとの間の空間を加圧して前記溶融樹脂シートを前記型面に沿って配置させる、請求項4又は請求項5に記載の燃料タンクの製造方法。
- 前記賦形工程では、前記成形型と前記溶融樹脂シートとの間の空間を加圧し、又は前記成形型に合わされた圧空成形型と前記溶融樹脂シートとの間の空間を減圧して前記溶融樹脂シートを伸張させて前記型面に対して余長を確保した後で、前記溶融樹脂シートを前記型面に沿って配置させる、請求項6に記載の燃料タンクの製造方法。
- 前記導入工程では、前記型面に対して余長を確保した前記溶融樹脂シートを前記成形型内に導入する、請求項6に記載の燃料タンクの製造方法。
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PCT/IB2014/002430 WO2015068028A1 (en) | 2013-11-06 | 2014-11-05 | Method of manufacturing fuel tank and fuel tank |
CN201480059998.0A CN105682890B (zh) | 2013-11-06 | 2014-11-05 | 制造燃料罐的方法以及燃料罐 |
US15/032,519 US9908280B2 (en) | 2013-11-06 | 2014-11-05 | Method of manufacturing fuel tank and fuel tank |
EP14802141.3A EP3065930B1 (en) | 2013-11-06 | 2014-11-05 | Method of manufacturing fuel tank and fuel tank |
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JP6586903B2 (ja) * | 2016-02-19 | 2019-10-09 | トヨタ自動車株式会社 | 樹脂燃料タンクの製造方法 |
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US5308427A (en) * | 1992-09-28 | 1994-05-03 | Ford Motor Company | Method for fastening plastic articles |
US6679399B2 (en) | 2002-01-28 | 2004-01-20 | Ti Group Automotive Systems Llc | Fuel tank fasteners |
FR2873321B1 (fr) | 2004-07-23 | 2008-05-09 | Inergy Automotive Systems Res | Procede pour la fixation d'un accessoire dans un reservoir a carburant en matiere plastique |
DE102004043716A1 (de) * | 2004-09-09 | 2006-03-16 | BSH Bosch und Siemens Hausgeräte GmbH | Verfahren zum Befestigung von Kunststoffmitnehmern in Wäschetrommeln |
FR2877256B1 (fr) | 2004-10-28 | 2008-10-03 | Inergy Automotive Systems Res | Procede pour la fabrication d'un reservoir a carburant en matiere plastique comprenant une goulotte integree |
DE102006006469B4 (de) | 2006-02-10 | 2018-02-22 | Kautex Textron Gmbh & Co. Kg | Verfahren zum Herstellen eines Kunststoff-Behälters |
US7552764B2 (en) | 2007-01-04 | 2009-06-30 | Nabors Global Holdings, Ltd. | Tubular handling device |
JP2008168435A (ja) * | 2007-01-06 | 2008-07-24 | Seiren Co Ltd | 抗菌性防水布帛 |
US9346211B2 (en) | 2007-05-10 | 2016-05-24 | Plastic Omnium Advanced Innovation And Research | Process for manufacturing a fuel tank equipped with an internal accessory |
FR2915923B1 (fr) | 2007-05-10 | 2009-07-10 | Inergy Automotive Systems Res | Procede de fabrication d'un reservoir a carburant muni d'un accessoire interne |
FR2918595B1 (fr) * | 2007-07-11 | 2009-10-09 | Inergy Automotive Systems Res | Procede pour la fixation d'un accessoire dans un reservoir en matiere plastique. |
US8911225B2 (en) * | 2007-10-24 | 2014-12-16 | Toyo Seikan Kaisha, Ltd. | Compression-molding apparatus and compression-molding method |
FR2934806A1 (fr) * | 2008-08-07 | 2010-02-12 | Inergy Automotive Systems Res | Procede pour fixer un accessoire dans un corps creux en matiere plastique. |
WO2010023267A1 (en) | 2008-09-01 | 2010-03-04 | Inergy Automotive Systems Research (Société Anonyme) | Plastic fuel tank comprising a noise reduction baffle and process for manufacturing it |
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EP3065930A1 (en) | 2016-09-14 |
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US20160271861A1 (en) | 2016-09-22 |
WO2015068028A1 (en) | 2015-05-14 |
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