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CN102112286A - 用于在塑料空心体模制过程中将辅件紧固到其上的方法和连接件 - Google Patents

用于在塑料空心体模制过程中将辅件紧固到其上的方法和连接件 Download PDF

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Publication number
CN102112286A
CN102112286A CN2009801301662A CN200980130166A CN102112286A CN 102112286 A CN102112286 A CN 102112286A CN 2009801301662 A CN2009801301662 A CN 2009801301662A CN 200980130166 A CN200980130166 A CN 200980130166A CN 102112286 A CN102112286 A CN 102112286A
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parison
connector
auxiliary
described method
inner core
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CN102112286B (zh
Inventor
弗雷德里克·雅诺
比约恩·克里埃尔
皮埃尔-弗朗索瓦·塔迪
拉尔夫·波尔曼
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Nergy Automotive Systems Research SA
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Inergy Automotive Systems Research SA
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    • Y10T29/49826—Assembling or joining
    • Y10T29/49863—Assembling or joining with prestressing of part
    • Y10T29/49876—Assembling or joining with prestressing of part by snap fit

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Abstract

用于使用一个塑料连接件将一个辅件紧固在一个通过模制一个熔融的塑料型坯而获得的空心体中的方法，该塑料连接件包括用于该辅件的联接装置以及旨在限制该连接件穿透进入该熔融的塑料中的一个停止表面，根据该方法该停止表面配备有一个弯曲的双唇缘(或者具有两个同心弯曲的边缘即两个优选位于其圆周处的隆起物的一件式部件，这两个隆起物是同心的并且相对于该部件的剩余部分是在凸凹部中)并且使用这个双唇缘将该连接件焊接到该型坯的内壁上。

Description

用于在塑料空心体模制过程中将辅件紧固到其上的方法和连接件
本发明涉及使用一个特殊的连接件在通过模制的塑料空心体(并且具体地，旨在用于一个机动车辆的一个空心体)的制造过程中用于将一个辅件紧固到其上的一种方法。
在不同种类的车辆上的燃料储箱总体上必须满足与它们被设计用于的用途的类型相关的密封和渗透标准以及它们必须满足的环境要求。目前，在欧洲以及世界各地对于这些有关在大气中以及整体上在环境中的污染物排放限制的要求存在着一种实质性的紧缩。
为了限制这些排放物，特别予以注意的是在储箱和/或加油管(具体见本申请人名下的申请WO 2004/024487)内部放置这些辅件(通气管线、阀门、挡板、加强件、等等)。然而，当这些部件在被模制后被紧固到储箱上时，总体上有必要在该储箱中制作至少一个开口，以便能够将所述部件引入储箱之中并将它们紧固到其上。由此在这个开口附近可能有潜在的密封问题。
因此，在几年前本申请人开发了最初模制一个切开的型坯(切成2个部分)的方法，以便在储箱的实际模制过程中能够将多个辅件引入其中并且紧固到其上并因此避免钻出多个开口(见本申请人名下的专利EP 1 110 697)。
此外，已知的是使用多个中间部件或连接件以便实现这种紧固。的确，进行的这种方式使之可能容易地紧固到该储箱上，基于一种材料的部件不同于形成该储箱内表面的材料。为了做到这点，选择由一种材料制成的一个连接件并且给其装备用于附接到所述辅件(紧固接片，一个“迅速连接”类型联接的部件，等)上的装置是充分的，该材料与该储箱的材料是相容的。
因此，申请US 6,726,967提出了包括一个本体、多个焊接瓣、以及用于一个辅件的联接机构(附接装置)的连接件，这些焊接瓣以一种花朵的形状从这个本体展开。然而，这个连接件具有几个缺点：
-它是庞大的并且减少了该储箱的工作高度，在这种(频繁的)情况下，其中该辅件必须位于该在该液体上面的气体凹座中(并且不被浸没)
-它是相对重的并且不利地影响了该储箱的重量(并且通过这样做，影响了它旨在用于的车辆的重量)
-良好的焊接质量要求这些焊接瓣的一个相对复杂的设计。
本发明目的在于通过提供一个连接件解决这些问题，该连接件的本体和重量是减少的并且这使之可能获得一个良好的焊接质量，尽管是一个简单的设计。
为此目的，本发明涉及一种使用一个塑料连接件用于将一个辅件紧固到通过模制一个熔融的塑料型坯获得的一个空心体上的方法，该连接件包括用于该辅件的联接装置以及一个旨在限制该连接件穿透进入该熔融的塑料中的停止表面，根据该方法该停止表面配备有一个弯曲的双唇缘并且使用这个双唇缘将该连接件焊接在该型坯的内壁上。
这种双唇缘(或者具有两个同心的弯曲边缘、即优选位于其圆周处两个隆起物的一件式部件，它们是同心的并且相对于该部件的剩余部分在凸凹部中)的使用使之可能使焊接点的粘合强度加倍，这伴是随着很少的材料并且经由一个部件，该部件容易与该联接件模制成一件或者紧固到其上。应该注意到该唇缘不必得是实心体但可以包括多个任何形状的槽缝或者其他开口/穿孔。还应该注意到它还不必得是圆形的并且它事实上总体上取决于该停止表面的形状，因此它优选位于后者的圆周上。
本发明应用到的空心体优选是用于一个机动车辆的旨在装燃料、一种污染控制添加剂或者在该车辆上的任何其他液体的一个箱。它可以是一种燃料箱(FT)或者一个脲箱(脲是一种添加剂，它用于纯化NOx排放气体)。它特别好地适用于FTs。
术语“FT”应理解为是指一种不渗透储箱，这种储箱能够在不同的和变化的使用以及环境条件下储存燃料。这种储箱的一个实例是机动车辆装备的储箱。
术语“塑料”是指包括至少一种合成树酯聚合物的任何材料。
所有类型的塑料都可能是适合的。特别适合的属于热塑性塑料的类别的塑料。
术语“热塑性塑料”应理解为是指任何热塑性聚合物，包括热塑性弹性体、以及它们的共混物。术语“聚合物”应理解为是指均聚物和共聚物(尤其是二元或三元共聚物)二者。这类共聚物的实例有(非限制性地)：不规则的共聚物类、直链嵌部分共聚物类、其他嵌部分共聚物类以及接枝共聚物类。
熔点在分解温度之下的任何类型的热塑性聚合物或共聚物都是适合的。具有在至少10摄氏温度上分布的一个熔化范围的合成的热塑性塑料是特别适合的。此类材料的实例包括呈现它们的分子量多分散性的那些材料。
特别地，可使用聚烯烃类、热塑性聚酯类、聚酮类、聚酰胺类以及它们的共聚物类。还可以使用聚合物或共聚物的共混物；类似地还有可能使用带有无机的、有机的和/或天然填充剂的聚合体材料的一种共混物，这些填充剂是(例如，但不限于)：碳、盐类以及其他无机衍生物类、和天然的或聚合的纤维类。还有可能使用多层结构，这些多层结构包括堆叠层和结合层，这些层包括以上所说明的这些聚合物或共聚物中的至少一种。
经常采用的一种聚合物是聚乙烯。用高密度聚乙烯(HDPE)已经获得了优异的结果。
该储箱的壁可以包括一个单热塑层、或者包括两层。有利的是，一个或多个其他可能的附加层可以由液体和/或气体的一个阻挡层的材料制成的多个层来构成。优选地，阻挡层的性质和厚度被选择为使与该储箱的内表面接触的液体和气体的渗透性最小化。优选地，这个层是基于一种阻挡树酯，即不渗透燃料的一种树酯，例如像EVOH(一种部分水解的乙烯/乙烯基乙酸酯共聚物)。可替代地，该储箱可以经受一种表面处理(氟化作用或磺化作用)，其目的是使该储箱不渗透燃料。
当根据本发明的储箱是一个燃料储箱时，它优选包括一个以基于EVOH的阻挡层，该阻挡层位于这些基于HDPE的外层之间。
鉴于此，根据本发明将该连接件使用其双唇缘焊接在该型坯的内壁上，该双唇缘优选基于与该储箱的塑料相容的一种塑料(至少这两个部件的表面的组分材料优选是相容的)或者甚至具有相同的性质的塑料。因此，当该储箱包括一个外部的基于HDPE的层时，优选地该连接件是基于HDPE的。
根据本发明，该储箱是通过模制一个型坯来生产的。术语“型坯”应被理解为是指一种总体上是熔融塑料挤出的预成型件，该预成型件是旨在模制成要求的形状和尺寸之后形成该储箱的壁。这个预成型件不必得是一种一件式的预成型件。
因此，有利的是该型坯事实上是由两个单独件制成的，例如，它们可以是两个薄片。然而，这些件优选地如在上述申请EP 1110697中所说明的是从同一个挤出的管状型坯中切割而产生的，为此目的，该申请的内容通过引用结合在本申请之中。根据这个变体，一旦一个单个的型坯已被挤出，将这个型坯沿在直径上相对的两条线经过其整个长度切割，以获得两个单独的部件(薄片)。
与具有恒定厚度的两个单独挤出的薄片的模制相比较，这种途径允许具有一个可变厚度(即在其长度上不是恒定的一个厚度)的型坯的使用，这通过一个适合的挤出装置而获得(总体上配备有一个模具的一个挤出机，该模具具有一个位置上可调整的心轴)。这样一个型坯考虑到由于在模具中该材料的非恒定的变形水平而在模制过程中在该型坯的某些点发生厚度的减少。
在一个型坯已经模制成两件之后，这些件通常对应地形成了该燃料储箱的下壁和上壁，这些壁各自具有一个内表面(指向该储箱的内部)；以及一个外表面(指向该储箱的外部)。
用在根据本发明的这个变体的方法中的模具优选包括一个内芯，即一个具有合适的尺寸和形状的部件，它能够在该型坯被定位在模具中时被插入模具的这些空腔之间、并且将储箱内的这些部件紧固到其上而未将型坯的这些边缘焊接(因为该内芯在最终模制该储箱之前必须被拆除，在这一步骤的过程中进行这些型坯部分的焊接)。例如，在专利GB 1 410 215中说明了这样一个部件(内芯)，其内容为此目的通过引用结合在本申请之中。
该模具优选包括两个空腔，这两个空腔旨在与该型坯的外表面接触，该型坯是通过吹气制模(使用注入该型坯内部的一种增压气体将该型坯压靠在这些空腔上)和/或通过热成形(将这些模具空腔的后面抽成真空)进行模制的。
优选地，它是通过吹气制模来进行的，但优选同时还在这些空腔后面提供了吸气(抽出一个真空)以便在型坯未被关闭并增压时使后者保持在模具中。因此，它优选在该方法的步骤6之前包括一个排气步骤，该方法将在以下进行说明。总体上讲，为了做到这一点，首先将该型坯刺穿(例如用针来刺破它)并且然后使流体从该模具中排出(例如使用一个阀门)。
在根据本发明的方法中，凭借一个连接件将该辅件紧固到该型坯的内表面上，优选地在该型坯已经被预吹气模制了，即被粘到该模具的这些空腔上。在以上说明的变体中，根据其该型坯是处于2个区段并且使用一个包括多个空腔和一个内芯的模具来模制，有利的是使用一个附接到内芯上的装置将这种连接件焊接到该型坯的内壁上，该芯部总体上包括一个致动器。
因此，根据本发明方法的一个特别优选的变体包括以下这些步骤：
1)将该型坯引入这些模具空腔之中；
2)将该内芯引入该型坯的内部，所述内芯已经首先装配了该辅件及其连接件；
3)关闭该模具，这样使得这些空腔与该内芯形成密封接触；
4)通过经由该内芯吹气和/或在这些空腔后面施加一个真空来将该型坯压靠在这些空腔上；
5)使用一个附接在该内芯上的装置通过焊接该连接件将该辅件紧固到该型坯上；
6)打开该模具以撤出该内芯；
7)通过吹气模制(通过在该型坯内部注入一种加压的液体)和/或加热成型(通过在这些空腔后面施加一个真空)对该型坯进行最终模制。
在该连接件与该辅件之间的联接机构优选使之可能提供这两个元件之间的一种快速连接件。这可以是紧固接片(优选它们是相对柔性的)、一个“枞树”连接件、或者任何其他类型的快速连接件。根据本发明的一种优选的变体，该连接件是处于一个夹子的形式，该夹子包括多个紧固接片，这些紧固接片从包括所述停止表面的基本上平坦的板延伸。这个板优选具有一个基本上圆形的截面。最特别优选地，这个板在其中心处是空心的，即它事实上是一个平坦的拱顶(或者变平的环)。这个变体是特别有利的，因为它使之可能获得该连接件与一个最小量材料的高粘合强度。特别最优选地，因为它在设计上非常简单的，所以该双唇缘事实上是由该拱顶的这些外和内边缘的一个延伸部分构成的，这些边缘优选是锥形的(即它们在圆周处的厚度是小于该拱顶的厚度)。这个唇缘是特别轻的并且易于模制，例如通过注塑模制。
使用这个唇缘的一种方式在于提供该辅件中的一个开口(或者在该辅件的制造过程中直接地，或者通过随后的机加工，这一般是更实际的)穿过其而插入的是所述的夹子，然后该夹子通过其双唇缘焊接到型坯上，在例如使用其紧固接片(当适当时，配备有一个适合于这个目的的几何形状)已经将其连接到该孔口的边缘上之后。
在本发明的背景下正在讨论的辅件可以是一个阀、一个涡旋罐、一个泵/量规模块(支架)、一个液体/蒸气分离容器等。它可以具体是一个阀支架、量规支架、涡旋罐或一个泵/量规模块支架。
在根据本发明的方法中，在该连接件被焊接在该型坯上之前，该连接件和该辅件优选使用联接机构附接。然而，当它是多个部件的问题时，这些部件的尺寸和位置是为使得它们可以随后安装在该连接件上，例如：在位于FT附近的一个维修开口(例如：由一个泵/量规模块的安装板密封的孔口)的多个通风阀的情况下，这是不必要的情况。
根据本发明的方法可以使用仅一个如上述的单个的连接件，如果该辅件的尺寸和重量允许它的话，或者在相反的情况下使用几个连接件。
对于体积庞大的和/或大尺寸的物体，根据本发明的一个有利的变体，既通过该连接件双唇缘的焊接又通过卡扣铆接将该辅件紧固到该型坯上。冶金学领域中常见的这种技术在于由熔融的材料在原位模制一个铆钉，已经使该熔融的材料流入和/或流入过有待被紧固的部件的一个孔口并且然后留在那里以便凝固，以使得原位形成一个卡扣铆钉或一种铆钉/螺栓。
在这种情况下，该连接件的双唇缘必须位于这样一个位置并且具有多个尺寸为使得在该卡口铆接过程中它至少部分地熔化并且使该连接件的焊接能够进行。
根据一个变体这是一个特别优选的(因而它使这些变形减少了，这些变形可以发生在卡扣连接的过程中该材料的局部压缩之后和/或在该型坯已经冷却之后在其收缩之后)，该卡扣连接在定位储箱壁中的一个凸凹部(一种拱顶)的地方发生，当从该储箱的外部看时该凸凹部是凹形的并且当从该内部看时是凸形的。实际上，这个凸凹部可以借助于在模具的这些空腔中的一个凸台进行生产。其尺寸取决于该储箱和该辅件的几何形状，具体地讲在该卡扣铆接孔口的区域中。总体上，它具有几厘米例如从2至5cm的直径以及范围从1至15mm、优选从2至8mm的高度。该卡扣铆接孔口本身优选具有大于1cm甚至至少等于2cm的直径。
在这个变体中，该辅件的卡扣铆接区域优选相对于该连接件的停止表面退后，这样使得当使该辅件与该型坯相接触从而有待紧固到其上时，该凸凹部(拱顶)中的区域中的卡扣铆接和焊接同时发生。
在以下情况下，其中根据本发明的储箱具有一个多层结构，该多层结构包括一个阻挡层，该唇缘的这些尺寸和形状优选为使得后者不会刺透该阻挡层。具体地讲，优选的是该隆起物相对该辅件的表面不会伸出(不会突出)超过2mm、或者甚至1.5mm。
本发明还涉及一个如前面说明的塑料连接件并且它是处于一个夹子的形式，该夹子包括多个紧固接片，这些紧固接片从配备有一个双唇缘的一个平坦的板或者拱顶上延伸，该双唇缘由该板或者拱顶的外和内边缘的一个延伸部分构成，其外和内边缘优选是锥形的。总体上，这个连接件具有cm级别的直径，典型地是在20与50mm之间。其厚度总体上属于mm级别，典型地是在1与4mm之间。
附图1以一种非限制性的方式展示了本发明。在该附图中，通过举例给出了这些尺寸，并且相同的数字表示相同的或类似的部件。
事实上它展示了一个优选的连接件几何构形，它是具有一个夹子的连接件，该夹子具有多个紧固接片1以及处于一个平坦的拱顶2”与一个弯曲的且锥形的双边3”形式的一个盖件，这些紧固接片旨在有待插入有待紧固的辅件的一个孔口(未示出)中并且该双边使焊接点的粘合强度加倍(由于所获得的双焊点)。

Claims (10)

1.用于使用一个塑料连接件将一个辅件紧固在一个通过模制一个熔融的塑料型坯而获得的空心体中的方法，该塑料连接件包括用于该辅件的联接装置以及旨在限制该连接件穿透进入该熔融的塑料中的一个停止表面，根据该方法该停止表面配备有一个弯曲的双唇缘(或者具有两个同心弯曲的边缘即两个优选位于其圆周处的隆起物的一件式部件，这两个隆起物是同心的并且相对于该部件的剩余部分是在凸凹部中)并且使用这个双唇缘将该连接件焊接到该型坯的内壁上。
2.根据前一权利要求所述的方法，其特征在于，该型坯是由两个单独的件制成，这两个件源自同一个被挤出的管状型坯，该管状型坯沿着在直径上相对的两条线在其整个长度上被切开，并且该型坯是使用包括多个空腔以及一个内芯的一个模具进行模制，所述方法包括以下这些步骤：
1)将该型坯引入这些模具空腔之中；
2)将该内芯引入该型坯的内部，所述内芯已经首先装配了该辅件及其连接件；
3)关闭该模具，这样使得这些空腔与该内芯形成密封的接触；
4)通过经由该内芯吹气和/或在这些空腔后面施加一个真空来将该型坯压靠在这些空腔上；
5)使用一个附接在该内芯上的装置通过焊接该连接件将该辅件紧固到该型坯上；
6)打开该模具以撤出该内芯；
7)通过吹气模制(通过在该型坯内部注入一种加压的气体)和/或加热成型(通过在这些空腔的后面施加一个真空)对该型坯进行最终模制。
3.根据上述权利要求中的任一项所述的方法，其特征在于该连接件是处于一个夹子的形式，该夹子包括多个紧固接片，这些紧固接片从包括该停止表面的基本上平坦的板延伸。
4.根据前一权利要求所述的方法，其特征在于，该板是处于一个平坦拱顶(或者变平的环)的形状。
5.根据前一权利要求所述的方法，其特征在于，该双唇缘是由该拱顶的这些外和内边缘的一个延伸部分构成的，这些内和外边缘是锥形的。
6.根据以上权利要求中的任一项所述的方法，其特征在于，既通过该连接件双唇缘的焊接又通过卡扣铆接将该辅件紧固到该型坯上。
7.根据前一权利要求所述的方法，其特征在于，该卡扣铆接在该储箱壁中的一个凸凹部处发生，该凸凹部当从该储箱的外部看时是凹形的，并且当从该内部看时是凸形的。
8.根据前一权利要求所述的方法，其特征在于，该型坯是使用一种包括多个空腔的模具模制的并且在于该凸凹部是使用这些空腔中的一个凸台制成的。
9.根据权利要求6至8中的任一项所述的方法，其特征在于，该辅件包括一个铆钉穿孔区域，该铆钉穿孔区域相对于该连接件的停止表面退后了。
10.处于一个夹子形式的塑料连接件，该夹子包括多个紧固接片，这些紧固接片从配备有一个双唇缘的一个平坦的拱顶延伸，该双唇缘具有由该拱顶的内和外边缘的一个延伸部分制成的两个同心的部件，其内和外边缘优选是锥形的。
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