JP2002285928A - Fuel tank, and method of manufacturing fuel tank - Google Patents

Abstract

PROBLEM TO BE SOLVED: To eliminate the problem of low vertical rigidity for conventional fuel tanks. SOLUTION: This fuel tank 1 is provided with a tank body 10 to store fuel, and a module fixed inside the tank body 10, in which functional components 22 such as a valve and a pump are integrally disposed; and the module is a columnar module 20, vertically provided between an inner wall upper surface 26 and an inner wall lower surface 27 of the tank body 10 for increasing vertical rigidity of the fuel tank 1. The method of manufacturing this fuel tank 1 includes a columnar module manufacturing process for manufacturing the columnar module 20, a columnar module disposing process to dispose the columnar module 20 on the inner circumferential side of a parison, a columnar module welding process for holding the parison and to weld the columnar module 20 to the inner circumferential surface of the parison, and a tank body forming process to form the tank main body 10 of the fuel tank 1 by expanding the parison.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fuel tank having a module in which functional components such as a valve and a pump are integrally provided, and a method of manufacturing the fuel tank.

[0002]

2. Description of the Related Art A fuel tank of an automobile or the like is provided with functional components such as a full capacity regulating valve and a fuel pump. These functional components are indispensable for smoothly supplying fuel to the engine and the like.

[0003] The functional components are usually arranged from the outside of the fuel tank via a flange or the like. However, when the functional component is provided via the flange, a seal member such as an O-ring needs to be separately attached in order to ensure airtightness or liquid tightness of the peripheral edge of the provided portion.

Therefore, Japanese Patent Application Laid-Open No. Hei 1-301227 introduces a resin fuel tank in which a functional component is disposed on the inner wall side of the fuel tank as a fuel tank in which the functional component is disposed without using a flange. Have been.

FIG. 4 is a sectional view of the fuel tank 108. The tank body 107 has a hollow rectangular parallelepiped shape. The tank body 107 is made of resin and is manufactured by blow molding. The plate-shaped module 103 includes a resin base 10.
9 and a functional component 100 disposed on the base 109. The module 103 is bridged between inner wall sides of the tank body 107 facing each other.

As described above, conventionally, the functional component 100 is integrally disposed on the plate-shaped module 103 and the plate-shaped module 103 is installed in the tank main body 107 in a cross-linked manner, whereby the functional component is provided. It was arranged on the inner wall side of the fuel tank.

[0007]

However, the above conventional fuel tank cannot reinforce the rigidity of the fuel tank in the vertical direction. That is, the conventional fuel tank 10
According to 8, the plate-like module 103 is provided so as to bridge between the side surfaces of the inner wall of the tank body 107 facing each other. For this reason, the rigidity in the horizontal direction of the fuel tank 108 can be reinforced, but the rigidity in the vertical direction cannot be reinforced. Rather, since the plate module 103 is suspended in the tank main body 107, the plate module 103 may be bent by its own weight, and the rigidity in the vertical direction may even be reduced.

A fuel tank and a method of manufacturing a fuel tank according to the present invention have been completed in view of the above problems. That is, an object of the present invention is to provide a fuel tank having high rigidity in a vertical direction and a simple manufacturing method of the fuel tank.

[0009]

Means for Solving the Problems (1) In order to solve the above problems, the fuel tank according to the first aspect has a tank main body for storing fuel and a functional configuration such as a valve and a pump fixed to the inside of the tank main body. And a module on which the object is integrally disposed, wherein the module is erected between the upper surface of the inner wall of the tank body and the lower surface of the inner wall to increase the rigidity of the fuel tank in the vertical direction. It is a columnar module.

That is, in the fuel tank of the first aspect, the module in which the functional components are disposed is a columnar module. The columnar module is installed like a column between the upper surface of the inner wall and the lower surface of the inner wall of the tank body that forms the outer shell of the fuel tank. By this pillar-shaped module acting just like a rebound bar,
Vertical distortion of the fuel tank is suppressed. That is, the vertical rigidity of the fuel tank is reinforced.

The shape of the columnar module is not particularly limited as long as the functional components can be provided. For example, it can be formed in a rectangular tube shape, a cylindrical shape, or the like. Preferably, the columnar module has a cylindrical configuration.

According to this configuration, the outer surface of the columnar module is a circumferential surface without corners. Therefore, the flow of the fuel in the fuel tank is not hindered by the columnar module.

Further, a mechanism for strengthening the connection between the columnar module and the tank body may be provided at the upper and lower ends of the columnar module. Preferably, the columnar module is provided with a retaining rib buried at the upper and lower ends in the upper and lower surfaces of the inner wall of the tank body to prevent the columnar module from being pulled out from the upper and lower surfaces of the inner wall.

That is, in this configuration, retaining ribs are arranged at the upper and lower ends of the columnar module. The retaining ribs are embedded in the upper surface of the inner wall and the lower surface of the inner wall of the tank body. Then, when a tensile stress is applied to the tank body from above and below, it has a role of preventing the columnar module from being pulled out. For this reason, the retaining rib may extend in the radial direction of the columnar module regardless of the inner circumferential direction or the outer circumferential direction. The shape of the retaining rib is not particularly limited. Further, the retaining rib does not need to be arranged over the entire periphery of the upper end and the lower end of the columnar module. For example, they may be arranged at intervals of a certain angle such as every 90 degrees or every 60 degrees.

The location of the wiring required for driving the functional components is not particularly limited. Preferably, the columnar module is provided with a pipe-shaped extension pipe in which the wiring of the functional component is housed on the outer peripheral surface and extends outside the tank body.

That is, in this configuration, the extension pipe is arranged on the outer peripheral surface of the columnar module. The extension pipe extends from the outer peripheral surface of the columnar module to the outside of the tank body. The wiring of the functional components is arranged on the inner peripheral side of the extension pipe. That is, the extension pipe has a role of leading out of the tank while protecting the wiring of the functional components.
The length and diameter of the extension pipe are not particularly limited.
The material of the extension pipe may be a material that is insoluble in fuel. The extension pipe may be extended from the filler neck pipe of the tank body to the outside, for example. As a result, since there is no communication part with the outside other than the filler neck pipe, fuel permeation resistance is good.

According to this configuration, it is possible to provide a fuel tank that is strong not only in the vertical compressive stress but also in the tensile stress. Further, according to this configuration, it is possible to provide a fuel tank that can protect the wiring of the functional components.

(2) According to a fifth aspect of the present invention, there is provided a method of manufacturing a fuel tank, comprising a module in which functional components such as a valve and a pump are integrally provided. A method for producing a columnar module by fixing a functional component to a resin base to produce a columnar module, and a diameter of a parison made of resin in a semi-molten state in a tube shape in the axial direction of the columnar module. A columnar module arranging step of arranging the columnar module on the inner peripheral side of the parison so that the directions are substantially parallel to each other, and clamping the parison on the outer peripheral side and from both axial sides of the columnar module; A column-shaped module clamping step of clamping both ends to the inner peripheral surface of the parison,
Forming the tank body of the fuel tank by expanding and expanding the parison into a container shape, and then cooling it to form a tank body of the fuel tank.

The fuel tank made of resin is generally manufactured by blow molding. Blow molding is a process in which a tube-shaped intermediate molded body called "parison" in a semi-molten state is first produced, then a container mold is placed on the outer periphery of the parison and closed, and finally the parison after closing This is a molding method in which a parison is inflated like a balloon by blowing air or the like from the inner peripheral side of the parison to obtain a molded body.

According to a fifth aspect of the present invention, a step of arranging and holding a columnar module is incorporated in a series of steps of the blow molding method, and the formation of the tank body and the holding of the columnar module are performed synchronously. Things. Specifically, a columnar module is inserted on the inner peripheral side of the parison before the mold is closed. Then, the columnar module is clamped on the inner peripheral surface of the parison by the pressing force of the container when the mold is closed.

Here, it is preferable that the resin forming the base of the columnar module and the resin forming the parison (tank body) have good welding properties. For example, when the columnar module and the parison are formed of the same resin, if the welding property is good, a welding effect can be obtained in addition to the clamping effect when the columnar module is clamped by the parison. For this reason, the joining strength between the molded tank body and the columnar module can be increased.

Even if the resin forming the base of the columnar module and the resin forming the parison (tank body) have poor weldability, retaining ribs extending in the radial direction are provided at the upper and lower ends of the columnar module. By providing the retaining ribs on the inner wall of the parison, the joining strength can be increased.

According to the fifth aspect of the present invention, the columnar module can be easily clamped without hindering the flow of the blow molding process, but rather utilizing the characteristic of the blow molding of using a parison in a semi-molten state. be able to.

[0024]

Embodiments of a fuel tank and a method of manufacturing a fuel tank according to the present invention will be described below.

(1) Fuel Tank FIG. 1 is a sectional view of a fuel tank according to this embodiment. As shown in FIG. 1, a fuel tank 1 of the present embodiment
0 and the columnar module 20.

The tank body 10 is made of high-density polyethylene (H
DPE) and has a hollow rectangular parallelepiped shape wide in the lateral direction. A circular filler neck pipe hole 11 is formed in a side wall of the tank body 10.

On the other hand, the columnar module 20 has a cylindrical shape. The columnar module 20 includes a base 21 made of HDPE.
And a functional component 22 (portion indicated by a dotted line in FIG. 1) fixed to the base 21. Columnar module 20
Is erected between the inner wall upper surface 26 and the inner wall lower surface 27 of the tank body 10. The upper end of the outer peripheral surface of the columnar module 20 is embedded in the upper surface 26 of the inner wall, and the lower end is embedded in the lower surface 27 of the inner wall. A ring-shaped retaining rib 23 is provided around the upper and lower ends of the columnar module 20. The retaining ribs 23 prevent the columnar module 20 from coming off the tank body 10 when a tensile stress is applied to the tank body 10 from above and below. A pipe-shaped extension pipe 24 is connected to the upper part of the outer peripheral surface of the columnar module 20. The extension pipe 24 extends laterally along the upper surface of the inner wall of the tank body 10, extends downward along the side surface of the inner wall, and extends outside the tank body 10 from the filler neck pipe hole 11. Inside the extension pipe 24, for example, an electric wiring for extracting an electric signal from the functional component 22 is arranged.

According to the fuel tank of the present embodiment, since the filler neck pipe hole 11 is used as it is as the path of the extension pipe 24, it is necessary to separately provide a through hole for the extension pipe 24 in the tank body 10. Absent.

In the fuel tank of the present embodiment, the retaining ribs 23 are provided at the upper end and the lower end of the columnar module 20. However, if there is no possibility that the columnar module comes off, the retaining rib 23 may not be provided. it can.
Further, although the upper and lower ends of the columnar module are buried in the upper surface and the lower surface of the inner wall of the tank body, the embodiment may be embodied in a non-buried state.

The installation place of the columnar module 20 is not particularly limited as long as it is between the upper surface 26 of the inner wall and the lower surface 27 of the inner wall of the tank body 10. That is, the upper end of the columnar module 20 is fixed in contact with the upper surface 26 of the inner wall of the tank main body, and the lower end of the columnar module 20 is fixed to the tank main body 10.
It is only necessary to be fixed in a state of contact with the lower surface 27 of the inner wall.

The functional components 22 integrally provided on the columnar module 20 include, for example, a fuel gauge sensor,
There are a pressure regulator, a full control valve, a supercharging prevention valve, a rollover valve, and a fuel pump.

(2) Manufacturing Method of Fuel Tank The manufacturing method of the fuel tank of the present embodiment includes a columnar module manufacturing step, a columnar module arranging step, a columnar module clamping step, and a tank body forming step.

First, the columnar module manufacturing process will be described. In this step, a columnar module is manufactured from the base and the functional components. The substrate is made of HDPE and is formed into a hollow cylindrical shape by injection molding. Ring-shaped retaining ribs are provided around the upper and lower ends of the outer peripheral surface of the base. On the other hand, a mounting seat is provided on the inner peripheral side of the base. The functional component is fixed to the mounting seat by screwing, welding, or the like. The electrical wiring of the functional components is passed through a stainless steel extension pipe extending laterally in a crank shape from the upper portion of the outer peripheral surface of the base.

Next, the columnar module disposing step will be described. In this step, first, as shown in FIG. 2, the columnar module 20 is placed sideways below the parison molding machine 7. At this time, the columnar module 20 is suspended in the air by the extension pipe 24 being fixed to the lower end of the parison molding machine 7 (not shown). Next, in this step, the tubular parison 30 is extruded from the parison molding machine 7. The parison 30 has a multilayer structure, and the innermost and outermost layers are H
It is made of DPE. The parison 30 is in a semi-molten state. By being extruded from the parison molding machine 7, the parison 30 is hung down to the periphery of the suspended columnar module 20. At this time, both ends of the columnar module 20 are prevented from contacting the inner peripheral surface of the parison 30. Further, the extension pipe 24 is adjusted so that the crank end thereof is located exactly at the radial center of the parison 30.

Next, the column module clamping process will be described. In this step, as shown in FIG. 2, the parison 30 is closed from the side direction by a pair of rectangular parallelepiped container molds 4 including a pair of side molds 40 and 41. This holding direction is parallel to the axial direction of the columnar module 20 inside the parison 30. Recesses 400, 410 are formed on the inner walls of the side dies 40, 41, respectively. Side type 4
When 0 and 41 are closed, both ends of the columnar module 20 are arranged in these concave portions 400 and 410. Then, the retaining ribs 23 at both ends of the columnar module 20 sink into the inner peripheral surface of the parison 30 in a semi-molten state. Also, the concave portions 400, 4
The semi-molten resin in the peripheral portion of 10 turns around so as to cover the retaining rib 23. Thus, the columnar module 2
0 are embedded in the inner peripheral surface of the parison 30. In this state, the heat of the parison 30 is transmitted to both ends of the columnar module 20. Then, the columnar module 20 is attached to the parison 30.
Are sandwiched and welded. When the container mold 4 is closed, an opening is formed at the upper center. The crank end of the extension pipe 24 is disposed in this opening.

Next, the tank body forming step will be described. In this step, as shown in FIG. 3, the blow pin 7 is formed on the inner peripheral side of the parison 30 through the opening 8 formed by closing the mold.
0 is inserted and air is injected. Then, the parison 30 is expanded in a rectangular parallelepiped shape along the cavity. At this time, the parison 30 expands mainly in the horizontal direction (perpendicular to the plane of FIG. 3). Then, the parison 30 is pushed out to every corner of the container mold 4. Thereafter, the parison 30 is cooled and solidified to form a tank body. Finally, a pair of side molds 4 of the container mold 4
Open 0 and 41 and cut burrs and the like. Thus, a fuel tank in which the columnar modules are arranged is obtained.

In the manufacturing method of this embodiment, the base of the columnar module is made of HDPE, but may be made of a resin such as POM or PA as long as it has a structure for preventing the columnar module from coming off.

In the columnar module arranging step of the manufacturing method of the present embodiment, the parison is hung around the columnar module arranged in advance so that both ends of the columnar module do not contact the inner peripheral surface of the parison. The reverse is also acceptable. As the method of arranging the columnar modules, there is a method of holding the extension pipe from the parison molding machine side as in the manufacturing method of the present embodiment, or a method of providing a dedicated holder.

In the columnar module clamping step of the manufacturing method of the present embodiment, molding is performed using a pair of container dies, namely, a pair of side dies, but the number of container dies is not particularly limited. As long as both ends of the columnar module can be sandwiched on the inner peripheral side of the parison, for example, four or six sheets may be used.

In the columnar module clamping step of the manufacturing method of the present embodiment, the retaining ribs at both ends of the columnar module are buried in the inner peripheral surface of the parison.

[0041]

According to the fuel tank of the present invention, a fuel tank having high rigidity in the vertical direction can be provided. Also,
According to the fuel tank manufacturing method of the present invention, it is possible to provide a manufacturing method capable of easily manufacturing a fuel tank having high rigidity in the vertical direction.

[Brief description of the drawings]

FIG. 1 is a sectional view of a fuel tank according to the present invention.

FIG. 2 is a view showing a state in which columnar modules are arranged in the manufacturing method of the present invention.

FIG. 3 is a view showing a state where a tank body is blow-molded in the manufacturing method of the present invention.

FIG. 4 is a sectional view of a conventional fuel tank.

[Explanation of symbols]

1: Fuel tank 4: Container type 7: Parison molding machine
8: Opening 10: Tank body 11: Filler neck pipe hole 2
0: Columnar module 21: Base 22: Functional component 23: Retaining rib
24: extension piping 26: inner wall upper surface 27: inner wall lower surface 30: parison 4
0: side mold 400: recess 41: side mold 410: recess 70:
Blow pin

 ────────────────────────────────────────────────── ─── Continuing on the front page (72) Inventor Hiroshi Nishi 1 Ogatachi Nagahata, Kasuga-cho, Nishikasugai-gun, Aichi F-term (reference) in Toyoda Gosei 3D038 CA03 CA04 CA15 CB01 CC06 CC17 CC20

Claims (5)

[Claims] 1. A fuel tank comprising: a tank body for storing fuel; and a module fixed inside the tank body and integrally provided with functional components such as a valve and a pump, wherein the module A fuel tank is a column-shaped module that is erected between the upper surface of the inner wall and the lower surface of the inner wall of the tank body in order to increase the rigidity of the fuel tank in the vertical direction. 2. The fuel tank according to claim 1, wherein the columnar module has a cylindrical shape. 3. The fuel tank according to claim 1, wherein the columnar module has a retaining rib at upper and lower ends embedded in upper and lower surfaces of an inner wall of the tank main body to prevent the pillar from being pulled out from the upper and lower surfaces of the inner wall. 4. The fuel tank according to claim 1, wherein the columnar module includes a pipe-shaped extension pipe that accommodates wiring of the functional component on an outer peripheral surface and extends outside the tank body. 5. A method of manufacturing a fuel tank including a module in which a functional component such as a valve or a pump is integrally disposed, wherein the functional component is fixed to a resin base to produce a columnar module. A columnar module producing step, and placing the columnar module on the inner peripheral side of the parison so that the axial direction of the columnar module and the diametrical direction of the parison formed of a tube-shaped and semi-molten resin are substantially parallel to each other. A columnar module disposing step of disposing; a columnar module clamping step of clamping the parison on the outer peripheral side and from both axial sides of the columnar module, and clamping both axial ends of the columnar module on the inner peripheral surface of the parison. A tank body forming step in which the parison is expanded and expanded into the container mold, and then cooled to form a tank body of a fuel tank. Method of manufacturing a tank.