阅读说明：本技术 制造塑料箱的方法 (Method for manufacturing plastic box ) 是由 H.胡门伯格 于 2020-10-28 设计创作，主要内容包括：一种用于制造塑料箱的方法,其中塑料箱的箱壁(1)的至少一个外层由第一材料组成,其中至少部分地由第一材料组成的加强片(2)在至少一个区域中附接到塑料箱的箱壁(1)的外层,其中,首先,箱壁(1)被准备为热的挤出物(1’),加强片(2)在成形工具(3)外部被固定(特别是被焊接)在挤出物(1’)上,该挤出物(1’)随后和固定的加强片(2)一起被引入到成形工具(3)中,并在成形工具(3)中成形以形成塑料箱的箱壁(1),由此,加强片(2)被更牢固地固定在箱壁(1)上,特别是更牢固地焊接到箱壁(1)。(A method for manufacturing a plastic tank, wherein at least one outer layer of a tank wall (1) of the plastic tank consists of a first material, wherein a reinforcement sheet (2) at least partly consisting of the first material is attached to the outer layer of the tank wall (1) of the plastic tank in at least one region, wherein, firstly, the tank wall (1) is prepared as a hot extrudate (1 '), the reinforcement sheet (2) is fixed, in particular welded, on the extrudate (1 ') outside a shaping tool (3), which extrudate (1 ') is subsequently introduced into the shaping tool (3) together with the fixed reinforcement sheet (2) and is shaped in the shaping tool (3) to form the tank wall (1) of the plastic tank, whereby the reinforcement sheet (2) is more firmly fixed on the tank wall (1), in particular more firmly welded to the tank wall (1).)

1. A method for manufacturing a plastic tank, wherein at least one outer layer of a tank wall (1) of the plastic tank consists of a first material, wherein a reinforcement sheet (2) consisting at least partially of the first material is attached in at least one region to the outer layer of the tank wall (1) of the plastic tank, characterized in that, first, the tank wall (1) is prepared as a hot extrudate (1 '), the reinforcement sheet (2) is fixed, in particular welded, outside a forming tool (3) on the extrudate (1 '), the extrudate (1 ') is subsequently introduced into the forming tool (3) together with the fixed reinforcement sheet (2) and is formed in the forming tool (3) to form the tank wall (1) of the plastic tank, whereby the reinforcement sheet (2) is fixed more firmly on the tank wall (1), in particular more firmly welded to the tank wall (1).

2. Method according to claim 1, characterized in that the reinforcement sheet (2) consists of a fibre-reinforced plastic, wherein a fibre-reinforced material is embedded in a matrix, and wherein the matrix consists of the first material, wherein the first material is preferably high-density polyethylene, wherein the reinforcement sheet is particularly preferably a glass fabric microstructure.

3. The method according to claim 1, characterized in that the reinforcing sheet (2) is fixed to the extrudate (1 ') outside the shaping tool (3) during the discharge of the extrudate (1 ') from the extruder (4) or in a rest position after the extrudate (1 ') has been discharged from the extruder (4).

4. A method according to claim 1, characterized in that the extrudate (1 ') is formed into a hose or sheet at the moment the reinforcing sheet (2) is fixed to the hot extrudate (1') outside the shaping tool (3).

5. A method according to claim 1, characterized in that outside the forming tool (3) the reinforcing sheet (2) is fixed to the extrudate (1') by means of an extendable ram (5).

6. The method according to claim 5, characterized in that the ram (5) holds the reinforcement sheet (2) by means of a vacuum, wherein the vacuum preferably ends after the reinforcement sheet (2) has been fixed on the hot extrudate (1').

7. A method according to claim 5, characterized in that the ram (5) is pressed into the hot extrudate (1 ') in a force-controlled or stroke-controlled manner in order to fix the reinforcing sheet (2) on the hot extrudate (1') outside the shaping tool (3).

8. Method according to claim 1, characterized in that the extrudate (1') is formed in the forming tool (3) by blow moulding to form the wall (1) of the plastic tank, wherein the reinforcement sheet (2) is fixed more firmly on the wall (1), in particular welded more firmly to the wall (1), by means of the pressure during blow moulding and/or by means of the vacuum in the forming tool (3).

Technical Field

The invention relates to a method for manufacturing a plastic box.

Background

Plastic tanks, which are for example recently installed as fuel tanks for motor vehicles such as passenger cars and heavy goods vehicles, are known to be problematic with regard to possible deformation of the fuel tank, in addition to having a variety of positive characteristics. During normal operation of a motor vehicle tank system, large deformations may occur in specific areas of the tank system. The combination of pressure and temperature peaks in the region of the tank can lead to large relative movements of the tank shell, in particular in the case of plastic tanks, and these relative movements must be limited by design means.

The prior art support concepts for reducing undesirable deformation of fuel tanks generally use support points fixed to the tank body to limit deformation of the tank wall. However, these measures are not sufficient, in particular for pressurized tank systems, and further measures have to be taken to reduce the deformations. Typically, the shell thickness of the tank bladder is increased or reinforcing components are secured to the tank wall to limit deformation. However, to date, the attachment of the reinforcement component to the tank wall is time consuming and expensive, and lacks flexibility with respect to feasible reinforcement component geometries.

Disclosure of Invention

The object of the invention is to specify a method for manufacturing a plastic box, wherein the plastic box is protected against deformation. At the same time, it should be possible to carry out the method in a particularly efficient manner and with flexibility with regard to the reinforcing geometry.

This object is achieved by a method for manufacturing a plastic tank, wherein at least one outer layer of a wall of the plastic tank consists of a first material, wherein a reinforcement sheet consisting at least partially of the first material is attached to the outer layer of the wall of the plastic tank in at least one region, wherein, firstly, the wall is prepared as a hot extrudate, the reinforcement sheet is fixed (in particular welded) on the extrudate outside a shaping tool, the extrudate is subsequently introduced into the shaping tool together with the fixed reinforcement sheet and is shaped in the shaping tool to form the wall of the plastic tank, whereby the reinforcement sheet is more firmly fixed on the wall, in particular more firmly welded to the wall.

According to the invention, the reinforcement sheet is applied as a reinforcement element to the tank wall, wherein the application takes place in two stages: first, the reinforcing sheet is only lightly held or contacted with the extrudate outside the forming tool. Since the reinforcement is at least partially composed of the same material as the tank wall, in particular composed of the same plastic or comprises the same plastic, it is a simple matter, in particular, for the reinforcement to be pressed onto the tank wall, for the reinforcement to be melted or welded onto the hot tank wall or the extrusion. This same wall, to which the reinforcement sheet (also called "patch") is attached, is subsequently formed in a forming tool into the final shape of the plastic tank, wherein the reinforcement sheet is even more firmly fixed to the wall, or welded thereto, due to conditions, in particular the pressures prevailing during this process.

By the introduction of the patches or stiffening webs according to the invention outside the forming tool, the reproducible complexity of the surface geometry of the stiffening webs and the achievable degree of forming are very high.

The term "outer layer" refers to the outer wall layer of the tank and, in the case of a fully formed plastic tank, may be either internal or external to the tank.

The tank wall is preferably a multilayer or composite structure, but may also consist of a single layer.

Developments of the invention are specified in the dependent claims, the description and the drawings.

The reinforcing sheet preferably consists of a fibre-reinforced plastic, wherein the fibre-reinforced material is embedded in a matrix, and wherein the matrix consists of the first material.

The first material is preferably High Density Polyethylene (HDPE).

As a particular preference, the reinforcing sheet is a glass fabric fiber structure.

The reinforcing sheet is preferably fixed on the extrudate outside the shaping tool during its discharge from the extruder or in a stationary position after its discharge from the extruder.

At the moment the reinforcing sheet is fixed to the hot extrudate outside the shaping tool, the extrudate is preferably formed into a hose or sheet, i.e. is preferably extruded in the form of a hose or sheet.

Outside the forming tool, the reinforcing sheet is preferably fixed to the extrudate by means of an extendable ram.

The ram may hold the reinforcing sheet by a vacuum. The vacuum is preferably terminated after the reinforcing sheet is secured to the hot extrudate. The ram is then removed from the extrudate again, in particular retracted.

The ram is preferably pressed into the hot extrudate in a force-controlled or stroke-controlled manner in order to fix the reinforcing sheet to the hot extrudate outside the shaping tool.

The extrudate is preferably formed by blow moulding in a forming tool to form the wall of the plastic tank, wherein the reinforcing sheet is more firmly fixed to the wall, in particular more firmly welded, by the pressure during blow moulding and/or by the vacuum in the forming tool.

Drawings

In the following, the invention is described in more detail by way of example with reference to the accompanying drawings.

Figure 1 is a schematic view of a plastic box made according to the present invention.

Fig. 2 is a schematic view of a method for manufacturing a plastic box according to the invention.

Fig. 3 is a schematic illustration of the attachment of a reinforcing sheet in the method of fig. 2 according to the present invention.

Detailed Description

Local deformation of the tank shell is reduced by attaching structural components, i.e. the reinforcement sheet 2, which are in particular fibre-reinforced structural components. To this end, these stiffening webs 2, structural parts or patches may be attached inside and/or outside the box. Fig. 1 shows such a plastic tank, wherein the tank wall 1 of the plastic tank is partially reinforced by attaching reinforcing sheets 2 or patches in different areas. At least the outer layer of the wall 1 of the plastic tank is composed of HDPE. Reinforcing sheets 2, which consist at least partially of the same material HDPE, are attached in regions of the outer layer of the wall 1 of the plastic tank. The reinforcement sheet 2 consists of a fibre-reinforced plastic, wherein the fibre reinforcement is embedded in a matrix, and wherein the matrix consists of high-density polyethylene.

As schematically shown in fig. 2, to manufacture such a plastic tank, the tank wall 1 is first prepared as a hot extrudate 1 ', wherein the extrudate 1' may additionally be in the form of a hose or sheet.

Outside the forming tool 3, in which the shape of the tank shell is subsequently formed, a reinforcing sheet 2 is fixed on the hot extrusion 1', in particular by melting on contact-as shown in more detail in fig. 3.

In fig. 2 it can be seen that the hot extrudate 1 ' is extruded by an extruder 4 and that the reinforcing sheet 2 is fixed to the extrudate 1 ' by contact outside the shaping tool 3 when the extrudate 1 ' is discharged by the extruder 4. The extrudate 1' may flow from the top down into the tool 3. A ram 5 for applying the reinforcing sheet 2 may be arranged between the die of the extruder 4 and the forming tool 3.

Outside the forming tool 3, the reinforcing sheet 2 is fixed to the extrudate 1' by means of an extendable ram 5.

The extrudate 1' with the secured reinforcement sheet 2 is then introduced into a forming tool 3 and formed in the forming tool 3 to form the wall 1 of the plastic tank, whereby the reinforcement sheet 2 is more firmly secured to the wall 1, i.e. more firmly welded or soldered to the wall 1.

The extrudate 1' is formed in the forming tool 3 by blow moulding to form the wall 1 of the plastic tank, wherein the reinforcing sheet 2 is more firmly fixed to the wall 1, in particular more firmly welded to the wall 1, by the pressure during blow moulding and/or by the vacuum in the forming tool 3.

The method described is therefore based on the positioning and welding of the matrix material HDPE of the fibrous patch or reinforcing sheet 2 to the HDPE outer layer material of the tank casing outside the forming tool 3.

The described fusion is carried out in a two-stage process. In a first step, the patches 2 are positioned in defined positions on the extrudate 1 'and are fixed by bringing the semifinished product 1' into contact with the fibrous patches or reinforcing sheets 2. By means of a subsequent forming process, in particular blow molding, the two materials are permanently welded and a permanent material-bonded connection is formed.

Fig. 3 schematically shows the attachment of the reinforcing sheet 2.

The extrudate 1' is moved into a defined position below the exit die of the extruder 4 and adjacent to the ram 5. The fibrous patch 2 is positioned on this press 5 and is brought into contact with the heat plate 1 'by applying it to the heat plate 1', in particular by extending the press 5. This may be a patch or a reinforcing sheet 2 which is heated or at room temperature.

The fibre patch 2 is held in place on the press head 5 by being subjected to a vacuum. The vacuum is preferably achieved through an annular groove or through a hole. During the application of the ram 5, the vacuum is maintained until the end of the positioning.

In order to apply the necessary contact pressure, the ram 5 is pressed into the partially plasticized extrudate 1' by means of force control or stroke control up to a specific end position. For this purpose, the edge region of the pressure head 5 may be provided with a chamfer. The contact pressure of the glass fiber patch 2 on the extrudate 1' may be additionally enhanced by an annular vacuum groove or an annular vacuum hole. In the process, the extrudate 1' is additionally adsorbed on the surface of the pressure head 5 by means of vacuum grooves or vacuum holes.

After the time of contact pressure has expired, the vacuum for fixing the patch 2 is released and the press head 5 without the fibre patch 2 is moved back to the initial position.

The extrudate 1', now reinforced by the fibre patch or reinforcement sheet 2, is fed to a blow-moulding process, in which a permanent material-bonded connection between the now formed fibre patch 2 and the tank wall 1 is obtained by applying a vacuum and/or an excessive pressure from the tool direction.

Reference numerals

1 case wall

1' extrudates

2 reinforcing sheet

3 Forming tool

4 extruder

5 pressure head