BARRIER FILM-CONTAINING TANK SHELL WITH PERMEATION-SECURE CONNECTOR FORMATION FOR CONNECTING A SEPARATE CONDUIT COMPONENT
20220289020 ยท 2022-09-15
Inventors
Cpc classification
B60K15/03177
PERFORMING OPERATIONS; TRANSPORTING
B60K15/03519
PERFORMING OPERATIONS; TRANSPORTING
B60K2015/03453
PERFORMING OPERATIONS; TRANSPORTING
B60K2015/03467
PERFORMING OPERATIONS; TRANSPORTING
B60K2015/03447
PERFORMING OPERATIONS; TRANSPORTING
B60K2015/03078
PERFORMING OPERATIONS; TRANSPORTING
B60K2015/03046
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
A tank shell for a motor vehicle tank, exhibiting a tank shell inner surface facing towards the tank volume surrounded by it and a tank shell outer surface facing away from the tank volume surrounded by it, where a tank shell wall exhibits at least section-wise a multilayer layer structure, where the layer structure having at least one interior wall section produced by injection molding and located nearer to the tank shell inner surface, at least one exterior wall section produced by injection molding and located nearer to the tank shell outer surface, and a barrier film located between the interior wall section and the exterior wall section, where the tank shell wall exhibits at least one aperture penetrating through the tank shell wall along an aperture path, where a section of the barrier film is exposed in the region of the aperture; the section of the barrier film exposed in the region of the aperture is configured integrally with the barrier film in the tank shell wall and for contacting by a sealing arrangement of a conduit component realized separately from the tank shell wall.
Claims
1-15. (canceled)
16. A tank shell for a motor vehicle tank which exhibits a tank shell inner surface facing towards the tank volume surrounded by it and a tank shell outer surface facing away from the tank volume surrounded by it, where a tank shell wall exhibits at least section-wise a multilayer layer structure, where the layer structure comprises at least one interior wall section produced by injection molding, located nearer to the tank shell inner surface, at least one exterior wall section produced by injection molding, located nearer to the tank shell outer surface, and a barrier film located between the interior wall section and the exterior wall section, where the tank shell wall exhibits at least one aperture penetrating through the tank shell wall along an aperture path, where a section of the barrier film is exposed in the region of the aperture, wherein the section of the barrier film exposed in the region of the aperture is configured integrally with the barrier film in the tank shell wall and for contacting by a sealing arrangement of a conduit component realized separately from the tank shell wall.
17. The tank shell according to claim 16, wherein the sealing arrangement is a sealing section of the conduit component, said sealing section being configured integrally with the separate conduit component, wherein the sealing section contacts directly the exposed section of the barrier film.
18. The tank shell according to claim 17, wherein the sealing arrangement is configured separately from the conduit component and separately from the barrier film and abuts with a first abutment section in a sealing manner on a sealing section of the conduit component and with a second abutment section in a sealing manner on the exposed section of the barrier film.
19. The tank shell according to claim 16, wherein the sealing arrangement is configured separately from the conduit component and separately from the barrier film and abuts with a first abutment section in a sealing manner on a sealing section of the conduit component and with a second abutment section in a sealing manner on the exposed section of the barrier film.
20. The tank shell according to claim 19, wherein the section of the barrier film exposed in the region of the aperture is arranged radially outside or radially inside the sealing section of the separate conduit component.
21. The tank shell according to claim 17, wherein the section of the barrier film exposed in the region of the aperture is arranged radially outside or radially inside the sealing section of the separate conduit component.
22. The tank shell according to claim 16, wherein the interior wall section and/or the exterior wall section exhibits and/or exhibit respectively a securing formation, and that the separate conduit component exhibits a securing counter-formation, where the securing formation in interaction with the securing counter-formation secures the separate conduit component to the tank shell by means of positive locking and/or firm bonding against detaching.
23. The tank shell according to claim 22, wherein the separate conduit component exhibits a conduit extending along a virtual conduit path, penetrating through the conduit component, where the conduit path defines an axial direction proceeding along the conduit path, a radial direction proceeding orthogonally to the conduit path, and a circumferential direction encircling the conduit path, where the securing counter-formation is arranged offset axially and/or radially relative to the sealing section.
24. The tank shell according to claim 23, wherein a formation consisting of a securing formation and a securing counter-formation exhibits a radial projection which engages behind a rear-engagement surface of the respective other formation in the radial direction, thereby limiting axial removal movement of the separate conduit component in the direction away from the tank shell.
25. The tank shell according to claim 22, wherein a formation consisting of a securing formation and a securing counter-formation exhibits a radial projection which engages behind a rear-engagement surface of the respective other formation in the radial direction, thereby limiting axial removal movement of the separate conduit component in the direction away from the tank shell.
26. The tank shell according to one of the claim 24, wherein the securing formation at least section-wise is injected onto the securing counter-formation.
27. The tank shell according to claim 24, wherein the radial projection is configured as a radially springily displaceable latching projection.
28. The tank shell according to claim 16, wherein the section of the barrier film exposed in the region of the aperture exhibits at least one radial and/or axial step.
29. The tank shell according to claim 16, wherein the section of the barrier film exposed in the region of the aperture proceeds at least also along the aperture path and preferably tapers along the aperture path.
30. The tank shell according to claim 16, wherein the barrier film is a multilayer film with at least one bonding layer located on the outside and with at least one functional barrier layer, whose specific barrier effect against permeation of hydrocarbons under the same permeation conditions is greater than the barrier effect of the bonding layer, where the functional barrier layer preferably comprises EVOH and/or PVOH or consists of EVOH and/or PVOH.
31. The tank shell according to claim 17, wherein the sealing arrangement protrudes into the barrier film over at least part of the thickness of the barrier film.
32. The tank shell according to claim 18, wherein the sealing arrangement protrudes into the barrier film over at least part of the thickness of the barrier film.
33. The tank shell according to the claim 30, wherein the sealing arrangement protrudes into the barrier film over at least part of the thickness of the barrier film, and wherein the sealing arrangement protrudes into the functional barrier layer.
34. A motor vehicle tank, in particular fuel tank, comprising at least two tank shells,
16. least one tank shell, is configured according to claim 16.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] The invention may take physical form in certain parts and arrangement of parts, a preferred embodiment of which will be described in detail and illustrated in the accompanying drawings which forms a part hereof and wherein:
[0043]
[0044]
[0045]
[0046]
[0047]
[0048]
[0049]
DESCRIPTION OF PREFERRED EMBODIMENTS
[0050] Referring now to the drawings wherein the showings are for the purpose of illustrating preferred and alternative embodiments of the invention only and not for the purpose of limiting the same, in
[0051] At the upper tank shell 12 there is arranged in the tank top 20 located opposite the tank bottom 19 a conduit component 22 formed separately from the tank shell 12, in such a way that a fluid conduit 24 configured in the conduit component 22 reaches into the interior 26 of the tank 10, which is surrounded section-wise by the concave inner surface 12a of the upper tank shell 12. For clearer exposition, the conduit component 22 and the section of the tank shell 12 accommodating it are depicted over-proportionally large.
[0052] In the fluid conduit 24 of the conduit component 22 there can be arranged a valve arrangement 25, in order to enable or block the flow through the fluid conduit 24 depending on parameters such as a pressure difference between the two sides of the valve arrangement 25, or depending on control commands of a control device of the motor vehicle V.
[0053] The tank wall 28 of the tank 10 comprises a preferably thermoformed barrier film 30 with a PVOH or EVOH layer as a barrier layer against permeation of hydrocarbons, and comprises an interior wall section 32 injected onto the side of the barrier film 30 nearer to the interior and an exterior wall section 34 injected onto the side of the barrier film 30 further from the interior. Preferably both the interior wall section 32 and the exterior wall section 34 are made from HDPE. On the barrier layer of the barrier film 30 there can be arranged on each side of the EVOH layer an LDPE adhesive layer and on it an HDPE layer, which makes possible permanently firm bonding of the interior wall section 32 and the exterior wall section 34 with the barrier film 30.
[0054] An exposed area of the interior wall section 32 forms the tank shell inner surface 12a of the tank shell 12. An exposed area of the exterior wall sections 34 forms a tank shell outer surface 12b of the tank shell 12.
[0055] An aperture 36 penetrates completely the tank wall 28 in the tank top 20 along a aperture path OB which is straight in the depicted example, thus rendering the interior 26 accessible from the outside.
[0056] The barrier film 30 extends in the region of the aperture 36 together with the interior wall section 32 along the aperture path OB chimney-like outwards away from the interior 26 of the tank 10. In this region, the interior wall section 32 covers the barrier film 30 radially inwards towards the aperture path OB, whereas the barrier film 30 is exposed radially outwards relative to the aperture path OB along a section FA. No material of the exterior wall section 34 is provided there. The exposed section FA proceeds in a closed manner around the aperture path OB, thus forming a cylindrical and/or conical sheath surface which surrounds an accommodating space 35.
[0057] A pipe section 33 formed in the first embodiment by the interior wall section 32 extends axially relative to the aperture path OB beyond the protruding end of the barrier film 30 and preferably also projects radially over the axial end face of the barrier film 30 and covers it, such that in fact only the side of the barrier film 30 facing radially outwards is exposed in the section FA in which no exterior wall section 34 is provided. Due to the covering of the barrier film 30 by means of the pipe section 33 of the interior wall section 32 on the radially inner side and at the axial end face of the axial end of the pipe attachment 37 formed by the barrier film, very good bonding of the barrier film 30 with the interior wall section 32 is achieved and a delamination tendency in the region of the axially projecting longitudinal end of the pipe attachment 37 formed by the barrier film 30 is decreased.
[0058] In the exposed section FA there abuts on the barrier film 30 a sealing arrangement 38, comprising two O-rings 38a and 38b, preferably of the same shape and/or material, arranged one behind the other with coaxial central axes. Due to the direct abutting of the sealing arrangement 38 on the barrier film 30, very high permeation protection against permeation of hydrocarbons is achieved since both the barrier layer of the barrier film 30 and the material of the O-rings 38a and 38b are difficult for hydrocarbons to penetrate through, whereas the polyethylene of the interior and exterior wall sections 32 and/or 34 respectively offers comparatively little to no resistance to permeation of hydrocarbons.
[0059] The sealing arrangement 38, which abuts radially inside on the barrier film 30, abuts at its opposite radially outer side on a sealing section 39 of the conduit component 22.
[0060] The conduit component 22 is made from a material incompatible with the polyolefin of the interior and exterior wall sections 32 and/or 34 respectively, for example from a polyamide, a polyoxymethylene, a blend of polyamides and a polyolefin, in particular polyethylene, and the like, such that the conduit component is not or only inadequately weldable with the tank shell 12.
[0061] The conduit component 22 exhibits a hose connector 40 with a Christmas tree structure directed radially outward, which should hamper removal of a hose pushed onto the hose connector 40.
[0062] The fluid conduit 24 penetrates completely through the conduit component 22 along a curved conduit path LB, which in the fully assembled state of the conduit component 22 coincides with the aperture path OB in the region of the aperture 36.
[0063] In order to mount the conduit component 22 on the tank shell 12, the conduit component 22 is brought near the aperture 36 from outside along the aperture path OB and the sealing arrangement 38 pushed over the exposed section FA of the barrier film 30, such that the sealing arrangement 38 completely encircles the barrier film 30 in the exposed section FA radially outside.
[0064] In order to secure the conduit component 22, there is configured at the exterior wall section 34 a securing formation 42 projecting outward, i.e. away from the interior 26 of the tank 10, which is engaged from behind with positive locking by a securing counter-formation 44 on the conduit component 22. To this end, the securing formation 42 and the securing counter-formation 44 exhibit in the aperture-near section relative to the aperture path OB and/or the conduit path LB respectively appropriate rear-engagement projections facing in radially opposite directions.
[0065] The securing counter-formation 44 is configured at the outer end of a radial projection 46 encircling the conduit path LB preferably in a closed manner, which is configured integrally with the conduit component 22, projects radially from the main body of the latter, and with increasing radial distance from the main body takes on an additional axial extension component towards the tank shell-near longitudinal end of the conduit component 22.
[0066] In the depicted example, at the conduit component 22 there are arranged the sealing section 39 encircling the conduit path LB in a closed manner and the securing counter-formation 44 axially overlapping and radially offset to one another relative to the conduit path LB. This makes possible the configuration of an axially short conduit component 22, which nevertheless can be mounted securely and with a high permeation barrier on the aperture 36 of the tank shell 12.
[0067]
[0068] The second embodiment of an upper tank shell 112 differs from the first inter alia in that the exposed section FA of the barrier film 130 exhibits an axial section FA1 proceeding along the aperture axis OB and a radial section FA2 proceeding orthogonally to the aperture axis OB. The axial section FA1 surrounds, as in the first embodiment, an accommodating space 135 which in the second embodiment extends into the interior 126 of the tank 110.
[0069] Once again the separate conduit component 122 is brought near the tank shell 112 from outside during the assembly, where in contrast to the first embodiment a section of the conduit component 122 is accommodated in the accommodating space 135 and is encircled radially outside by the axial exposed section FA1 of the barrier film 130.
[0070] In contrast to the first embodiment, the securing formation 142 is not configured specifically at a wall section injected on, but rather is formed by the free longitudinal end of the pipe section 133 formed by the interior wall section 132 and jutting axially and radially beyond the axial exposed section FA1. In order to increase its form stability, the axial end of the pipe section 133 is configured as tapered outside and inside.
[0071] The securing counter-formation 144 is configured integrally with the part of the conduit component 122 forming the fluid conduit 124, namely at its longitudinal end which in the assembled state is nearest to the tank's interior space 126. In order to facilitate the arrangement of the conduit component 122 in the operational position shown in
[0072] As in the first embodiment, the sealing arrangement 138 comprises two O-rings 138a and 138b, of which the sealing ring 138a abuts on the axial exposed section FA1 in a sealing manner and of which the sealing ring 138b abuts on the radial exposed section FA2 in a sealing manner. Accordingly, the sealing section 139 of the conduit component 122 is also divided into a axial sealing section portion 139a and a radial sealing section portion 139b.
[0073] The securing counter-formation 144 is therefore arranged offset axially to the sealing section 139 and overlapping with it radially, in particular overlapping with the axial sealing section portion 139a.
[0074] The sealing ring 138b is accommodated in an accommodating groove, whose groove base forms the radial sealing section portion 139b and which is configured at the radial projection 146, which at its radial projecting end overlaps the exterior wall section 134 protectively. The radial projection 146 proceeds preferably in a closed manner around the conduit path LB and forms a disc-like radial projection 146. Likewise, the radial exposed section FA2 proceeds in a closed manner around the aperture 136.
[0075]
[0076] As in the second embodiment, in the third embodiment the pipe section 233 of the interior wall section 232 and the pipe attachment 237 of the barrier film 230 project from the tank wall 228 towards the tank's interior space 226. The pipe section 233 of the interior wall section 232 does not jut beyond the longitudinal end of the pipe attachment 237 of the barrier film 230, but instead extends together with it and parallel to it.
[0077] The sealing arrangement 238 corresponds essentially to the sealing arrangement 38 of the first embodiment, with the difference that the two sealing rings 238a and 238b of the sealing arrangement 238 abut radially outward in a sealing manner against the pipe attachment 237 of the barrier film 230 in the axial exposed section FA1 and radially inward against the sealing arrangement 239 of the conduit component 222.
[0078] The encircling radial projection 246 abuts on the radial exposed section FA2 of the barrier film 230, whereby the position of the conduit component 222 relative to the tank shell 212 is defined axially in respect of the aperture path OB.
[0079] The radial projection 246 exhibits an axially thicker section located radially further inside and an axially thinner section located radially further outside, where the latter forms the securing counter-formation 244. In the embodiment example of
[0080] The pipe attachment 237 and likewise the pipe section 233 encircle the free longitudinal end of the section of the conduit component 222 accommodated in the accommodating space 235 and overlap this longitudinal end radially. The longitudinal end of the conduit component 122 is, therefore, faced in the axial direction by a section of the barrier film 230 and of the interior wall section 232.
[0081]
[0082] In the fourth embodiment according to
[0083] Aside from the fact that the fluid conduit 324 widens in the direction from the hose connector 340 to the tank shell-near longitudinal end of the conduit component 322, the conduit component 322 also exhibits an encircling disc-like radial projection 346.
[0084] The radial projection 346 serves both for attaching the conduit component 322 to the tank shell 312 and for sealing the conduit component 322 to the barrier film 330. As in the third embodiment, in the fourth embodiment being discussed here too, material of the exterior wall section 334 is injected as a securing formation 342 onto a radial projection formation at the radial projection 346 as the securing counter-formation 344.
[0085] The sealing arrangement 338 of the fourth embodiment comprises two encircling blade-shaped seals 338a and 338b configured integrally with the radial projection 346 and comprises additionally an elastomeric seal 338c arranged radially between the blade-shaped seals 338a and 338b, which is inserted as a separate sealing component, more precisely: sealing ring, in a groove which is configured radially between the blade-shaped seals 338a and 338b at the radial projection 346.
[0086] The attachment of the sealing component 322 to the tank shell 312 and its sealing are shown in greater detail in
[0087] As can be discerned in
[0088] The securing formation 342 and the securing counter-formation 344 have flush outer surfaces facing outwards in the axial direction.
[0089] As can further be discerned in
[0090] The blade-shaped seal 338a located radially further outside forms besides a cavity wall for the material of the exterior wall section 334 injected for forming the securing formation 342.
[0091]
[0092] The fifth embodiment of the tank shell 412 too, like the preceding fourth embodiment, exhibits no accommodating space in the region of the aperture 436 of the tank wall 428 defined by the barrier film 430, the interior wall section 432, or the exterior wall section 434.
[0093] Once again the securing formation 442 is created by injection onto an encircling radial projection 446. In the radial projection 446 there is configured an encircling axial groove as the securing counter-formation 444, which is filled up by material of the securing formation 442. The securing formation 442 of the exterior wall section 434 extends radially up to the main body of the conduit component 422 defining the fluid conduit 424 and touches it.
[0094] The sealing arrangement 438 is configured integrally with the encircling radial projection 446 as an encircling, axially protruding projection. Unlike the fourth embodiment, the encircling axially protruding projection of the sealing arrangement 438 is not blade-like but instead blunt in configuration, such that it does not intrude into the barrier film 430 but instead abuts on the latter in a planar manner at the radial projection 446 and its axial projection, thus forming a labyrinth seal.
[0095] The interior wall section 432 likewise follows in the region of the sealing arrangement 438 the course of the axial projection of the conduit component 422.
[0096] A further difference to the previously discussed embodiments consists in the hose connector 440 proceeding along the aperture path OB, such that the conduit path LB defined by the conduit component 422 and the aperture path OB are coaxial straight paths.
[0097] In order to form a fluid barrier also, there can be arranged between the radial projection 446 and the securing formation 442 and/or between the radial projection 446 and the barrier film 430 at least one separately configured elastomeric seal, for instance a sealing ring.
[0098]
[0099] As in the first embodiment, the pipe attachment 537 of the barrier film 530 and the pipe section 533, this time however of the exterior wall section 534, project outwards in the direction from the tank's interior space 526 away from the tank wall 528.
[0100] In order to enhance delamination security, the pipe section 533 of the exterior wall section 534 juts beyond the pipe attachment 537 axially and radially, such that in fact only the area of the barrier film 530 facing towards the tank's interior space 526 and/or towards the aperture path OB respectively is exposed.
[0101] As in the second embodiment, a part of the conduit component 522 is accommodated in the accommodating space 535 and encircled radially outside by the pipe attachment 537 and by the pipe section 533.
[0102] Like the second embodiment, the sealing arrangement 538 exhibits two sealing rings (O-rings) 538a and 538b, of which the former seals against a radially exposed section FA2 of the barrier film 530 and of which the latter seals against an axially exposed section FA1 of the barrier film 530. As in the second embodiment, the sealing rings 538a and 538b exhibit different diameters and are arranged at an axial distance from one another. Each sealing ring 538a and 538b seals on its side opposite the barrier film 530 against a portion of the sealing section 539 of the conduit component 522. The sealing rings 538a and 538b are permeation and fluid barriers.
[0103] At the conduit component 522 there is furthermore arranged a third sealing 548 in the form of a further O-ring, which seals on the one hand against the sealing component 522 and on the other against the pipe section 533 of the exterior wall section 534. The third O-ring 548 and the O-ring 538b can exhibit the same shape and can be formed from the same or from different sealing materials. The third O-ring 548 forms a further fluid barrier against leakage of fluid tank content through gaps between the tank shell 512 and the conduit component 522.
[0104] Similarly to the first embodiment, a securing formation 542 axial projects from a wall section, this time however from the interior wall section 532. The securing formation 542 exhibits a recess in which latching lugs engage with positive locking as securing counter-formations 544.
[0105] Whereas all the previously discussed embodiments show a conduit component approaching the respective tank shell from outside during assembly, the conduit component 522 of the sixth embodiment approaches the tank wall 528 from inside, i.e. coming from the tank's interior space 526, for mounting on the tank shell 512, until the latching of the securing formation 542 and the securing counter-formation 544 occurs.
[0106] The drawings described by way of example an upper tank shell as the tank shell of the present invention. Additionally or alternatively, the conduit arrangement could be arranged at a lower tank shell.
[0107] In the individual embodiments, the configurations of the respective sealing arrangement and of the securing formation and securing counter-formation are combined only randomly. The securing formation and securing counter-formation of an embodiment can also be combined with a sealing arrangement of another embodiment. The conduit component can carry a valve arrangement and/or can exhibit a different conduit connector than the depicted hose connector.
[0108] While considerable emphasis has been placed on the preferred embodiments of the invention illustrated and described herein, it will be appreciated that other embodiments, and equivalences thereof, can be made and that many changes can be made in the preferred embodiments without departing from the principles of the invention. Furthermore, the embodiments described above can be combined to form yet other embodiments of the invention of this application. Accordingly, it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation.