INJECTION-MOLDING METHOD AND LIQUID CONTAINER FOR A MOTOR VEHICLE

Abstract

An injection-molding method for manufacturing a half-shell of a liquid container for a motor vehicle, comprising the following steps: providing a barrier film in a cavity of an injection-molding tool, the cavity being provided for the purpose of shaping the half-shell; providing a barrier sleeve in the cavity; injecting plasticized injection-molding material into the cavity, wherein plasticized injection-molding material is sprayed onto the barrier film and/or the barrier film is back-injected with plasticized injection-molding material; and wherein the barrier sleeve is back-injected with plasticized injection-molding material and/or overmolded with plasticized injection-molding material to form a connection element of the half-shell.

Claims

1-14. (canceled)

15. A method for manufacturing a half-shell of a liquid container for a motor vehicle, comprising: providing a barrier film in a cavity of an injection-molding tool; providing a barrier sleeve in the cavity; injecting plasticized injection-molding material into the cavity, wherein the plasticized injection-molding material is applied onto the barrier film and/or the barrier film is back-injected with the plasticized injection-molding material; wherein the barrier sleeve is back-injected with the plasticized injection-molding material and/or overmolded with the plasticized injection-molding material to form a connection element of the half-shell; and wherein the connection element comprises an adapter.

16. The method as set forth in claim 15, further comprising: inserting the barrier sleeve into a recess to shape the connection element; and/or pushing the barrier sleeve onto a mandrel of the injection-molding tool.

17. The method as set forth in claim 15, wherein: a longitudinal axis of a through hole of the barrier sleeve is oriented transverse to an outer surface or an inner surface of the barrier film; and/or the barrier film rests against the barrier sleeve.

18. The method as set forth in claim 15, wherein: a through hole of the barrier film is arranged so as to be flush with a through hole of the barrier sleeve at least in some portion; and/or a through hole of the barrier film and a through hole of the barrier sleeve are arranged coaxially at least in some portion.

19. The method as set forth in claim 15, wherein: the barrier sleeve is seated at least partially in a through hole of the barrier film.

20. The method as set forth in claim 15, further comprising: integrally connecting the barrier sleeve and the barrier film; and/or integrally connecting the plasticized injection-molding material to the barrier sleeve and/or the barrier film.

21. A liquid container for a motor vehicle, comprising: two connected half-shells that define a storage volume to hold a liquid; wherein at least one of the half-shells has a barrier film as a diffusion barrier and has a connection element to connect a hose or pipe; and wherein at least one barrier sleeve is associated with the connection element that forms a diffusion barrier in a region of the connection element.

22. The liquid container as set forth in claim 21, wherein: a longitudinal axis of a through hole of the barrier sleeve is oriented transverse to an outer surface or an inner surface of the barrier film.

23. The liquid container as set forth in claim 21, wherein: a through hole of the barrier film is arranged so as to be flush with a through hole of the barrier sleeve at least in some portion; and/or a through hole of the barrier film and a through hole of the barrier sleeve are arranged coaxially at least in some portion; and/or the barrier sleeve is seated at least partially in a through hole of the barrier film.

24. The liquid container as set forth in claim 21, wherein: the barrier film and/or the barrier sleeve is a monolayer; and/or the barrier film and/or the barrier sleeve is multilayered; and/or the barrier film is perforated.

25. The liquid container as set forth in claim 21, wherein: a through hole of the connection element has a curved shape or has a bend.

26. The liquid container as set forth in claim 25, wherein: the bend of the connection element is at least a 45 bend.

27. The liquid container as set forth in claim 21, wherein: the barrier film and the barrier sleeve are arranged so as to overlap at least in some portion; and/or the barrier film has a flange or funnel shape at least in some portion; and/or the barrier sleeve has a flange or funnel shape at least in some portion.

28. The liquid container as set forth in claim 21, wherein: the barrier film and the barrier sleeve are integrally connected to one another; and/or at least one of the barrier film and the barrier sleeve is connected to an injection-molding material of the half-shell.

29. The liquid container as set forth in claim 21, wherein: the barrier film has a wall thickness in a range from 100 m to 1000 m; and/or the barrier sleeve has a wall thickness in a range from 100 m to 1000 m.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0056] In the following, the invention is described in further detail with reference to a drawing that illustrates exemplary embodiments:

[0057] FIG. 1 shows a cross section of a connection element of a liquid container according to the prior art;

[0058] FIG. 2 shows another cross section of a connection element of a liquid container according to the prior art;

[0059] FIG. 3 shows a cross section of a connection element of a liquid container according to the invention;

[0060] FIG. 4 shows a cross section of a liquid container according to the invention;

[0061] FIG. 5 shows a barrier sleeve and a barrier film before injection molding;

[0062] FIG. 6 shows the barrier sleeve and the barrier film from FIG. 5 after the injection molding;

[0063] FIG. 7-FIG. 14 show additional alternative cross-sectional shapes of a connection element of a liquid container according to the invention; and

[0064] FIG. 15 shows a workflow of an injection-molding method according to the invention.

DETAILED DESCRIPTION

[0065] FIGS. 1 and 2 each show a cross section of a connection element 1 of a liquid container 3 according to the prior art. Only a portion of a wall 5 of the liquid container 3 is shown. The wall 3 of the liquid container 3 has a barrier layer 7 and a carrier layer 9. The connection element 1 is arranged on a side of the barrier layer 7 that faces away from the carrier layer 9 (variant according to FIG. 1) or is seated on the carrier layer 9 and the barrier layer is on the inside (variant according to FIG. 2). A hose 11 is pushed onto the connection element 1 and is part of a venting of the liquid container 3, for example.

[0066] If fuel is stored in the liquid container 3, there are increased diffusion-related fuel emissions along permeation paths 13. Fuel can diffuse out via the permeation paths 13, since plastic of the support layer 9 or the nozzle 1 is not confined from the surroundings U by the barrier layer 7 along these paths. As a result, hydrocarbon diffusion that is not limited by the barrier layer 7 occurs along the permeation paths 13 via the plastic of the carrier layer 9 and/or of the connection element 1, for example. The greater the number of connection elements 1 provided on a liquid container 3, the greater the fuel leaks due to diffusion-related hydrocarbon emissions or leakage into an environment U.

[0067] FIG. 3 shows a cross section of a connection element 2 of a liquid container 4 according to the invention (FIG. 4). In the present case, the liquid container 4 is a fuel container 4 for a motor vehicle.

[0068] The liquid container 4 has two interconnected half-shells 6, 8. The half-shells 6, 8 define a storage volume 10 for receiving a liquid 12. Here, the liquid 12 is fuel 12 for an internal combustion engine of a motor vehicle. The half-shells 6, 8 each have a multilayer barrier film 14, 16 as a diffusion barrier.

[0069] In the present case, the half-shell 6 has three connection elements 2. It will readily be understood that the arrangement, number, and geometry of connection elements that are provided on the half-shells 6, 8 can be varied in accordance with an alternative exemplary embodiment. For instance, as an alternative or in addition to the arrangement shown in FIG. 4, additional connection elements can be provided on a half-shell 6, 8 as shown in FIGS. 6 to 14, for example.

[0070] In the present case, the connection elements 2 are connecting pieces 2 that are set up for connecting a hose 18, as exemplarily illustrated in FIG. 3.

[0071] As can be seen in FIG. 3, a multilayer barrier sleeve 20 is associated with the connection element 2. Here, the barrier sleeve 20 forms a diffusion barrier in the region of the connection element 2. It is true that diffusion-related fuel emissions cannot be completely prevented by the barrier sleeve 20, as is indicated by the permeation paths 22. In the present example, however, by using the barrier sleeve 20, the free cross section along a permeation path 22 is reduced in comparison to the prior art according to FIGS. 1 and 2, and the diffusion path is also lengthened in comparison to the prior art. This enables the diffusion-related fuel emissions to be reduced substantially.

[0072] The barrier sleeve 20 has a longitudinal axis L along which a through hole 24 extends, the through hole 24 being oriented transverse, in this case perpendicular, to an outer surface 26 and an inner surface 28 of the barrier film 14. The barrier sleeve 20 is seated in a through hole 30 of the barrier film 14, and the through hole 30 also extends along the longitudinal axis L and is thus arranged coaxially with the barrier sleeve 20.

[0073] The barrier film 14 and the barrier sleeve 20 have a multilayer construction in the present case. The barrier film 14 has a barrier layer 32 that is enclosed on two sides by cover layers 34. The barrier sleeve 20 has a barrier layer 36 that is enclosed on two sides by cover layers 38.

[0074] The barrier film 14 and the barrier sleeve 20 are integrally connected to one anotherin the present case welded to one another. In the present case, the barrier sleeve 20 and the barrier film 14 are also integrally connected to an injection-molding material 40 of a structuring carrier layer 41 of the half-shell 6. The injection-molding material 40 is a thermoplasticHDPE in the present case. The cover layers 34, 36 are also HDPE, which makes same-type welding possible.

[0075] In the present case, the barrier film 14 has a wall thickness d1 of approximately 700 m. In the present case, the barrier sleeve 20 has a wall thickness d2 of approximately 500 m.

[0076] According to alternative embodiments, a provision can be made that the barrier sleeve 20 and/or the barrier film 14 are embodied as monolayers, meaning that they are composed of a single layer. In this case, the monolayer is both used for the integral connection of the barrier layer to the carrier material 40 and also has the function of a diffusion barrier for the stored fuel 12, particularly for hydrocarbons.

[0077] The ratio of a width b1 or wall thickness b1 of the connection element 2 in the region of a permeation path 22 to a length L1 of the permeation path is less than 0.5 in the present case (b1/L1<0.5).

[0078] As can be seen from FIG. 4, the two half-shells 6, 8 of the liquid container 4 are welded together in the regions 42.

[0079] FIG. 5 shows a multilayer barrier sleeve 44 and a multilayer barrier film 46 before the injection or back-injection with carrier material 40. The barrier sleeve 44 and the barrier film 46 are arranged so as to overlap in a region 48. In the present case, the barrier sleeve 44 has a circular collar 50.

[0080] By injecting injection-molding material 40 into an injection mold (not shown), the barrier sleeve 44 and the barrier layer 46 are welded to one another in an overlapping manner as a result of the pressure and temperature input, as can be seen in FIG. 6. Moreover, an integral connecting or welding of the barrier sleeve 44 and the barrier layer 46 to the carrier material 40 also occurs.

[0081] The connection element 52 formed in this way thus has an inner barrier sleeve 44, the barrier film 46 also being arranged on the inside, i.e., so as to face toward a fuel to be stored.

[0082] FIG. 7 shows another variant of a connection element 54 with an inner barrier sleeve 56. Compared to the example of FIG. 6, however, one barrier film 58 is arranged on the outside of a half-shell of a liquid container in this casethat is on a side of the half-shell facing away from the fuel to be stored.

[0083] The barrier film 58 is thus integrally connected to the carrier material 40 in the region of an inner side 60, while the connection element 54 is injection-molded locally on a side 62 facing away from the side 60. Like in the example of FIG. 6 as well, the example according to FIG. 7 has a collar or a flange 64 in the vicinity of which the barrier film 58 and the barrier sleeve 56 are arranged so as to overlap and are integrally connected to one another.

[0084] FIG. 8 shows another alternative of a connection element 65 in which a barrier sleeve 66 and also a barrier film 68 are each arranged on the outside, i.e., in the region of an outer side of a half-shell of the liquid container facing away from a storage volume of a liquid container.

[0085] In the present case, the barrier sleeve 66 has already been adapted to the resulting contour of the connection element 65 before the injection molding of the carrier material 40 and also has a flange 70 before the injection molding, in the vicinity of which the barrier sleeve 66 is integrally connected to the barrier film 68 as a result of the process of the injection molding of the initially plasticized carrier material 40. The barrier sleeve 66 and/or the barrier film 68 can be embodied as a monolayer or in multiple layers.

[0086] FIG. 9 shows another variant of a connection element 72 in which a flange 74 is provided on a barrier film 76. The barrier film 76 is thus already perforated with the carrier material 40 before the back-injection and has the flange 74 in order to form an overlap with a sleeve 78 that is provided in an injection-molding tool before the injection-molding process.

[0087] Depending on the hose, pipe, or cable to be connected, connection elements can have different types of profiles, as will be explained further below with reference to FIGS. 10-14. A variant is shown in FIGS. 10-14 on the left side of the dashed line in which the barrier layer and barrier sleeve are arranged on the outside, while a variant is shown on the right side of the dashed line for the illustrated profile of the connection element with barrier film and barrier sleeve on the inside.

[0088] FIG. 10 shows a connection element 80 having a fir tree profile. As shown exemplarily on the left side, a barrier sleeve 82 and a barrier film 84 can be arranged on the outside. In the present case, the barrier sleeve has already been adapted to the fir tree profile before injection molding. According to alternative exemplary embodiments, however, a provision can be made for a substantially circular cylindrical barrier sleeve that is formed into the fir tree profile exclusively by means of the injection-molding process. Alternatively, a barrier sleeve 86 and a barrier film 88 can be arranged on the inside, as is shown in the right part of the figure.

[0089] FIG. 11 shows another variant of a connection element 90 with barrier sleeve 92 on the outside and barrier film 94 on the outside in the illustration to the left in the image. On the right-hand side of the image, the connection element 90 is again shown with the barrier sleeve 96 on the inside and the barrier film 98 on the inside.

[0090] According to FIG. 12, a connection element 100 has a bulge 102 that is enclosed on the outside by a barrier sleeve 104 together with an outside barrier film 106. Alternatively, the connection element 100 can be used in combination with an inner barrier sleeve 108 and an inner barrier film 110.

[0091] FIG. 13 shows a connection element 112 that is embodied as a 45 connection, with a barrier sleeve 120 and a barrier film 116.

[0092] FIG. 14 shows a connection element 118 that is embodied as a 90 connection, with a barrier sleeve and a barrier film 122.

[0093] As will readily be understood, single- or multilayer barrier sleeves and single- or multilayer barrier films can be used in all of the variants discussed above.

[0094] The workflow of an injection-molding method according to the invention is described by way of example with reference to FIG. 15. The following method steps take place in an injection-molding method according to the invention for manufacturing a half-shell of a liquid container for a motor vehicle:

[0095] A providing a barrier film in a cavity of an injection-molding tool, the cavity being provided for the purpose of shaping the half-shell;

[0096] B providing a barrier sleeve in the cavity;

[0097] C injecting plasticized injection-molding material into the cavity, [0098] with plasticized injection-molding material being sprayed onto the barrier film and/or the barrier film being back-injected with plasticized injection-molding material; and [0099] with the barrier sleeve being back-injected with plasticized injection-molding material and/or overmolded with plasticized injection-molding material to form a connection element, in particular a connecting piece, of the half-shell.

REFERENCE SYMBOLS

[0100] 1 connection element [0101] 2 connection element [0102] 3 liquid container [0103] 4 liquid container [0104] 5 wall [0105] 6 half-shell [0106] 7 barrier layer [0107] 8 half-shell [0108] 9 carrier layer [0109] 10 storage volume [0110] 11 hose [0111] 12 fuel [0112] 13 permeation path [0113] 14 barrier film [0114] 16 barrier film [0115] 18 hose [0116] 20 barrier sleeve [0117] 22 permeation path [0118] 24 through hole [0119] 26 outer surface [0120] 28 inner surface [0121] 30 through hole [0122] 32 barrier layer [0123] 34 covering layer [0124] 36 barrier layer [0125] 38 covering layer [0126] 40 injection-molding material, carrier material [0127] 41 carrier layer [0128] 42 area [0129] 44 barrier sleeve [0130] 46 barrier film [0131] 48 area [0132] 50 collar [0133] 52 connection element [0134] 54 connection element [0135] 56 barrier sleeve [0136] 58 barrier film [0137] 60 side [0138] 62 side [0139] 64 flange [0140] 65 connection element [0141] 66 barrier sleeve [0142] 68 barrier film [0143] 70 flange [0144] 72 connection element [0145] 74 flange [0146] 76 barrier film [0147] 80 connection element [0148] 82 barrier sleeve [0149] 84 barrier film [0150] 86 barrier sleeve [0151] 88 barrier film [0152] 90 connection element [0153] 92 barrier sleeve [0154] 94 barrier film [0155] 96 barrier sleeve [0156] 98 barrier film [0157] 100 connection element [0158] 102 bulge [0159] 104 barrier sleeve [0160] 106 barrier film [0161] 108 barrier sleeve [0162] 110 barrier film [0163] 112 connection element [0164] 114 barrier sleeve [0165] 116 barrier film [0166] 118 connection element [0167] 120 barrier sleeve [0168] 122 barrier film [0169] A method step [0170] B method step [0171] C method step [0172] L longitudinal axis [0173] L1 length [0174] U environment [0175] d1 wall thickness [0176] d2 wall thickness