LIQUID CONTAINER FOR A MOTOR VEHICLE AND METHOD FOR MANUFACTURING A LIQUID CONTAINER

Abstract

A liquid container for a motor vehicle, having a first half-shell and a second half-shell, the half-shells delimiting a storage volume for accommodating liquid, the first half-shell having a first support layerand a first barrier layer, the second half-shell having a second support layerand a second barrier layer, the first barrier being situated on a side of the first support layer facing the storage volume, and the second barrier layer being situated on a side of the second support layer facing the storage volume.

Claims

1-15. (canceled)

16. A liquid container for a motor vehicle, comprising: a first half-shell that forms an upper shell of the liquid container; and a second half-shell that forms a lower shell of the liquid container, wherein: the half-shells delimit a storage volume for accommodating liquid, the first half-shell has a first support layer and a first barrier layer, the second half-shell has a second support layer and a second barrier layer, the first barrier layer is externally situated on a side of the first support layer facing the storage volume, and the second barrier layer is internally situated on a side of the second support layer facing the storage volume.

17. The liquid container according to claim 16, wherein the first support layer on a side facing the storage volume has one or more molded elements, connecting parts, or functional units.

18. The liquid container according to claim 17, wherein: the molded elements, connecting parts, or functional units extend with protrusion into the storage volume; and/or the molded elements and/or connecting parts have been formed in one piece with the first support layer in an injection molding process and/or sequentially molded onto the first support layer.

19. The liquid container according to claim 17, wherein all molded elements, connecting parts, or functional units situated in the storage volume are provided on the first support layer, with no molded elements, connecting parts, or functional units situated in the storage volume being provided on the second barrier layer.

20. The liquid container according to claim 16, wherein a plastic that is used for attaching molded elements, connecting parts, or functional units is locally molded onto a side of the second barrier layer facing away from the second support layer.

21. The liquid container according to claim 16, wherein: at least one of the barrier layers is a one-ply film that has been integrally joined to the associated support layer in an injection molding process; and/or at least one of the barrier layers is a multi-ply film that has been integrally joined to the associated support layer in an injection molding process.

22. The liquid container according to claim 16, wherein: the half-shells in the connecting area are integrally joined together, the first support layer in the connecting area being integrally joined to the second barrier layer and/or the second support layer; and the first barrier layer and the second barrier layer in the connecting area are spaced apart from one another and border the first support layer on both sides, wherein the first support layer in the connecting area forms a permeation path between the storage volume and the surroundings of the liquid container.

23. The liquid container according to claim 22, wherein: a length of the permeation path, viewed in a cross section, is greater than or equal to twice the width of the permeation path; and the width of the permeation path corresponds to the distance between the barrier layers in the connecting area.

24. The liquid container according to claim 22, wherein a length of the permeation path, viewed in a cross section, is greater than a wall thickness of the first half-shell and of the second half-shell.

25. The liquid container according to claim 16, wherein the first barrier layer and the second barrier layer are integrally joined together.

26. The liquid container according to claim 16, wherein: the first barrier layer essentially completely covers the side of the first support layer facing away from the storage volume; and/or the second barrier layer essentially completely covers the side of the second support layer facing the storage volume.

27. The liquid container according to claim 16, wherein: at least one of the half-shells has a web, wherein the web is seated in a form-fit manner in a receptacle of the respective other half-shell that has a complementary shape, at least in sections; and an integral bond of the half-shells is formed along the web.

28. The liquid container according to claim 27, wherein the barrier layer of the half-shell that has the web is turned down around the web on the end or encloses the web, the barrier layer at least partially covering an end-face side of the web.

29. The liquid container according to claim 27, wherein the web, at least in sections, is made of a laser-transparent plastic, the integral bond having been formed by laser transmission welding.

30. A method for manufacturing a liquid container, comprising the steps of: injection molding of a first half-shell that forms an upper shell of the liquid container, the first half-shell having a first support layer and a first barrier layer; injection molding of a second half-shell that forms a lower shell of the liquid container, the second half-shell having a second support layer and a second barrier layer; and joining the half-shells in such a way that the half-shells delimit a storage volume for accommodating liquid, the first barrier layer being externally situated on a side of the first support layer facing away from the storage volume, and the second barrier layer being internally situated on a side of the second support layer facing the storage volume.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0045] The invention is described in greater detail below with reference to the drawings, which schematically illustrate one exemplary embodiment, as follows:

[0046] FIG. 1 shows a liquid container according to the invention in a cross section;

[0047] FIG. 2 shows an enlarged detail from FIG. 1;

[0048] FIG. 3 shows another exemplary embodiment of a liquid container according to the invention in a cross section;

[0049] FIG. 4 shows another exemplary embodiment of a liquid container according to the invention in a cross section;

[0050] FIG. 5 shows another exemplary embodiment of a liquid container according to the invention in a cross section;

[0051] FIG. 6 shows another exemplary embodiment of a liquid container according to the invention in a cross section;

[0052] FIG. 7 shows another exemplary embodiment of a liquid container according to the invention in a cross section;

[0053] FIG. 8 shows another exemplary embodiment of a liquid container according to the invention in a cross section;

[0054] FIG. 9 shows another exemplary embodiment of a liquid container according to the invention in a cross section;

[0055] FIG. 10 shows another exemplary embodiment of a liquid container according to the invention in a cross section;

[0056] FIG. 11 shows another exemplary embodiment of a liquid container according to the invention in a cross section;

[0057] FIG. 12 shows another exemplary embodiment of a liquid container according to the invention in a cross section; and

[0058] FIG. 13 shows another exemplary embodiment of a liquid container according to the invention in a cross section.

DETAILED DESCRIPTION

[0059] FIG. 1 shows a liquid container 2 for a motor vehicle in a cross section. The liquid container 2 is a plastic fuel container 2.

[0060] The liquid container 2 has a first half-shell 4 and a second half-shell 6. The half-shells 4, 6 delimit a storage volume 8 for accommodating liquid 10. In the present case the liquid 10 is fuel 10 for operating an internal combustion engine of a motor vehicle. The first half-shell 4 has a first support layer 12 and a first barrier layer 14. The second half-shell 6 has a second support layer 16 and a second barrier layer 18.

[0061] The first barrier layer 14 is situated on a side 20 of the first support layer 12 facing away from the storage volume 8. The second barrier layer 18 is situated on a side 22 of the second support layer 16 facing the storage volume 8. The first barrier layer 14 may therefore be referred to as an exterior barrier layer 14, while the barrier layer 18 may be referred to as an interior barrier layer 18.

[0062] In the example in FIG. 1, the first barrier layer 14 is a one-ply film that has been integrally joined to the support layer 12 in an injection molding process. In addition, the second support layer 16 has also been molded onto the second barrier layer 18 in an injection molding process in order to integrally join the second barrier layer 18 to the second support layer 16. In the present case, the second barrier layer 18 is also designed as a one-ply film.

[0063] It is understood that according to further exemplary embodiments of the invention, the first barrier layer may be made up of one layer, in particular a one-ply film, while the second barrier layer may be made up of multiple layers, in particular a multi-ply film, each of which has been joined to associated support layers in the injection molding process.

[0064] The half-shells 4, 6 are integrally joined together in a connecting area 24. The first support layer 12 is integrally joined to the second barrier layer 18 in the connecting area 24. The first barrier layer 14 and the second barrier layer 18 are spaced apart from one another in the connecting area 24, and border the first support layer 12 on both sides.

[0065] The first support layer 12 forms a permeation path 26 in the connecting area 24, between the storage volume 8 and the surroundings U of the liquid container 2. In other words, the first barrier layer 14 and the second barrier layer 18 in the connecting area 24 do not form a closed barrier bladder, which would essentially completely surround the storage volume 8, but instead delimit the permeation path 26 on both sides.

[0066] FIG. 2 shows an enlarged illustration of the connecting area 24 from FIG. 1. As is apparent from FIG. 2, a length 1 of the permeation path 26 is more than twice the width b of the permeation path 26. The width b of the permeation path 26 corresponds to the distance between the barrier layers 14, 18 in the connecting area 24. Thus, according to the first exemplary embodiment, diffusion-related emissions of the fuel 10 occur through the material of the first support layer 12 into the surroundings U via the permeation path 26.

[0067] FIG. 3 shows another exemplary embodiment of a liquid container 28 according to the invention. The liquid container 28 is a plastic fuel container 28 for a motor vehicle. In the following description, identical features with reference to FIG. 2 are assigned the same reference numerals. Therefore, to avoid repetition, only the differences from the first exemplary embodiment are discussed.

[0068] The first support layer 12 of the liquid container 28 has a molded element 32, a connecting part 34, and a functional unit 36 on a side 30 facing the storage volume 8. The molded element 32 has been formed in one piece with the first support layer 12 in the injection molding process, and may be used to reinforce the structure. In the present case the connecting part 34 is a clip that may be used to fasten functional units inside the liquid container 28. The clip 34 has been subsequently integrally joined to the support layer 12 formed in the injection molding process. This similarly applies for the functional unit 36, which in the present case may be a pressure sensor or a filling level sensor, for example.

[0069] The molded element 32, the connecting parts 34, and the functional unit 36 extend with a protrusion into the storage volume 8. In the present example of the liquid container 28 according to FIG. 3, all molded elements 32, connecting parts 34, and functional units 36 situated in the storage volume, each of which is illustrated by way of example, are provided on the first support layer 12, with no molded elements, connecting parts, or functional units that are situated in the storage volume 8 being provided on the second barrier layer 18.

[0070] FIG. 4 shows another variant according to the invention of a liquid container 38. The liquid container 38 is a plastic fuel container 38 for a motor vehicle. To avoid repetition, once again only the differences in the exemplary embodiment according to FIG. 4 compared to the previously described exemplary embodiment according to FIG. 3 are discussed. Identical features are assigned the same reference numerals.

[0071] In contrast to the liquid container 28 from FIG. 3, for the liquid container 38 in FIG. 4 a plastic 40 that is used for attaching molded elements, connecting parts, or functional units is locally molded onto a side 39 of the second barrier layer 18 facing away from the second support layer 16.

[0072] The locally molded-on plastic 40 in the present case forms a pedestal 40 to which a surge tank 42 is welded.

[0073] The pedestal 40 has been produced by sequential injection molding. The barrier film 18 held in an injection mold has initially been integrally joined to the support layer 16. In a subsequent, second injection molding step the pedestal 40 has been molded onto the side 39 of the barrier layer 18 facing away from the support layer 16. In a further step the surge tank 42 has been integrally joined to the pedestal 40 by welding. It is thus possible for the surge tank 42 to be incorporated into the storage volume 8, with an interior barrier layer 18, without destroying the structural integrity of the barrier layer 18.

[0074] Further elements such as valves, Venturi nozzles, or the like may be provided on the pedestal or multiple separate pedestals or localized material moldings.

[0075] FIG. 5 shows another variant of a liquid container 44 according to the invention. The liquid container 44 is a plastic fuel container 44 for a motor vehicle. In contrast to the exemplary embodiments described above, a first barrier layer 46 and a second barrier layer 48 designed as multi-ply films 46, 48 are provided.

[0076] The first barrier layer 48 [sic; 46] has a central layer made of EVOH, which is covered on both sides by adhesion promoter layers made of LDPE. The LDPE adhesion promoter layers are in turn covered by cover layers made of HDPE. This five-ply, integrally joined film layer composite forms the first barrier layer 46. The first support layer 12 in the present case is likewise made of the HDPE of the cover layers of the first barrier layer, so that the first barrier layer 46 and the first support layer 12 have been integrally joined in the injection molding process, using the same materials. The second barrier layer 48 of the second half-shell 6 has an analogous design, and once again is internally situated on the second support layer 16.

[0077] It is understood that according to further exemplary embodiments of the invention, for example the first half-shell may be provided with a one-ply barrier layer or film, while the second half-shell may have a multi-ply or multilayer film as the barrier layer, or vice versa.

[0078] FIG. 6 shows another variant of a liquid container 52 according to the invention, in which the barrier layer 14 on the end-face side encloses, at least in sections, a web 50 that is formed on the support layer 12. The permeation path 26 of the liquid container 52 shown in FIG. 6 is thus narrowed on the end-face side due to being enclosed by the barrier layer 40 [sic; 14], in order to keep the diffusion-related emissions of fuel 10 into the surroundings U low.

[0079] FIGS. 7 through 13 show further variants of liquid containers according to the invention, which differ in particular in the geometry of the connecting areas between the half-shells.

[0080] FIG. 7 shows a liquid container 54 whose first half-shell 4 has a web 50, the web 50 being seated in a form-fit manner in a receptacle 56 in the second half-shell 6 which has a complementary shape, at least in sections. According to the exemplary embodiment in FIG. 7, the first support layer 12 of the first half-shell 4 and the first barrier layer 14 of the first half-shell 4 are made of a laser-transparent plastic, so that the second barrier layer 18, which in the present case is made of a non-laser-transparent plastic, may be welded to the first support layer 12 by laser transmission welding with the aid of a laser 58.

[0081] FIG. 8 shows another variant of a liquid container 60 which differs from the variant in FIG. 7 in that the first barrier layer 14 overlaps the second barrier layer 18. The barrier layers 14, 18 are integrally joined together in the area of the overlap.

[0082] FIG. 9 shows another variant of a liquid container 64 according to the invention, in which the first half-shell 4 forms a cover of the second half-shell 6. The first barrier layer 14 is turned down on the end-face side in the area of the circumferential web 50, so that an end-face side 62 of the web 50 is at least partially covered.

[0083] FIG. 10 shows another variant of a liquid container 68 according to the invention; in contrast to the variant in FIG. 9, the barrier layers 14, 18 in the present case are integrally joined together. Thus, the first barrier layer 14 is completely turned down around the circumferential web 50; i.e., the end-face side 62 is completely covered by the barrier layer 14, so that the barrier layers 14, 18 are welded together in the area of an overlap 66.

[0084] FIGS. 11 through 13 show liquid containers 70, 72, 74, respectively, and illustrate how the length of the permeation path 26 may be increased by optimizing the design of the connecting area 24 in order to limit the diffusion-related fuel emissions.

[0085] Of the three examples shown in FIGS. 11, 12, and 13, the shortest permeation path 26 results for the variant in FIG. 11, showing a liquid container 70. The permeation path 26 may be lengthened by orienting the web 50 at an angle with respect to a horizontal plane H (FIG. 12).

[0086] In order to design the web 50 with a longer extension along an outer side of the second half-shell 6, as illustrated in FIG. 13, the permeation path 26 may be extended farther in order to further limit the diffusion-related emissions.

LIST OF REFERENCE SYMBOLS

[0087] 2 liquid container/plastic fuel container [0088] 4 first half-shell [0089] 6 second half-shell [0090] 8 storage volume [0091] 10 liquid/fuel [0092] 11 first support layer [0093] 12 first barrier layer [0094] 14 second support layer [0095] 16 second barrier layer [0096] 20 side [0097] 22 side [0098] 24 connecting area [0099] 26 permeation path [0100] 28 liquid container/plastic fuel container [0101] 30 side [0102] 32 molded element [0103] 34 connecting part [0104] 36 functional unit [0105] 38 liquid container/plastic fuel container [0106] 39 side [0107] 40 local plastic molding/pedestal [0108] 42 surge tank [0109] 44 liquid container/plastic fuel container [0110] 46 first barrier layer [0111] 48 [second] barrier layer [0112] 50 web [0113] 52 liquid container/plastic fuel container [0114] 54 liquid container/plastic fuel container [0115] 56 receptacle [0116] 58 laser [0117] 60 liquid container [0118] 62 end-face side [0119] 64 liquid container [0120] 66 overlap [0121] 68 liquid container/plastic fuel container [0122] 70 liquid container/plastic fuel container [0123] 72 liquid container/plastic fuel container [0124] 74 liquid container/plastic fuel container [0125] l length [0126] b width [0127] H plane