FUEL TANK FOR A MOTORCYCLE

Description

[0001] The invention relates to a fuel tank (10) for a motorcycle.

[0002] It is common practice for containers for motor vehicles that have at least one visible surface to be painted, at least in the visible areas. Such a container could be, for example, a fuel tank for a motorcycle.

[0003] To achieve a high-quality appearance, such containers are made from a material that is easy to paint, for example, metal. However, these containers are expensive and heavy.

[0004] JP H10 181658 A discloses a state-of-the-art fuel tank for motorcycles.

[0005] US 2017 / 0217075 A1 describes a plastic tank to which a heat shield is welded or bonded. The heat shield may include a reflective layer of aluminum.

[0006] US2004 / 0009315 A1 reveals a plastic tank coated with an additional layer of plastic.

[0007] US Patent 3,934,747 describes a plastic container that is composed of several segments and may be painted.

[0008] WO 02 / 09924 A1 discloses a barrier film that is back-injected with a polymeric material. The barrier film may contain a metallic layer.

[0009] DE 10 2006 056 430 A1 describes a multi-part tank with two end pieces and a middle piece.

[0010] US Patent 2016 / 0039282 A1 relates to a fuel tank made of a composite material, which is attached to the underbody of a vehicle by straps incorporating fibrous material. It is therefore an object of the present invention to provide a container for a motor vehicle that is lightweight, inexpensive to manufacture, and has a surface that is easily paintable.

[0011] This problem is solved according to the invention by the features of claim 1.

[0012] This type of container has the advantage that the use of plastic segments allows for a low overall weight and lower manufacturing costs. It is possible to apply a paintable coating to only the visible plastic segments or to manufacture them from a paintable material. This results in a high-quality appearance for the customer. In particular, specific advantages of the coating can be utilized.

[0013] Dividing the plastic container into individual plastic segments also makes it easy to paint specific areas of the container. For example, the individual plastic segments can be painted before welding. This eliminates the need to mask off individual areas during painting.

[0014] It is particularly advantageous if the plastic segments are designed such that, in the assembled state of the plastic container, at least one plastic segment is almost entirely visible, while at least one other plastic segment is completely concealed. This makes it possible to provide the visible areas with a particularly high-quality surface finish, while the plastic segments in the concealed area remain free of paint or a coating and can therefore be particularly cost-effective.

[0015] The use of a detachable fastener, such as a screw, has the advantage that if the top layer is damaged, it can be replaced easily and cost-effectively.

[0016] According to one embodiment, the paintable top layer can be a metal sheet. Paints generally adhere particularly well to metallic materials. Furthermore, it is possible to customize metal sheets with a unique design. For example, the metal sheet can be engraved or painted. A customer can have their name engraved or a family crest or club logo painted onto the metal sheet. Such customization can be easily achieved through subsequent installation of the metal sheet by a retailer. Additionally, a metal sheet can improve the stability of a plastic segment. Thus, the economic advantages of plastic can be combined with the visual and structural benefits of metal.

[0017] The metal sheet preferably has a thin wall thickness. This is possible because the metal panel itself does not need to function as a container. For the same reason, a high degree of stretching can be achieved during the manufacturing of the metal panel to implement high-quality design shapes.

[0018] For example, the paintable top layer can be made of aluminum or titanium. These materials are perceived as particularly high-quality and can also remain at least partially unpainted. In a particularly cost-effective version, the paintable top layer can be made of sheet steel.

[0019] According to another embodiment, the paintable top layer can be made of or consist of plastic. For example, the paintable top layer is a molded plastic part. In this case, the plastic segment can consist of a base body and a top layer, wherein the base body has a first plastic component and the top layer has a second plastic component, which differs in composition from the first plastic component. A container with a plastic top layer can be particularly lightweight compared to a container with metallic components. Since stiffeners can be easily integrated into molded plastic parts, particularly high stability of the individual plastic segments and consequently high stability of the entire container can be achieved.

[0020] To facilitate easy mounting of the cover layer onto a plastic element, the cover layer can incorporate at least one mounting element. For example, the mounting element might include a hook. This mounting element can be used to hook or snap the cover layer onto a plastic segment. The mounting element is particularly useful for pre-assembling the cover layer, for instance, by hooking it onto the plastic segment before permanently bonding it to the segment with a fastener. Therefore, the inclusion of at least one mounting element simplifies the installation of the cover layer and reduces the number of fasteners required.

[0021] Each of the plastic segments can have at least one welding flange that circumferentially, at least partially. The welding flanges serve to join the plastic segments by means of plastic welding.

[0022] The plastic container can have at least three plastic segments, with at least one plastic segment forming a central section open on two sides and at least two further plastic segments forming lids open on one side, the lids being arranged on both sides of the central section. This has the advantage that even complex geometries of the plastic container can be implemented without the need for complex tooling.

[0023] The plastic container is a fuel tank for a motorcycle. On motorcycles, the tank is typically located between the handlebars and the seat and has a painted surface visible from the outside. The invention allows the advantages of plastic to be combined with the optical properties of metallic or other materials.

[0024] Preferably, the plastic container is at least partially covered by a cover. The cover can serve a protective function. For example, the cover is made of metal and also painted. In the case of a fuel tank, such as a motorcycle fuel tank, the cover can protect the tank from damage in the event of an impact with the ground. There is a particular risk of damage to the plastic container from stones or other sharp objects. By using a cover, the plastic container can have a thinner wall and still be protected from damage. Furthermore, repair costs can be kept low, as only the cover, and not the entire plastic container, needs to be replaced.

[0025] Further features and advantages of the invention will become apparent from the following description and from the following drawings, to which reference is made. The drawings show: Figure 1 schematically a partial section of an exemplary plastic container, Figure 2 schematically a plastic segment for a plastic container according to the invention and the Figures 3a to 3c Schematically, various process steps of a possible method for manufacturing an exemplary plastic container.

[0026] Figure 1 Figure 1 shows a partial section through a modular plastic container 10, which has at least two plastic segments 12. The plastic container 10 is a fuel tank.

[0027] The plastic segments are, for example, cost-effectively manufactured as injection-molded parts. To connect the plastic segments 12 to one another, they are welded together, for example, along at least partially circumferential welding flanges 14 by plastic welding.

[0028] A paintable top layer 16 is arranged on one of the two plastic segments 12. The paintable top layer 16 can be a metal sheet, a metal foil, a molded plastic part, a plastic film, or similar material. This makes it possible to manufacture the plastic container 10 cost-effectively and provide it with a high-quality surface finish. The paintable top layer 16 does not necessarily have to be completely painted. It is also possible to paint only a portion of the top layer 16. For example, the top layer 16 can be made of a particularly high-quality material such as aluminum or titanium. Furthermore, it is possible to engrave the top layer 16 according to customer specifications.

[0029] In the embodiment shown, the paintable top layer is back-injected and the plastic segment 12 and the paintable top layer 16 are connected to each other.

[0030] In addition to the paintable top layer 16, a cover plate 18 is arranged on the plastic container 10. The cover plate 18 can also be painted, but its primary function is protective. In particular, the cover plate 18 can be highly rigid. This allows the plastic segments 12 of the plastic container 10 located beneath the cover plate 18 to be thin, thus saving material, reducing costs, and making them lightweight. If necessary, for example, in the event of an impact on the plastic container 10, the cover plate 18 protects the underlying plastic segments 12 from damage. At the same time, the cover plate 18 simplifies repairs, as it can be easily replaced.

[0031] Figure 2 shows a plastic segment 12 for a plastic container 10, in which, unlike the one in Figure 1In the illustrated embodiment, the paintable top layer 16 is not overmolded, but rather the top layer 16 is attached to the plastic segment 12 by means of a bonding agent 20. The bonding agent is in Figure 2 This is only a schematic representation. It could be a screw or something similar.

[0032] To simplify the assembly of the paintable top layer 16 onto the plastic segment 12, the paintable top layer 16 has a mounting element 22, in particular a hook 23. The paintable top layer 16 can be pre-assembled, in particular hooked, onto the plastic segment 12 using the hook 23. This allows the connecting element 20 to be attached easily without the need for an installer to hold the top layer 16 in position during assembly.

[0033] The Figures 3a to 3cThe figures schematically illustrate various process steps of a possible method for manufacturing an exemplary plastic container 10, in particular the production of a plastic segment 12. The advantage of the described method lies in the combination of several work steps. However, it is also possible to produce the plastic segment 12 conventionally in a sequential manner.

[0034] In a first step, shown in Figure 3a , the material for a paintable top layer 16 is placed into a two-part tool mold 24.

[0035] Then, as in Figure 3b The paintable top layer 16 is shown being pressed into the cavity 28 by a plastic melt 26, which is injected into the cavity 28 at high pressure, and thereby deformed. Alternatively, the paintable top layer can be deformed before being placed in the mold 24 or before the melt 26 is injected, for example by deep drawing.

[0036] In a further procedural step, which takes place in Figure 3c As shown, the molten plastic 26 is compressed by an embossing die 30. The plastic segment 12 can then be removed from the mold 24. Any excess material can be removed by punching.

Claims

1. Fuel tank (10) for a motorcycle, comprising at least three plastic segments (12) which are connected to one another by means of plastic welding, wherein at least one of the plastic segments (12) has on its outer side a paintable cover layer (16), wherein the cover layer (16) is detachably mounted on a plastic segment (12) by means of at least one connecting means, and wherein at least one plastic segment (12) is formed as a central part open on two sides and at least two further plastic segments are formed as covers open on one side and the covers are arranged on both sides of the central part.

2. Fuel tank (10) according to claim 1, characterized in that the paintable cover layer (16) is a metal sheet.

3. Fuel tank according to claim 1, characterized in that the paintable cover layer (16) comprises plastic or consists of plastic.

4. Fuel tank (10) according to one of the preceding claims, characterized in that the cover layer (16) has at least one mounting element (22).

5. Fuel tank (10) according to one of the preceding claims, characterized in that each plastic segment (12) has at least one welding flange (14) extending at least partially around the circumference.

6. Fuel tank (10) according to one of the preceding claims, characterized in that the fuel tank (10) is covered at least in regions by a cover panel (18).