Blow Molding Parison Integration for Fuel Tank Component Bonding
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Solution Overview
Problem
The existing blow molding processes for producing multilayer fuel tanks face challenges in efficiently integrating fuel system components and ensuring uniform inflation and bonding of parison halves, leading to potential defects and increased production costs.
Innovation Solution
The method involves using a blow molding apparatus with grippers, spreaders, and blow pins to stretch and inflate the parison, while introducing fuel system components during molding, and employing film or coatings to enhance bonding between mold halves, ensuring precise control over pressure and temperature to achieve a sealed and uniform product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional blow molding process is used to produce multilayer fuel tanks, then the basic molding function is achieved, but the integration of fuel system components and uniform bonding of parison halves is inefficient, leading to potential defects and increased production costs
Solution Approach 1:
The patent combines the molding of fuel tank parison halves with the integration of fuel system components into a single blow molding operation. The carrier holding multiple fuel system components is positioned within the parison before inflation, allowing components to be molded in place with the tank structure itself, eliminating separate assembly steps and improving both ease of manufacture and productivity
Solution Approach 2:
The blow molding apparatus is designed to perform multiple functions simultaneously: forming the parison halves, inflating them to desired shape, and integrating fuel system components through the carrier mechanism. This multi-functionality allows the single process to achieve what previously required multiple separate operations, directly addressing the productivity and integration efficiency contradiction
2Manufacturing precision
If traditional blow molding process is used, then the molding operation is performed, but uniform inflation and bonding of parison halves is difficult to achieve, resulting in potential defects
Solution Approach 1:
The patent applies different qualities and conditions to different regions of the parison during molding. The carrier and its interaction with the parison create localized zones with controlled properties for component integration, while the rest of the parison maintains uniform characteristics for tank wall formation. This localized control enables both precise component placement and uniform bonding without compromising overall product consistency
Solution Approach 2:
The carrier holding fuel system components is pre-positioned within the parison before the blow molding inflation occurs. This preliminary positioning ensures that components are correctly located and the parison is properly configured before the critical bonding phase, preventing defects and ensuring uniform inflation and bonding of parison halves, thereby improving manufacturing precision and product reliability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the efficient integration of fuel system components, improves the bonding of parison halves, and reduces defects, resulting in a more consistent and cost-effective production of multilayer fuel tanks with enhanced structural integrity.
Implementation Method 1
the blow pin injects pressurized gas into the interior of the parison to displace the parison into conformity with interior surfaces of the mold halves
Implementation Method 2
The spreader pins expand to stretch the hot parison in a radial direction toward mold halves
Implementation Method 3
employing film or coatings to enhance bonding between mold halves, ensuring precise control over pressure and temperature to achieve a sealed and uniform product
Data Source
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AI summary
A method of manufacturing a product, including extruding a parison (24), and separating the parison into parison halves by cutting a partially expanded parison or by pulling apart a longitudinally weakened parison, and forming the parison halves against corresponding mold halves (26). The method may also include applying a film against the parison halves and/or the mold halves, and forming the film and parison halves against the mold halves to produce multi-layer product halves. Apparatuses for performing the method are also disclosed.