Parison Insertion Frame for Tear-Free Plastic Tank Components
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Solution Overview
Problem
The insertion of devices such as noise or slosh baffles, internal reinforcement elements, valves, ventilation or fluid lines, and sensors into a parison for manufacturing plastic tanks for motor vehicles often results in production defects due to direct contact with the parison, leading to tears or the need for larger extrusion heads and increased plastic waste.
Innovation Solution
A method involving a component with deflection means, such as a slide, that guides the parison's movement during insertion, reducing the distance between the parison and the device without increasing the extrusion head size, using materials with higher melting points and lower friction to prevent tearing and waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a tank component is made from a single material to simplify manufacturing, then manufacturing complexity is reduced, but resistance to different types of damage (mechanical, thermal, chemical) is insufficient
Solution Approach 1:
The tank component employs a composite structure consisting of a thermoplastic base material reinforced with a fibrous reinforcement material. This composite construction provides enhanced mechanical strength, thermal resistance, and chemical resistance compared to single-material alternatives, while maintaining manufacturability through integrated molding processes.
Solution Approach 2:
The patent applies different materials and structural characteristics to different regions of the tank component. The wall thickness varies across different areas, and specific reinforcement patterns are applied where needed, allowing optimal performance in each location without uniformly increasing complexity throughout the entire component.
2Productivity
If cooling channels are added to the injection molding process to improve cooling efficiency, then production time is reduced, but the structure becomes more complex and costly
Solution Approach 1:
The cooling channels are integrated directly into the tank component's wall structure during the injection molding process. This merging of the cooling system with the product structure eliminates the need for separate cooling apparatus, reducing overall system complexity while maintaining high cooling efficiency and productivity.
Solution Approach 2:
The thermoplastic material itself serves as an intermediary that incorporates the cooling channels. The material's inherent properties allow it to be molded with internal channels that facilitate efficient heat removal during the injection molding process, bridging the gap between product structure and cooling function.
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 minimizes production defects and waste by allowing safe insertion of components while maintaining the parison's integrity, ensuring efficient manufacturing with reduced scrap rates.
Implementation Method 1
a thermoplastic material which is processed by injection molding
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a component (1) for a plastic tank for a motor vehicle. According to the invention, such a component (1) is suitable for being inserted into a parison (2) during the manufacture of the plastic tank for a motor vehicle, the component (1) having at least one dimension, in at least one plane perpendicular to the direction of extrusion of the parison, which is substantially equal to or greater than the minimum distance between two opposing points located on a solid inner wall of the parison in said at least one perpendicular plane, and the component (1) comprises a frame (10) comprising a first deflection means (11) comprising at least one surface (110) suitable for coming into contact with and guiding the travel of the parison when the component (1) is inserted into the parison (2).