Thermoplastic Fuel Tank Blow Moulding for Internal Component Insertion
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Solution Overview
Problem
Current manufacturing methods for thermoplastic tanks in vehicles are limited by the shape of internal components that must be inserted into a closed tubular parison during blow moulding, leading to issues such as improper shaping and uneven pressure, which can result in defects.
Innovation Solution
A blow moulding tool with at least one insertion pin and a mould comprising displaceable spacers that allow for the insertion and positioning of components within the closed tubular parison, enabling the creation of a void space for the insertion pin to align with welding means, thus facilitating the integration of larger or thicker components without damaging the parison.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a component is inserted into the closed tubular parison during blow moulding, then the thermoplastic tank can be manufactured with integrated components, but the component must keep clearance to the parison to avoid bulging or wrapping
Solution Approach 1:
A support member is introduced as an intermediary element between the component and the parison wall. This support member provides temporary structural support during the blow moulding process, allowing larger or thicker components to be positioned closer to the parison without causing bulging or wrapping defects. The support member acts as a mediator that enables closer positioning while preventing harmful deformation.
Solution Approach 2:
The component is positioned and secured to the parison before the blow moulding process begins. This preliminary positioning ensures the component is firmly attached and properly aligned prior to expansion, preventing movement or misalignment during the blowing process that could lead to shape defects.
2Loss of substance
If the component is positioned close to the walls of the closed tubular parison, then material usage is reduced, but uneven pressure during blow moulding causes defects
Solution Approach 1:
The support member serves as a mediator that distributes the pressure evenly across the component and parison interface during blow moulding. By providing a larger surface area contact point, the support member prevents localized stress concentrations that would otherwise occur when components are positioned close to the parison walls, thereby maintaining uniform pressure distribution and preventing defects.
3Adaptability or versatility
If larger or thicker components are used, then the functionality of the thermoplastic tank is improved, but the closed tubular parison may bulge or wrap during insertion
Solution Approach 1:
The support member acts as a protective intermediary between larger or thicker components and the parison wall during insertion and positioning. This intermediary structure prevents the component from directly contacting and deforming the parison, allowing the use of larger, more functional components without compromising the structural integrity or shape of the parison.
4Ease of manufacture
If the component is inserted through the opening at the distal end of the closed tubular parison, then the component can be integrated into the tank, but the insertion process may damage the parison
Solution Approach 1:
The component is positioned and secured to the parison through the distal end opening before the blow moulding process begins. This preliminary action allows for careful, controlled insertion and positioning without the risks associated with forcing components into the expanded tank after moulding. The component is firmly attached in its final position prior to expansion, ensuring integration without damage.
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 solution allows for the production of thermoplastic tanks with improved shape accuracy and reduced material usage, while minimizing the risk of defects and deformation, thereby enhancing the efficiency and cost-effectiveness of the manufacturing process.
Implementation Method 1
the first displaceable spacer and the second displaceable spacer configured to move into each of a first position, a second position and a third position on an axis substantially perpendicular to an extrusion direction of the closed tubular parison
Implementation Method 2
the third displaceable spacer being configured to surround the at least one insertion pin and to create a void space inside the closed tubular parison allowing the at least one insertion pin to move and be positioned into alignment
Implementation Method 3
the mould comprises at least a first mould portion and a second mould portion and the mould portions each comprise a cavity with at least one welding means
Data Source
Figure 1~2
Figure 3A~3B
Figure 4A~4B
AI summary
The present invention relates to a blow moulding tool (100) for manufacturing a thermoplastic tank for a vehicle comprising: at least one insertion pin (102) configured to position at least one component (104) through an opening at a first distal end (105) of a closed tubular parison (106); a mould configured to receive the closed tubular parison (106); a first and a second displaceable spacers (116, 118) arranged on a periphery of a cavity (112, 113) of a first mould portion (108) and a second mould portion (110), respectively; the first and the second displaceable spacers (116, 118) configured to move into three positions (open, partially-open and closed) on an axis substantially perpendicular to an extrusion direction of the closed tubular parison (106); When the blow moulding tool (100) is partially-open, the first and the second displaceable spacers (116, 118) are configured to receive a third displaceable spacer (120) in a region between the first and the second displaceable spacers (116, 118).