• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:

    公开号:NL2004926A
    申请号:NL2004926
    申请日:2010-06-21
    公开日:2010-12-27
    发明作者:Ulrich Borchert；Jens Skowronek
    申请人:Benteler Automobiltechnik Gmbh；
    IPC主号:
    专利说明:

    METHOD FOR MANUFACTURING A FUEL TANK
    The invention relates to a method for manufacturing a fuel tank with the features of claim 1.
    It is known to provide fuel tanks of motor vehicles with leak-proof casings. Such jackets, after ballistic action by projectiles or fragments, should help to minimize fuel escaping from the fuel tank to prevent ignition of the vehicle subfloor caused by fire shafts or other sources of ignition. The aim is to provide time for the occupants of the motor vehicle to remove the motor vehicle from the danger zone and to reduce the general danger of ignition of the motor vehicle.
    It is well-known in the art to coat motor vehicle series tanks with one or more separate layers of a rubber or rubber-based material. Certain rubber compositions swell on contact with fuels, such as gasoline or diesel. This feature can be used to close openings.
    The rubber composition is usually applied by applying separate part pieces, so that overlaps and / or material seams are created, which can lead to different material thicknesses and therefore to fluctuations in the method of operation. In order to provide the elastomer layer with sufficient support, a second layer, a so-called protective jacket, consisting of plastic or resin, is applied, which may also be partially fabric-reinforced. As a rule, the application of the plastic or resin layer also takes place manually. A disadvantage of this is that irregularities occur on the outer surface of the series tank thus encased. That is, the process safety with this manufacturing method is relatively low. Fluctuations in material strength occur automatically due to manual manufacturing. However, since the fuel tank is surrounded by various attachments and aggregates, a uniform geometry with the same material thickness as possible is pursued.
    DE 28 53 784 A1 can be mentioned as a state of the art which relates to a flexible self-sealing wall, wherein two or more layers of an elastomer are in surface contact with each other and are mutually connected at spaced points, that the layers between these points can move freely relative to each other, so that smaller holes are closed off by shifting the layers relative to each other. The elastomer layers used are formed into a fuel tank by bluntly joining the cutting edges of the material used, either with an adhesive or by vulcanization.
    DE 297 00 151 UI describes a safety tank as it is used with motor vehicles and in particular with racing vehicles. A multi-part outer shell is preferably produced, for example from a composite material. A prefabricated inner tank made of rubber, which is not yet vulcanized, is placed in the outer shell and vulcanized after the outer shell is closed.
    By WO 2007/045466 A1, fuel tanks for vehicles belong to the state of the art, which have a multi-layer structure. An inner tank consists of a thermoplastic material that is provided to come into contact with the fuel. An intermediate layer consists of a composite material. A top layer is applied to the intermediate layer. The top layer can be a lacquer layer or a paint layer, to protect the surfaces of the layers below.
    Based on this, the object of the invention is to provide a method for manufacturing a fuel tank with which it is possible to form a uniformly thick and uniformly effective elastomer layer, so that as a result the outer geometry of the fuel tank is as even as possible. .
    This objective is achieved by a method with the measures of claim 1.
    Advantageous further embodiments of the idea of the invention are the subject of the subclaims.
    In the method according to the invention, an elastomer layer of a rubber mixture is applied on the outside on an inner shell which serves to receive a fuel, such as for instance gasoline or diesel. The rubber mixture has the property of swelling on contact with the fuel. This elastomer layer is then surrounded with a protective jacket. The fuel tank provided with the protective jacket is subsequently vulcanized at temperatures between 80 ° C and 180 ° C over a period of 2 to 36 hours, in particular at 80 ° C - 120 ° C over 6 - 14 hours. The vulcanization causes the elastomer layer consisting of the rubber mixture to be homogenized.
    The rubber molecules with long chains are cross-linked by sulfur bridges under the temperature influence. The special advantage of the method according to the invention is that, due to vulcanization, overlaps and seams between individual rubber layers can be compensated, so that a homogeneous elastomer layer is provided with wall thicknesses that are as constant as possible, so that with the method according to the invention the repeat accuracy and in particular the geometric process reliability can be achieved substantially better than with non-vulcanized elastomer layers.
    When damage occurs to the fuel tank, so that fuel comes into contact with the elastomer layer, the elastomer layer, due to the resistant inner shell and the support by the protective jacket, swells essentially exclusively in the direction of the hole to be sealed, so that further discharge of fuel is prevented. In any case, the configuration according to the invention touches material of the elastomer layer in the area of the hole, as long as it is guaranteed that fuel comes into contact with the elastomer. A protective fiber material is used as the protective sheath, which is suitable for sufficiently supporting the elastomeric layer due to its high strength and rigidity.
    For the production, the fuel tank provided with the elastomer layer is arranged in a molding tool, into which the fiber composite material was previously introduced, the fiber composite material being adhered within the molding tool with the elastomer layer. In contrast to the manual application of individual resin-impregnated fabric layers to the previously applied elastomeric layer, the use of a molding tool ensures that the fuel tanks encased in this way have the same outer geometry. Moreover, the molding tool may consist of a sufficiently heat-resistant material, such as, for example, aluminum, so that the fuel tank is still vulcanized within the molding tool after the fiber-hardening material has been sufficiently cured, for example after an hour. To this end, the forming tool can be placed in a heating oven. The exact temperature control within the heating oven depends decisively on the rubber mixture used. The vulcanization preferably takes place at temperatures between 80 ° C and 120 ° C. A preferred time frame for vulcanizing to vessel from 6 hours to 14 hours. Vulcanization temperatures and times are influenced by three factors: a) the temperature resistance of the fuel tank to be protected, which consists of plastic; b) the temperature take-up of the molding tool (heating-up phase) and c) the rubber mixture used.
    The protective sheath of the fiber composite material is multi-layered. To manufacture the protective jacket, a cover layer is first applied in the forming tool to provide a smooth surface. A coupling layer is then applied to connect the cover layer with a subsequent layer of fabric. In connection with this outer fabric layer, at least one further fabric layer is applied to the outer fabric layer with the insertion of a laminating resin. Finally, an adhesion with the elastomer layer attached to the inner shell takes place using the laminating resin. This subsequent sticking takes place in that the inner shell provided with the elastomer layer is provided in the forming tool.
    To increase fire safety, an epoxy resin-based gelcoat is used as the cover layer, which, due to its higher flash point, keeps the elastomeric layer and thus the fuel tank longer fire resistant. The flash point of the gelcoat or of the cover layer is higher than the flash point of the elastomer layer.
    It has been found to be advantageous if the outer fabric layer is a glass fiber fabric. A mixed fabric is preferably used for the at least one further, inner fabric layer. This is in particular a mixed fiber made from carbon fiber and aramid fiber. It is particularly advantageous for a mixed fabric comprising 61% carbon fibers and 39% aramid fibers.
    The coupling layer preferably consists of a laminating resin that is enriched with cotton flakes.
    Just as the fiber composite material can be multi-layered, it is also possible within the scope of the invention to design the elastomeric layer in multiple layers. Here, at least one further elastomer layer is applied to an inner elastomer layer contacting the inner shell. The second elastomer layer can be applied without the use of additional adhesives, since the elastomer layers adhere directly to each other due to their adhesion forces. Taking into account that the elastomer layers thus connected are subsequently still vulcanized and already fuse with each other, there is no need to use additional adhesives.
    With the method according to the invention, it is possible to provide a leak-proof covering of fuel tanks with high process reliability, which has no weaknesses due to different material thicknesses due to overlaps and material seams and moreover has a constant, precisely defined outer geometry, so that the assembly of the fuel tank does not lead to conflicts with adjacent attachments and units.
    The invention is explained in more detail below with reference to an exemplary embodiment shown in the drawings.
    Figure 1 shows a fuel tank in perspective view;
    Figure 2 shows the fuel tank of Figure 1 in partial section; and
    Figure 3 shows a detail of the representation of Figure 2.
    Figure 1 shows a fuel tank 1, as produced by the method according to the invention as an end product. The fuel tank 1 has a complex structure adapted to the relevant vehicle geometry. The fuel tank 1 has a three-layer structure, as can be recognized below with reference to Figures 2 and 3.
    The fuel tank 1 first comprises an inner shell 2. This inner shell 2 is formed by a tank of the motor vehicle produced in series. Within this inner shell 2, the fuel to be carried for the motor vehicle is included. This inner shell 2 is surrounded by a protective casing, which in turn is subdivided into an elastomer layer 3 and a protective jacket 4. Figure 3 shows in a highly simplified representation that the elastomer layer 3 is arranged between the inner shell 2 and the protective jacket 4. In the event of damage to the fuel tank 1 by bombardment, the elastomer layer 3 is provided to close the hole in the inner shell 2. This takes place in that the elastomer layer 3 is made of a rubber mixture which, upon contact with fuel, swells and thereby closes the hole created by ballistic influence.
    Reference figures: 1 - fuel tank 2 - inner shell 3 - elastomer layer 4 - protective jacket
    权利要求:
    Claims (10)
    [1]
    A method for manufacturing a fuel tank (1) with the following steps: a) an elastomer layer (3) from a rubber mixture is applied to an inner shell (2), which serves to receive a fuel; b) the elastomer layer (3) is surrounded with a protective sheath (4) made of a fiber composite material; c) the fuel tank (1) provided with the elastomer layer (3) is arranged in a molding tool, into which the fiber composite material was previously introduced, the fiber composite material being adhered within the molding tool with the elastomer layer (3); d) to manufacture the protective sheath from the fiber composite material, first a coating is applied in the forming tool, then a coupling layer is applied to connect the coating to a fabric layer which is applied to the coupling layer, the coating being an epoxy resin-based gelcoat which has a higher flash point than the elastomer layer, then at least one further fabric layer is applied with the insertion of a laminating resin, the further fabric layer being adhered to the elastomer layer (3) attached to the inner shell (2) via applied laminating resin; e) the fuel tank (1) provided with the protective jacket (4) is vulcanized at temperatures between 80 ° C and 180 ° C over a period of 2 h - 36 h.
    [2]
    Method according to claim 1, characterized in that the fuel tank (1) is vulcanized within the molding tool.
    [3]
    Method according to claim 1, characterized in that the forming tool is placed in a heating oven before vulcanizing.
    [4]
    Method according to one of claims 1 to 3, characterized in that a glass fiber fabric is used as the outer fabric layer.
    [5]
    Method according to one of Claims 1 to 4, characterized in that a mixing fabric is used as at least one further, inner fabric layer.
    [6]
    Method according to claim 5, characterized in that the mixing fabric comprises carbon fibers and aramid fibers.
    [7]
    Method according to one of claims 1 to 6, characterized in that the elastomer layer (3) is designed in a multi-layered manner, wherein at least one further elastomer layer is applied to an inner elastomer layer adhered to the inner shell (2).
    [8]
    A method according to claim 7, characterized in that the at least one further elastomer layer is connected to the preceding elastomer layer without additional adhesives.
    [9]
    The method according to any of claims 1 to 8, characterized in that the cover layer is a surface resin.
    [10]
    Method according to one of claims 1 to 9, characterized in that a cover layer is used which has a higher flash point than the elastomer layer.
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    同族专利:
    公开号 | 公开日
    DE102009030221B4|2011-04-14|
    NL2004926B1|2022-01-20|
    DE102009030221A1|2010-12-30|
    MX2010006712A|2011-06-02|
    US20110146895A1|2011-06-23|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    IT1202805B|1977-12-15|1989-02-09|Broadhurst J C|SELF-SEALING FLEXIBLE WALL ELEMENT FOR CONTAINERS|
    US4368086A|1980-03-25|1983-01-11|The United States Of America As Represented By The Secretary Of The Air Force|Method of fabricating an aircraft self-sealing fuel tank|
    US4865907A|1987-09-30|1989-09-12|Bisco Products Inc.|Rigid fire block sheet and method|
    DE29700151U1|1997-01-08|1997-02-27|Driesch Clemens|Security tank|
    ES2253127B1|2005-10-20|2007-04-01|Marketing Active Sport Markets, S.L.|FUEL TANK FOR VEHICLES.|
    AT553167T|2007-05-23|2012-04-15|Hexcel Composites Ltd|LIABILITY LAYER FOR COMPOSITE ARRANGEMENTS|DE102013004929B4|2013-03-22|2018-07-12|Kautex Textron Gmbh & Co. Kg|The working fluid container|
    法律状态:
    2012-06-13| SD| Assignments of patents|Effective date: 20120607 |
    优先权:
    申请号 | 申请日 | 专利标题
    DE102009030221A|DE102009030221B4|2009-06-23|2009-06-23|Method for producing a fuel tank|
    DE102009030221|2009-06-23|
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