The present invention relates to a process for manufacturing a plastic fuel tank (FT).

Fuel tanks on board vehicles of various kinds generally have to meet sealing and permeability standards in relation to the type of use for which they are designed and the environmental requirements that they have to satisfy. At the present time, both in Europe and throughout the world, there is a substantial tightening of the requirements regarding the limitation of pollutant emissions into the atmosphere and into the environment in general.

To limit these emissions, care is taken in particular to position the accessories (ventilation lines, valves, baffles, stiffeners, etc.) inside the tank and/or the fill pipe (see in particular Application WO 2004/024487 in the name of the Applicant). However, when these components are fastened to the tank after it has been moulded, it is generally necessary to make at least one opening in the tank so as to be able to introduce said components into the tank and to fasten them thereto. Hence there may be potential sealing problems near this opening.

Several years ago the Applicant therefore developed a process of initially moulding a cut parison (cut into 2 sections) in order to be able to introduce thereinto and fasten thereto accessories during the actual moulding of the tank and to thus avoid drilling openings (see Patent EP 1 110 697 in the name of the Applicant).

The Applicant has also developed a particular method for this fastening (in situ snap-riveting, the subject of Applications WO 2006/008308, FR 0756411 and PCT/EP2007/051326, the content of which is also incorporated by reference into the present application).

This technique, which is common in the field of metallurgy and that consists in moulding a rivet in situ, from molten material that has been allowed to flow in and/or through an orifice of the part to be fastened and then that is left therein to solidify so as to form in situ a snap rivet or sort of rivet/bolt, has, however, several drawbacks.

The Applicant has specifically observed that in order for the material to be able to effectively flow into the snap-riveting orifice and optionally to overflow therefrom, it is necessary that this orifice has a diameter greater than 1 cm, even at least equal to 2 cm. A single fastening point is not generally sufficient to obtain a reliable fastening (to obtain therefrom one having a perfect isostatism, it is ideally necessary to provide 3 fastening points that unequivocally define a fastening plane for the part, thus avoiding an unsatisfactory fastening). Hence, this technique is not suitable for parts of small dimensions.

Moreover, in the case where the parts to be fastened are heavy, if it turns out in practice that the number of snap-riveting orifices is not sufficient to be able to support the weight of the part without damaging the parison or the wall of the tank, it will be necessary to profoundly modify the mould of the injection- moulded part, the mould of the FT and the snap-riveting tool in order to insert therein 1 or 2 supplementary snap rivets.

The Applicant has hence had the idea of providing said part with protuberances of small dimensions so that, when it is fastened by snap riveting to the parison that will be moulded in the shape of an FT, these protuberances will at least partially melt to form a local weld (i.e. a molecular entanglement of their molecules with those of the inner surface of the wall of the tank).

For this purpose, the invention relates to a process for manufacturing a plastic fuel tank equipped with an internal accessory, by moulding a parison using a mould comprising two cavities and a core, said process comprising the following steps :

1. the parison is introduced into the mould cavities ;

2. the core is introduced inside the parison, said core having first been fitted with the accessory ; 3. the mould is closed so that the cavities come into leaktight contact with the core ;

4. the parison is pressed against the cavities by blowing through the core and/or applying a vacuum behind the cavities ;

5. the accessory is fastened to the parison by snap riveting using a device attached to the core ;

6. the mould is opened to withdraw the core ; and

7. the final moulding of the parison is carried out by blow moulding

(by injecting a pressurized fluid inside the parison) and/or thermo forming (by applying a vacuum behind the cavities), wherein the accessory comprises an orifice for the snap riveting and at least one protuberance, for which the constituent material, the dimensions and the position are such that during the fastening of the accessory by snap riveting, this protuberance will at least partially melt to form a local weld which is at another location than the obtained rivet (so that two different attachment points are obtained). The expression "fuel tank" is understood to mean an impermeable tank, able to store fuel under diverse and varied usage and environmental conditions. An example of this tank is that with which motor vehicles are fitted.

The fuel tank according to the invention is made of plastic.

The term "plastic" means any material comprising at least one synthetic resin polymer.

Any type of plastic may be suitable. Particularly suitable plastics belong to the category of thermoplastics.

The term "thermoplastic" is understood to mean any thermoplastic polymer, including thermoplastic elastomers, and also blends thereof. The term "polymer" is understood to mean both homopolymers and copolymers

(especially binary or ternary copolymers). Examples of such copolymers are, non-limitingly : random copolymers, linear block copolymers, other block copolymers and graft copolymers.

Any type of thermoplastic polymer or copolymer, the melting point of which is below the decomposition temperature, is suitable. Synthetic thermoplastics having a melting range spread over at least 10 degrees Celsius are particularly suitable. Examples of such materials include those that exhibit polydispersion in their molecular weight.

In particular, it is possible to use polyolefϊns, thermoplastic polyesters, polyketones, polyamides and copolymers thereof. A blend of polymers or copolymers may also be used ; similarly it is also possible to use a blend of polymeric materials with inorganic, organic and/or natural fillers such as, for example but non-limitingly : carbon, salts and other inorganic derivatives, natural or polymeric fibres. It is also possible to use multilayer structures composed of stacked and joined layers comprising at least one of the polymers or copolymers described above.

One polymer that is often used is polyethylene. Excellent results have been obtained with high-density polyethylene (HDPE).

The wall of the tank may be composed of a single thermoplastic layer, or of two layers. One or more other possible additional layers may, advantageously, be composed of layers made of a barrier material to liquids - A -

and/or gases. Preferably, the nature and thickness of the barrier layer are chosen so as to minimize the permeability of liquids and gases in contact with the internal surface of the tank. Preferably, this layer is based on a barrier resin, that is to say a resin that is impermeable to the fuel such as, for example, EVOH (a partially hydro lysed ethylene/vinyl acetate copolymer). Alternatively, the tank may be subjected to a surface treatment (fluorination or sulphonation) for the purpose of making it impermeable to the fuel.

The tank according to the invention preferably comprises an EVOH-based barrier layer located between the HDPE-based outer layers. According to the invention, the tank is produced by moulding a parison.

The term "parison" is understood to mean a generally extruded preform of molten plastic that is intended to form the wall of the tank after moulding to the required shapes and dimensions. This preform does not necessarily have to be a one-piece preform. Thus, advantageously, the parison is in fact made up of two separate pieces, which may be two sheets, for example. However, these pieces preferably result from cutting one and the same extruded tubular parison as described in the aforementioned Application EP 1 110 697, the content of which is, for this purpose, incorporated by reference in the present application. According to this variant, once a single parison has been extruded, this parison is cut over its entire length, along two diametrically opposed lines, to obtain two separate portions (sheets).

Compared with the moulding of two separately extruded sheets, of constant thickness, this approach allows the use of parisons having a variable thickness (that is to say a thickness that is not constant over their length), which are obtained by a suitable extrusion device (generally an extruder provided with a die having a positionally-adjustable mandrel). Such a parison takes account of the thickness reduction that occurs during moulding at certain points on the parison, as a result of non-constant levels of deformation of the material in the mould.

After a parison has been moulded in two pieces, these pieces generally form the lower and upper walls respectively of the fuel tank, each having an inner surface (pointing towards the inside of the tank) and an outer surface (pointing towards the outside of the tank). The mould used in the process according to the invention comprises a core, i.e. a part of suitable size and shape for being able to be inserted between the cavities of the mould when the parison is located therein and to fasten thereto the components inside the tank without the edges of the parison being welded (since the core must be removed before the final moulding of the tank, a step during which the welding of the parison sections is carried out). Such a part (core) is, for example, described in Patent GB 1 410 215, the content of which is for this purpose incorporated by reference into the present application.

This mould also comprises two cavities that are intended to be in contact with the outer surface of the parison, the parison being moulded by blow moulding (pressing the parison against these cavities using a pressurized gas injected inside the parison) and/or by thermo forming (drawing a vacuum behind the mould cavities).

Preferably, it takes place by blow moulding, but preferably while also providing suction (drawing a vacuum) behind the cavities to keep the parison in the mould when the latter is not closed and pressurized. Hence, it preferably comprises a degassing step prior to step (6). Generally, in order to do this the parison is first pierced (for example by puncturing it with a needle) and then the fluid is discharged from the mould (for example using a valve).

In the process according to the invention, the accessory is fastened to the inner surface of the parison by virtue of a device attached to the core that generally comprises a jack. Preferably, the core allows several accessories to be fastened to the inside of the tank, these accessories preferably being preassembled on the core, before it is inserted into the mould, at their corresponding location on the parison (see the aforementioned Application WO 2007/000454). According to the invention, the accessory is fastened both by snap riveting at at least one point and by a local weld at at least one other point. For this purpose it is equipped with at least one orifice (generally of substantially circular or oblong cross section) for the snap riveting and with at least one protuberance for the local weld. This protuberance must be situated at a location and have dimensions such that during the snap riveting it at least partially melts in contact with the molten plastic that constitutes the parison and optionally penetrates therein, whilst the portion of the accessory surrounding said protuberance does (almost) not melt (if it is optionally not at the surface depending on its constituent material). This portion therefore acts as a stop surface making it possible to limit the overall penetration of the accessory into the molten parison (and by doing so, to prevent the barrier layer of the FT from being damaged, where appropriate).

In the case where the FT has a multilayer structure that includes a barrier layer, the dimensions and the shape of the protuberance are preferably such that the latter does not pierce the barrier layer. In particular, it is preferable that the protuberance does not protrude (does not stick out) by more than 2 mm, or even 1.5 mm relative to the surface of the accessory.

According to one variant that is particularly preferred (since it reduces the distortions that may occur following the local compression of the material during snap riveting and/or following the shrinkage of the parison after it has cooled), the snap riveting takes place to the right of a relief (a sort of dome) in the wall of the tank, which is concave when seen from the outside of the tank and convex when seen from the inside. In practice, this relief may be produced with the aid of a boss in the cavities of the mould. Its dimensions are dependent on the geometry of the tank and of the accessory, in particular in the area of the snap- riveting orifice. Generally, it has a diameter of a few centimetres, for example of 2 to 5 cm, and a height ranging from 1 to 15 mm, preferably from 2 to 8 mm.

In this variant, the snap-riveting zone of the accessory is preferably set back relative to the welding zone so that, when the accessory is brought into contact with the parison in order to be fastened thereto, the snap riveting in the zone in relief (dome) and the welding take place simultaneously.

The accessory according to the invention may be made of any material suitable for its function, on condition that the aforementioned protuberance is made of a material identical to or compatible with that of the inner surface of the tank in order to be able to achieve the local weld. Most particularly preferably, it is a similar polymer (of the same nature, for example HDPE), but that preferably has a higher melt flow index (MFI) than that of the tank so as to melt thereon more easily. According to one advantageous variant of the invention, the accessory comprises at least one portion based on a material that has a thermal resistance greater than that of the tank (for example : based on PA (polyamide) or on POM (polyoxymethylene) when the tank is made of HDPE).

When the accessory is based on a material identical to or compatible with that of the tank, the protuberance may be moulded from one part with it. However, according to one preferred variant, the protuberance belongs to a part attached to the accessory. One way of achieving this consists in making an orifice in the part (either during the moulding of this part, or via subsequent machining, which is generally more practical) inserted through which is a part that for ease will subsequently be described as a "clip". This variant has the advantage that the accessory may be made of any material ; it is enough for the clip to be made from a material compatible with that of the FT.

In this variant, the clip may have any shape. Generally, it comprises a cover (dome) that constitutes or includes the protuberance itself and that generally has a substantially circular cross section. It may be a plate that has a flat surface and a tapered, optionally curved, edge, or a thin crown (or ring) that preferably has its two edges curved to double the bond strength of the weld. An embodiment that gives good results when the clip is shaped like a "solid" plate (and not like a ring) consists in providing the edge of the clip with a kind of tongue in order to enable what is called the "flower test" and hence, enable the testing of the quality of the weld. This test is a destructive test consisting in cutting two welded components in equal parts (for instance, 8 or 16 parts) and in trying to separate the welded components by tearing them apart (manually or with a tension machine). If the parts break in one of the components, then the weld is of good quality. On the contrary, if they break inside the weld, then it is a bad or so called "cold" weld.

The accessory fastened by the process according to the invention may comprise sorts of welding spots preferably that are uniformly distributed over the welding clips and/or over the part itself (when it is made of a material compatible with that of the FT).

In the case where the size and the weight of the accessory allow it, in order to obtain a robust and isostatic fastening, use will preferably be made of at least 3 fixation points and more preferably, of a snap rivet and 2 welded clips to fasten it. More fastening points may be required depending on the size and/or the weight of the accessory. Generally, the latter (i.e. their number, nature (snap rivet or weld) and location) are determined experimentally. They are generally spread homogeneously at the surface of the accessory which will be in contact with the inner tank wall. The present invention also relates to an FT equipped with an accessory fastened to its inner wall using at least one snap rivet and at least one weld that is delocalized with respect to said snap rivet. By "delocalized" is meant located somewhere else on the accessory, in an area remote enough to be considered as a different fixation point. This accessory may be any accessory. It may be, for example, a valve, a pump/gauge module, a liquid/vapour separation vessel, etc. The invention gives good results with pump/gauge modules or the support thereof.

The invention is illustrated non-limitingly by the appended Figures 1 to 6. In these figures, the dimensions are given by way of example and identical numbers denote identical or similar components. Appended Figures 1 to 4 illustrate preferred geometries for the welding clips mentioned above, and Figures 5 and 6 illustrate two different views of one and the same accessory intended for the process according to one variant of the invention.

The clips illustrated in Figures 1 to 4 all comprise fastening tabs (1) that are intended to be inserted into an orifice of the accessory to be fastened (not represented) and a cover that has the shape :

- of a plate (2) with a tapered edge (3) in the variant from Figures 1 and 4 ;

- of a plate (2') with a curved tapered edge (3 ') in the variant from Figure 2 ;

- of a crown (2") with a double curved edge (3") in the variant from Figure 3, which is preferred as it doubles the bond strength of the weld (due to the double weld obtained).

In the variant illustrated in Figure 4, the clip also comprises spots (4) that are evenly distributed over the plate (4) and that will create additional local welds reinforcing the bond strength of the clip. This variant is therefore also preferred.

The accessory illustrated in Figures 5 and 6 is a gauge support that comprises a snap-riveting orifice (5) and reliefs or welding platforms (6) positioned on a stop surface (7), the purpose of which is to limit the penetration of the accessory into the molten plastic. As can be seen in this figure, the snap- riveting zone surrounding the orifice (5) is set back by 1 mm relative to the stop surface (7) so that the snap riveting can be carried out at the same time as the welding, despite the fact that it takes place over a zone in relief (dome) of the parison. To the right of this zone, the cavities of the mould (not represented) have a boss, i.e. a zone in relief of complementary shape.