ABSTRACT
`
`The invention concerns a process for the production of an article enclosing built-in fitment
`components in the form of a hollow body of thermoplastic material. The hollow body is
`preferably in the form of a fuel tank. The process includes the extrusion of one or more
`preforms in web or tube form of plasticized material between the opened portions of a mold
`tool forming a cavity, wherein at least one built-in fitment component to be enclosed by the
`finished article is placed between the portions of the mold tool and the tool is closed around
`the preforms and the built-in fitment component, wherein the preforms within the cavity
`enclosed by the tool acquire the external configuration of the article. The built-in fitment
`component is pressed during or directly after the shaping operation against the inside wall
`of the article while still plastic so that the plastic material of the hollow body penetrates
`through at least one recess or opening of the built-in fitment component and flows
`therebehind.
`
`DONGHEE Ex. 1010 Page 1 of 14
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`

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`METHOD FOR PRODUCING A CONTAINER OF THERMOPLASTIC MATERIAL
`
`CROSS-REFERENCE TO RELATED APPLICATIONS
`
`This application claims priority to U.S. Provisional Application 60/806,487 filed Jul. 3,
`2006.
`
`FIELD
`
`The invention concerns a process for the production of a plastic hollow body and a plastic
`container.
`
`BACKGROUND
`
`A very wide range of different production processes are known for the production of hollow
`bodies of thermoplastic material, for example extrusion blow molding, deep drawing or
`injection molding. In the extrusion blow molding process the hollow body can be seamlessly
`produced for example from a single tubular preform. It will be noted that there is also the
`possibility of dividing up a tubular preform in respect of length into webs, placing the webs
`separately in a two-part or multi-part tool and expanding or shaping the webs within the tool
`by means of a reduced pressure or by the action of gas pressure.
`
`Particularly in the production of technical components such as fuel tanks which are produced
`in the above-described manner in one or more parts from thermoplastic material, it is
`necessary for various built-in fitment components or attachments to be fixed to the hollow
`body. That can be effected in the first heat in the production procedure or also subsequently.
`If the hollow body is intended to accommodate the built-in fitment components in its interior,
`it is frequently necessary, because of the size of those components, for them to be introduced
`into the hollow body in the production of the latter. The built-in fitment components and
`attachments which are to be installed or attached can be clipped or welded to the hollow
`body, in which case the welding operation can be effected in production of the hollow body
`in the first heat or subsequently in the second heat, for example by friction welding or
`welding with a heat reflector.
`
`Limits are often imposed on positively locking anchorage of a built-in fitment component in
`the interior of the hollow body, by virtue of the process for the production thereof. For
`example, when producing hollow bodies by an extrusion blow molding process, it is only
`limitedly possible to provide in the contour of the hollow body undercut configurations
`which permit built-in fitment components to be locked to the wall of the hollow body in
`positively engaging relationship. For that reason recourse is frequently had to welding as the
`joining procedure.
`
`However welding the components together suffers from the disadvantage that the plastic
`materials to be joined must form a mutually weldable material pairing. That limits the choice
`of the built-in fitment components or attachments for the hollow body.
`
`By way of example in the production of fuel tanks of plastic material that can represent a
`far-reaching limitation as certain plastic materials, in the presence of fuel, are sources or are
`
`DONGHEE Ex. 1010 Page 2 of 14
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`

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`permeable for hydrocarbons. Therefore for certain conduits and valves it is necessary to
`choose a material which from the outset excludes the possibility of welding to the tank or the
`hollow body.
`
`Therefore the object of the invention is to provide a process for the production of an article
`enclosing built-in fitment components in the form of a hollow body of thermoplastic
`material, which permits particularly simple and secure fixing of built-in fitment components
`in the hollow body in the course of the production thereof.
`
`A further object of the invention is to provide a plastic hollow body to which built-in fitment
`components or attachments are joined in positively locking relationship in a particularly
`simple fashion.
`
`SUMMARY
`
`The object is firstly attained by a process for the production of an article enclosing built-in
`fitment components in the form of a hollow body of thermoplastic material, in which one
`or more preforms in web or tube form of plasticized material are placed between the opened
`portions of a mold tool forming a cavity, at least one built-in fitment component to be
`enclosed by the finished article is placed between the portions of the mold tool and the tool
`is closed around the preforms and the built-in fitment component and the preforms within
`the cavity enclosed by the tool acquire the external configuration of the article, wherein the
`built-in fitment component is pressed during or directly after the shaping operation against
`the inside wall of the article while still plastic so that the plastic material of the hollow body
`penetrates through at least one recess or opening of the built-in fitment component and
`flows therebehind.
`
`In that way it is possible to provide for positively locking anchorage of the built-in fitment
`component to the wall of the hollow body with comparatively simple means. The inside
`wall of the hollow body passes through and flows behind an anchorage opening in the built-
`in fitment component so that, after the components have cooled, the result obtained wasis a
`positively locking non-detachable join. There is no need for compatibility of the materials
`in the sense of weldability of the parts. The built-in fitment component can also comprise
`for example metal or another material.
`
`Due to the configuration of the opening of the fitment component, the material of the wall
`of the hollow body, which flows through that opening into the fitment component,
`preferably constitutes a head which holds the join similarly to a rivet head.
`
`In a preferred variant of the process, the operation of pressing the built-in fitment
`component against the inside wall of the article is effected without lost aids which for
`example after the article is finished have to be removed therefrom again.
`
`In a particularly preferred variant of the process according to the invention the head of the
`join is produced without aids for producing a change in direction (restraining the plastic
`material of the wall of the hollow body, which flows into the opening).
`
`DONGHEE Ex. 1010 Page 3 of 14
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`

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`Desirably two preforms in web form are extruded between the opened halves of a two-part
`blow molding mold, wherein the mold halves are firstly closed against a fitment carrier
`frame arranged between them, arranged within the fitment carrier frame are means for the
`positioning of built-in fitment components, with which the built-in fitment component is
`pressed out of the plane of the frame against the inside wall of the article, and wherein in a
`further step in the process the fitment carrier frame is removed and the mold halves are
`closed against each other to finish the article. With the latter step in the process welding of
`the two halves of the article is achieved while still in the first heat.
`
`It is readily apparent to the man skilled in the art that, instead of a fitment carrier frame, it is
`also possible to provide a fitment carrier plate. In addition the fitment carrier frame does not
`necessarily have to be in the form of an open or opened element.
`
`The object of the invention is further attained by a plastic hollow body having at least one
`built-in fitment component or attachment which was joined to the hollow body in the
`production thereof, wherein the hollow body and the built-in fitment component or
`attachment are positively lockingly joined together in such a way that the built-in fitment
`component or attachment has at least one through opening in the region of its contact surface
`with the wall of the hollow body, the plastic material of the wall of the hollow body passing
`through and engaging behind the through opening.
`
`The through opening is desirably in the form of a circular round bore. Alternatively the
`through opening can be profiled, which is advantageous in particular when the built-in
`fitment component has only one through opening and a unique orientation of the fitment
`component in relation to the wall of the hollow body is wanted. Preferably the plastic material
`which passes through the through opening, in the built-in fitment component or attachment,
`forms an enlarged head which provides for positively locking anchorage of the two
`component parts.
`
`In accordance with a preferred variant of the plastic hollow body according to the invention
`it is provided that the built-in fitment component has at least one foot element which forms
`a stepped or shouldered contact surface with the wall of the hollow body. In that way the
`pressure in relation to area against the wall of the hollow body is increased in the region of
`the contact surface, with the pressing force remaining the same. The foot element or elements
`produce a ram-like action which boosts the flow of the thermoplastic material of the wall of
`the hollow body into the through opening. Desirably the through opening passes through the
`contact surface of the foot element.
`
`In a variant of the plastic hollow body it is provided that the contact surface is of a concave
`or conical configuration and the through opening forms approximately the deepest location
`of the hollow, whereby the flow movement of the plastic material of the wall of the hollow
`body through and behind the through opening is positively influenced.
`
`In a further advantageous configuration of the plastic hollow body it is provided that the
`through opening is of an undercut configuration at its end remote from the wall of the hollow
`body. The undercut configuration forms the support for the enlarged head of the projection
`formed by molten material when it has cooled down.
`
`DONGHEE Ex. 1010 Page 4 of 14
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`

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`If the plastic hollow body according to the invention is for example in the form of a fuel
`tank, then built-in fitment components of the fuel tank can be provided with a plurality of
`foot elements in the above-described manner.
`
`Thus, increasing the number and distribution of the join locations makes it possible to
`achieve a join or anchorage, which is secure for any operating condition of the vehicle, for
`the fitment components in the interior of the fuel tank.
`
`DESCRIPTION OF THE DRAWINGS
`
`The invention is described hereinafter by means of an embodiment by way of example
`illustrated in the drawings in which:
`
`FiguresFIGS. 1 and 2 are diagrammatic views of the join of a built-in fitment component to
`the wall of the hollow body, and
`
`FiguresFIGS. 3 through 12 are diagrammatic views of the production process for a fuel tank
`of plastic material according to the invention.
`
`As shown in greatly simplified form in FiguresFIGS. 1 and 2 the built-in fitment component
`1 which is shown in section has a foot element 2 with a through opening 3.
`
`As already mentioned hereinbefore the process according to the invention is described
`hereinafter by way of example with reference to the production of a fuel tank of plastic
`material. The invention however is to be so interpreted that any hollow body can be
`produced. The join can be implemented both within and also outside the hollow body. In the
`present case the built-in fitment component 1 is in the form of a surge pot in a fuel tank.
`
`The built-in fitment component 1 shown in FigureFIG. 1 is pressed with its foot element 2
`against the wall 4 of the hollow body to be produced, more specifically when the plastic
`material of the wall 4 is still or again in the plastic state. In the production process described
`hereinafter, the join is made in the first heat in production of the hollow body so that the
`material of the wall 4 is still in the molten state and, when sufficient pressure is applied to
`the foot element 2 in the direction of the arrow shown at the right in FigureFIG. 1, the
`material of the wall forms the head 5 shown in FigureFIG. 2, which engages behind the
`through opening 3 in the fitment component 1. The through opening 3 is preferably in the
`form of a circular round bore which is beveled or undercut at its end remote from the wall 4.
`
`For the purposes of improving the flow characteristics of the material which is in the plastic
`state the foot element 2 has a concave contact surface 6 through which the through opening
`3 passes centrally, that is to say at the deepest location of its hollow curvature. That
`configuration of the contact surface 6 and the foot element 2 which is stepped in relation to
`the fitment component 1 advantageously affects the flow characteristics of the molten
`material through the through opening 3. The ram-shaped, stepped configuration of the foot
`element 2 increases the pressure in relation to surface area in the region of the contact
`surface, with a given pressing force. The concave configuration of the contact surface in
`conjunction with the increased pressure in relation to surface area which occurs there
`provides that the molten material is guided into the through opening 3.
`
`DONGHEE Ex. 1010 Page 5 of 14
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`

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`On its side remote from the contact surface 6 the through opening 3 is provided with an undercut
`configuration 7 which serves as a support for the head 5. (See FIG. 2.) The latter is formed
`even if the undercut configuration 7 is not present, then it is necessary under some
`circumstances for the thickness of the foot element 2 to be selected as less.
`
`As already mentioned hereinbefore the process according to the invention is illustrated
`diagrammatically in FiguresFIGS. 3 through 12.
`
`The process according to the invention includes the production of the article 8 in the form of
`a fuel tank by extrusion blow molding.
`
`The mold tool comprises two mold halves 9a, 9b which are of a mutually complementary
`configuration and which in the closed condition define a mold cavity 10 which determines
`the external configuration of the article 8 to be finished. Placed between the mold halves 9a,
`9b is a fitment carrier frame 11 which is arranged displaceably between the mold halves 9a,
`9b. Fitment component holders 12 are arranged variably in position within the fitment carrier
`frame 11. The holders 12 are displaceable or movable within the fitment carrier frame 11
`hydraulically or pneumatically in the plane of the fitment carrier frame and transversely relative
`thereto. As shown in FigureFIG. 4 the holders 12 are equipped with fitment components 1. In the
`present case the fitment components 1 are connected together by way of a conduit (no identified
`in greater detail). Each of the fitment components is approximately of the configuration shown
`in FiguresFIGS. 1 and 2.
`
`After the fitment carrier frame 11 has been positioned between the mold halves 9a, 9b,
`preforms 13 in web form are extruded from one or more extrusion heads (not shown),
`between the opened mold halves 9a, 9b. It is equally possible for the preforms 13 not to be
`extruded at the place at which the tool is disposed but remote therefrom and to be moved to
`a position between the opened mold halves 9a, 9b with a handling apparatus.
`
`The preforms 13 extend in the position shown in FiguresFIGS. 5 and 6 between a respective
`mold half 9a, 9b and the fitment carrier frame 11. In a further step in the process the preforms
`are applied against the contour of the mold halves 9a, 9b in the mold cavity 11 by means of
`a reduced pressure. That can be effected with closure of the mold halves 9a, 9b against the
`fitment carrier frame 11 or can already have been effected previously.
`
`The preforms 13 are caused to bear completely against the contour of the mold cavity 10 by
`means of reduced pressure or also increased pressure.
`
`The component holders 12 then move out of the plane of the frame and press the fitment
`components 1 against the wall 4 of the article 8 or against the preforms which are bearing
`against the mold cavity 10. (See FIG. 7.) The above-described anchorage of the fitment
`components 1 to the wall 4 of the article 8 takes place accordingly.
`
`The fitment component holders 12 then move back into their starting position. (See FIG. 8.)
`The mold halves are moved away from each other, with the previously formed half-shell
`portions of the article 8 remaining in the mold cavity. (See FIG. 9.) The fitment carrier frame
`11 is moved away between the mold halves 9a, 9b, (See FIG. 10.) the tool closes again and
`welds the two half-shell portions of the article together.
`
`DONGHEE Ex. 1010 Page 6 of 14
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`The operations of shaping and removing the finished article 8 are diagrammatically shown
`in FiguresFIGS. 11 and 12.
`
`List of references
`
`built-in fitment component
`1
`foot element
`2
`through opening
`3
`wall
`4
`head
`5
`contact surface
`6
`undercut
`7
`article
`8
`9a, 9b mold halves
`10
`mold cavity
`11
`fitment carrier frame
`12
`fitment component holder
`13
`preforms
`
`CLAIMS
`
`1. A process for the production of an article enclosing built-in fitment components wherein
`the article is in the form of a hollow body of thermoplastic material, in whichwherein one or
`more preforms in web or tube form of plasticized material are placed between the opened
`portions of a mold tool forming a cavity, at least one built-in fitment component to be
`enclosed by the finished article is placed between the portions of the mold tool and the tool
`is closed around the preforms and the at least one built-in fitment component and the
`preforms within the cavity enclosed by the tool acquireare shaped to form the external
`configuration of the article, wherein the built-in fitment component is pressed during or
`directly after the shaping operation against thean inside wall of the articlepreform while still
`plastic so that the plastic material of the hollow bodypreform penetrates through at least one
`recess or opening of the built-in fitment component and flows therebehind.
`
`2. A process as set forth in claim 1 characterized in that the operation of pressing the built-
`in fitment component against the inside wall of the articlepreform is effected without lost
`aids.
`
`3. A process as set forth in one of claimsclaim 1 and 2 characterized in that two preforms
`in web form are extruded between the opened halves of a two-part blow molding mold tool,
`
`DONGHEE Ex. 1010 Page 7 of 14
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`wherein the mold halves are firstly closed against a fitment carrier frame arranged between
`them, arranged within the fitment carrier frame are means for the positioning of said at least
`one built-in fitment components, with which thewherein said at least one built-(cid:173) in fitment
`component is pressed out of the plane of the frame against the inside wall of the
`articlepreform, and wherein in a further step in the process the fitment carrier frame is
`removed from between the mold halves and the mold halves are closed against each other to
`finish the article.
`
`4. A plastic hollow .body having at least one built-in fitment component or attachment
`which was joined to the hollow body in the production thereof, wherein the hollow body and
`the built-in fitment component or attachment are positively lockingly joined together in such
`a way that the built-in fitment component or attachment has at least one (2.) through opening
`(3) in the region of a contact surface (6) with the wall (4) of the hollow body, the plastic
`material of the wall (4) of the hollow body passing through and engaging behind the through
`opening.
`
`5. A plastic hollow body as set forth in claim 4 characterized in that the built-in fitment
`component or attachment has at least one foot element (2) which forms a stepped or
`shouldered contact surface (6) with the inside wall (4) of the hollow body.
`
`6. A plastic hollow body as set forth in claim 54 characterized in that the through opening
`(3) passes through the contact surface (6) of the foot element (2)..
`
`7. A plastic hollow body as set forth in one of claims 4 through 6claim 4 characterized in
`that the contact surface (6) is of a concave or conical configuration and the through opening
`(3) forms approximately the deepest location of the hollow.
`
`8. A plastic hollow body as set forth in one of claims 4 through 7claim 4 characterized in
`that the through opening (3) is of an undercut or beveled configuration at its end remote from
`the wall (4) of the hollow body.
`
`DONGHEE Ex. 1010 Page 8 of 14
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`Figures of Borchert Provisional
`Application
`
`Figures of Borchert
`
`DONGHEE Ex. 1010 Page 9 of 14
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`DONGHEEEx.1010 Page 10 of 14
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`DONGHEE Ex. 1010 Page 10 of 14
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`DONGHEEEx.1010 Page 11 of 14
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`DONGHEE Ex. 1010 Page 11 of 14
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`DONGHEEEx.1010 Page 12 of 14
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`DONGHEE Ex. 1010 Page 12 of 14
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`DONGHEEEx.1010 Page 13 of 14
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`DONGHEE Ex. 1010 Page 13 of 14
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`DONGHEEEx.1010 Page 14 of 14
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`DONGHEE Ex. 1010 Page 14 of 14
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