Process for manufacturing a fuel tank

1. A process for manufacturing a plastic fuel tank equipped with a component, by molding a parison using a mold comprising two cavities and a core, said process comprising the following steps:

A) introducing a parison into the mold cavities;

B) introducing the core inside the parison, said core having first been fitted with a component;

C) closing the mold so that the cavities come into leaktight contact with the core;

D) pressing the parison against the cavities by blowing through the core and/or applying a vacuum behind the cavities;

E) installing the component on the inner wall of the parison using a device attached to the core;

F) opening the mold in order to withdraw the core; and

G) finally, molding the parison by blow-molding and/or thermoforming;

wherein step B comprises mounting the component around a needle or an oblong object comprising a cutting device, attached to the core, and wherein step E comprises the following steps:

E1) displacing the needle or cutting device so as to first deform the parison and after, piercing an opening into it, the needle or oblong object carrying the component with it in order to position the component in the opening; and

E2) withdrawing the needle or oblong object, leaving the component lodged in the opening.

2. The process according to claim 1 , wherein the deformation of the parison creates a flange towards the outside of the tank, and wherein said flange, the component and the needle/oblong object are received in a hole of suitable size and shape in one of the mold cavities, which is created by retraction of a moving part into said hole.

3. The process according to claim 1 , wherein the parison is made up of two separate pieces originating from one and the same extruded tubular parison that is cut over its entire length, along two diametrically opposed lines.

4. The process according to claim 1 , wherein the needle or oblong object is movably mounted relative to the core.

5. The process according to claim 1 , wherein the component is a filler neck, a ventilation pipe, an OBD line, or an electrical connector.

6. The process according to claim 1 , wherein the component comprises a passage that has a diameter similar to the diameter of the base of the needle or the oblong object, and through which passage the needle/cutting device pierces the parison, while the deformation of the parison is mainly induced by the component itself.

7. The process according to claim 6 , wherein the passage is closed when the component is mounted on the needle/oblong object, and wherein said passage is only pierced when the needle/oblong object pierces the parison.

8. The process according to claim 1 , wherein the component is a filler neck integrating an ICV (Inlet Check Valve) comprising a flapper door.

9. The process according to claim 8 , wherein step E comprises the following sub-steps:

a plunger bearing a cutting device in retracted position, is introduced into the filler neck while its flapper door is open;

the assembly is pushed by the core against the parison, inside a hole in one of the mold cavities so as to compression mold an integrated flange recovering the filler neck;

the cutting device is moved forward and cuts an opening through the end of the filler neck and through the parison on top of it; and

the plunger bearing the parts cut off from the parison is retracted.

10. The process according to claim 9 , wherein the parts cut off from the parison are removed from the cutting device, and wherein the plunger and its cutting device are re-used in said process.

11. The process according to claim 10 , wherein during step G, which is a blow-molding operation, a plug is used to close the opening which has been cut into the filler neck.

12. The process according to claim 9 , wherein the plunger only makes a precut and the tip of the filler neck is only completely opened after the tank molding, during a secondary (finishing) operation.

13. The process according to claim 12 , wherein the flapper door rest against a seal which is located in a gutter molded in the ICV, the height of which being adapted in order to limit the compression of the seal during step G.