Patent Description:
Vehicle washer systems require reservoirs to retain the fluid until needed. The required fluid reservoir size is increasing as more features on vehicles need washing, e.g. rear windows, headlights, etc. However, vehicle packaging space is limited for such reservoirs. Typically, washer reservoirs are injection molded using thin wall or light weight structure. The washer reservoirs then have to be welded. The current welding approach is a weld flange at <NUM> degree (perpendicular to reservoir walls). This creates a limited weld surface area and requires a minimum proximity to other components with high thermal conditions, which takes up limited packaging space within a vehicle. However, a direct fracture point at the internal weld is created that can be breached during freeze conditions, vibration testing, and from thermal shock. Such a reservoir is known from <CIT>, where a plain electrical heater is used to heat up the welding surface which have to be shaped completely planar. An alternative heating solution with hot air allows a non-planar welding surface, but requires a very complex and expensive hot air system. In a further, different reservoir infrared welding method known from <CIT>, the weld seam is irradiated through the material of the outer half-shell after the two half-shells of the reservoir have been joined, and then mechanically pressed from the outside inwards with a rubber ring. For this purpose, the outer half-shell must necessarily be made of a specific material that is partially translucent to infrared radiation.

A fluid reservoir for a vehicle comprises a first reservoir portion and a second reservoir portion, wherein the first and the second reservoir portions define a reservoir to retain fluid for a washer system. An overlapping portion of the first reservoir portion and the second reservoir portion is formed between them when the portions are secured together. The overlapping portion is a weld formed using an infrared weld apparatus.

A method of infrared welding a fluid reservoir for a vehicle comprises placing a first reservoir portion inside a first cavity defined by a first weld portion and a second reservoir portion inside a second cavity defined by a second weld portion. A first light array concentrically surrounds the first reservoir portion and a second light array is concentrically inside the second reservoir portion. The first weld position and the second weld portion are heated using the first and second light array. Then the light arrays are moved away and the first weld portion and the second weld portion are moved together until an overlapping portion is formed by the first reservoir portion and the second reservoir portion. A pair of slides are placed to concentrically surround the overlapping portion and pressurized air is applied to the reservoir to force the overlapping portion against the slides to secure the first reservoir portion and the second reservoir portion together at the weld.

An infrared weld apparatus for a fluid reservoir comprises a first weld portion defining a first weld cavity to receive a first reservoir portion and a second weld portion defining a second weld cavity to receive a second reservoir portion. A pair of slides concentrically surround an overlapping portion of the first reservoir portion and the second reservoir portion, when the first reservoir portion, first weld portion, second reservoir portion and second weld portion are assembled together. A first light array is located concentrically surrounding the overlapping portion and assembled inside the pair of slides and a second light array located concentrically inside the overlapping portion, parallel to the first light array. The first light array and second light array are configured to apply heat at the overlapping portion to weld the first reservoir portion to the second reservoir portion.

Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the disclosure, are intended for purposes of illustration only and are not intended to limit the scope of the disclosure.

The following description is merely exemplary in nature and is in no way intended to limit the disclosure, its application, or uses. For purposes of clarity, the same reference numbers will be used in the drawings to identify similar elements. <FIG> illustrate a washer reservoir <NUM> for a vehicle. The reservoir <NUM> is intended for use in a washer system for a vehicle. However, the reservoir <NUM> can also be used for other types of applications. The washer reservoir <NUM> is formed by injection molding to for a first reservoir portion <NUM> and a second reservoir portion <NUM>. The first reservoir portion <NUM> and the second reservoir portion <NUM> are partially nested together with an overlapping portion <NUM>. The first reservoir portion <NUM> may define a fluid inlet <NUM>. A fluid passage <NUM> may connect to the fluid inlet <NUM>. The fluid inlet <NUM> and fluid passage <NUM> may be used when the washer reservoir is in the vehicle to add fluid into the reservoir <NUM>. During the welding process the fluid inlet <NUM> and fluid passage <NUM> can be used to introduce pressurized air into the reservoir <NUM> as explained in further detail below.

Referring to <FIG> the washer reservoir <NUM> is shown with a welding apparatus <NUM>. The welding apparatus <NUM> has a first weld portion <NUM> and a second weld portion <NUM>. The first weld portion <NUM> defines a first cavity <NUM> corresponding to the shape of the first reservoir portion <NUM>. The second weld portion <NUM> defines a second cavity <NUM> corresponding to the shape of the second reservoir portion <NUM>. During the weld process the first reservoir portion <NUM> and the second reservoir portion <NUM> are nested in the first weld portion <NUM> and second weld portion <NUM>.

An aperture <NUM> in the first weld portion <NUM> accomodates the fluid inlet <NUM>, allowing air to pass through the fluid inlet <NUM> and fluid passage <NUM> into the washer reservoir <NUM>. An air nozzle <NUM> for the weld apparatus <NUM> can apply pressurized air into the washer reservoir <NUM>. The pressurized air forces the first reservoir portion <NUM> and the second reservoir portion <NUM> outward again the first weld portion <NUM> and the second weld portion <NUM> to hold the reservoir <NUM>, <NUM> during the weld process. The air nozzle <NUM> can be configured to match an opening into the air passage <NUM>.

Additional fluid inlets <NUM> may be used to allow pressurized air into the washer reservoir. For example, an aperture in the second portion <NUM>, which is used to allow fluid to exit the reservoir <NUM> to the washer system during use in the vehicle, may also be use to allow pressurized air into the washer reservoir <NUM> during the weld process. Other apertures may also be use to provide pressurized air during the weld process and then sealed or used for other purposes. Once skilled in the art would be able to determine the desired number of inlets <NUM> to provide pressurized air during the weld process based upon the shape, size, and process for a particular washer reservoir <NUM> and weld apparatus <NUM>.

The welding apparatus <NUM> also includes a pair of slides <NUM> which fit over the washer reservoir <NUM> at positions that correspond to the overlapping portion <NUM>. Once the first reservoir portion <NUM> an first weld portion <NUM> are positioned together with the second reservoir portion <NUM> and the second weld portion <NUM> the overlapping portion <NUM> is formed. The overlapping portion <NUM> is the targeted weld zone.

During the weld process a first infrared light array <NUM> is placed to surround the first reservoir portion <NUM> corresponding to what will be the overlapping portion <NUM> of the first weld portion <NUM>. A second infrared light array <NUM> is placed within the second reservoir portion <NUM> and also corresponds to the location of the overlapping portion <NUM> of the second weld portion <NUM>. Infrared light is applied by the first infrared light array <NUM> and the second infrared light array <NUM> to weld the first reservoir portion <NUM> to the second reservoir portion <NUM> at the overlapping area <NUM>. The light array directs the heat to the desired specific weld zone(s).

The first and the second light arrays <NUM> and <NUM> are heated until the areas which will form the overlapping portion <NUM> have reached a sufficient predetermined temperature. If necessary the first and the second light arrays <NUM> and <NUM> are then moved out of the way and the first weld portion <NUM> and the second weld portion <NUM> are moved together to form the overlapping portion <NUM>. The second light array <NUM> is located inside the second reservoir portion <NUM> and will likely need to be moved out of the way in order for the first reservoir portion <NUM> and the second reservoir portion to be assembled together. Likewise, the second light array <NUM> will likely need to be moved out of the way in order for the slides <NUM> to surround the overlapping portion <NUM>.

From the outside, once assembled the pair of slides <NUM>, are moved into position to surround the overlapping portion <NUM>. The washer reservoir <NUM> is filled with pressurized air, which forces the overlapping portion <NUM> outward against the slides <NUM>.

Using internal pressure and the moving nests <NUM>, <NUM> the welding can occur in a manner that is not typical possible using infrared or hot plate welding. This process requires both sides of the weld, i.e. upper portion <NUM> and lower portion <NUM> at the overlapping area <NUM>, to be pressed together and held using the nests <NUM>, <NUM> on both sides and pressurized air within. A perpendicular weld flange, i.e. first and second light arrays <NUM>, <NUM>, is used to provide access for the needed pressure. Placing the weld surface <NUM> in the manner proposed removes the fracture point, increases weld surface area creating a stronger weld, and allows greater flexibility to respond to thermal and dynamic conditions acting on the reservoir <NUM> when it is assembled in the vehicle.

Therefore, referring to <FIG>, a fluid reservoir <NUM> for a vehicle comprises a first reservoir portion <NUM> and a second reservoir portion <NUM>, wherein the first and the second reservoir portions <NUM>, <NUM> define a reservoir <NUM> to retain fluid for a washer system. An overlapping portion <NUM> of the first reservoir portion <NUM> and the second reservoir portion <NUM> is formed between them when the portions <NUM>, <NUM> are secured together. The overlapping portion is a weld <NUM> formed using an infrared weld apparatus <NUM>.

The infrared weld apparatus <NUM> comprises a first nest <NUM> defining a first weld cavity <NUM> to receive the first reservoir portion <NUM> and a second nest <NUM> defining a second weld cavity <NUM> to receive the second reservoir portion <NUM>. A first light array <NUM> is located concentrically surrounding the first reservoir portion <NUM> at the location that will become the overlapping portion <NUM> and a second light array <NUM> is located concentrically inside the second reservoir portion <NUM> at the location that will become the overlapping portion <NUM>, and parallel to the first light array <NUM>.

The first and the second light arrays <NUM> and <NUM> are heated using infrared heat, until the areas which will form the overlapping portion <NUM> have reached a sufficient predetermined temperature. The first and the second light arrays <NUM> and <NUM> are then moved out of the way and the first nest <NUM> and the second nest <NUM> are moved together to form the overlapping portion <NUM>.

A pair of slides <NUM> are moved in place to concentrically surround the overlapping portion <NUM> when the first reservoir portion <NUM>, first weld portion <NUM>, second reservoir portion <NUM> and second weld portion <NUM> are assembled together. Pressurized air is pumped into the fluid reservoir <NUM> after the first reservoir portion <NUM>, first weld portion <NUM>, second reservoir portion <NUM>, second weld portion <NUM>, and the slides <NUM> are assembled together. The first reservoir portion <NUM> defines a fluid inlet <NUM> to receive the pressurized air when the fluid reservoir <NUM> is assembled in the weld apparatus <NUM> and to receive washer fluid when the fluid reservoir <NUM> is assembled in the vehicle.

A method of infrared welding a fluid reservoir <NUM> for a vehicle comprises placing a first reservoir portion <NUM> inside a first cavity <NUM> defined by a first weld portion <NUM> and a second reservoir portion <NUM> inside a second cavity <NUM> defined by a second weld portion <NUM>. A first light array <NUM> concentrically surrounds the first reservoir portion <NUM> and a second light array <NUM> is concentrically inside the second reservoir portion <NUM>. The first light array <NUM> and the second light array <NUM> apply infrared heat to the first reservoir portion <NUM> and the second reservoir portion <NUM>.

The first light array <NUM> and the second light array <NUM> are moved out of the way. The first weld portion <NUM> and the second weld portion <NUM> are moved together until an overlapping portion <NUM> formed is formed by the first reservoir portion <NUM> and the second reservoir portion <NUM>. A pair of slides <NUM> are placed to concentrically surround the overlapping portion <NUM> and the reservoir <NUM> is filled with pressurized air to weld the first reservoir portion <NUM> to the second reservoir portion <NUM>, forming the weld <NUM>. wherein the first reservoir portion defines a fluid inlet to receive washer fluid when the fluid reservoir is assembled in the vehicle.

The infrared weld apparatus <NUM> for welding a fluid reservoir <NUM> comprises a first weld portion <NUM> defining a first weld cavity <NUM> to receive a first reservoir portion <NUM> and a second weld portion <NUM> defining a second weld cavity <NUM> to receive a second reservoir portion <NUM>. A first light array <NUM> is located concentrically surrounding the overlapping portion <NUM> of the first reservoir portion <NUM> and a second light array <NUM> is located concentrically inside the overlapping portion <NUM> of the second reservoir portion <NUM>, parallel to the first light array <NUM>. The first light array <NUM> and second light array <NUM> are configured to apply heat at the overlapping portion <NUM>. A pair of slides <NUM> concentrically surround an overlapping portion <NUM> of the first reservoir portion <NUM> and the second reservoir portion <NUM>, when the first reservoir portion <NUM>, first weld portion <NUM>, second reservoir portion <NUM> and second weld portion <NUM> are assembled together.

Pressurized air is pumped into the fluid reservoir <NUM> after the first reservoir portion <NUM>, first weld portion <NUM>, second reservoir portion <NUM>, second weld portion <NUM>, and the slides <NUM> are assembled together.

The first reservoir portion <NUM> also defines a fluid inlet <NUM> to receive the pressurized air when the fluid reservoir <NUM> is assembled in the weld apparatus <NUM> and to receive washer fluid when the fluid reservoir <NUM> is assembled in the vehicle.

Claim 1:
An infrared welding apparatus (<NUM>) for welding a fluid reservoir (<NUM>) for a vehicle washer system, wherein the reservoir (<NUM>) is defined by a first reservoir portion (<NUM>) and a second reservoir portion (<NUM>) partially nested together with an overlapping portion (<NUM>), wherein the overlapping portion (<NUM>) is a weld, comprising:
• a first weld portion (<NUM>) defining a first weld cavity (<NUM>) to receive the first reservoir portion (<NUM>);
• a second weld portion (<NUM>) defining a second weld cavity (<NUM>) to receive the second reservoir portion (<NUM>);
• a first infrared light array (<NUM>), configured to be placed concentrically surrounding the first reservoir portion (<NUM>) during the weld process, in an area corresponding to what will be the overlapping portion (<NUM>);
• a second infrared light array (<NUM>), configured to be placed concentrically inside the second reservoir portion (<NUM>) during the weld process, in an area corresponding to what will be the overlapping portion (<NUM>) and at the same time parallel to the first infrared light array (<NUM>), wherein the first infrared light array (<NUM>) and the second infrared light array (<NUM>) are configured to apply infrared heat to the first reservoir portion (<NUM>) respectively the second reservoir portion (<NUM>);
• a pair of slides (<NUM>) configured to surround the overlapping portion (<NUM>) of the first reservoir portion (<NUM>) and the second reservoir portion (<NUM>) concentrically, when the first reservoir portion (<NUM>), first weld portion (<NUM>), second reservoir portion (<NUM>) and second weld portion (<NUM>) are assembled together;
• wherein pressurized air is foreseen to be pumped into the fluid reservoir (<NUM>), after the first reservoir portion (<NUM>), the first weld portion (<NUM>), the second reservoir portion (<NUM>), the second weld portion (<NUM>) and the slides (<NUM>) are assembled together in order to force the overlapping portion (<NUM>) outward against the slides (<NUM>) to weld the first reservoir portion (<NUM>) to the second reservoir portion (<NUM>).