Co-injection Thermoplastic Fuel Tank Impact Absorption
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Solution Overview
Problem
Existing operating fluid tanks for motor vehicles face challenges in absorbing impact-related deformation forces without compromising tightness and stability, particularly in fuel and coolant tanks, where excessive structural reinforcement can concentrate destructive forces and lead to fuel or substance leakage.
Innovation Solution
The use of injection-molded thermoplastic shells with elastically deformable regions, such as thermoplastic elastomers, and varying material strengths within the tank body, achieved through co-injection molding or sandwich injection molding, allows for controlled deformation and distribution of forces, preventing structural damage and leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If structural reinforcements such as supports, tie rods, or composite materials are provided in the tank body to increase structural strength, then the tank can withstand elevated internal pressure, but the crash strength does not improve and destructive forces may concentrate in certain regions leading to leakage
Solution Approach 1:
The patent applies local quality by providing elastically deformable regions at specific locations where impact forces are expected to occur, while other regions maintain higher structural strength. This is achieved by using different thermoplastic materials with varying elasticity moduli in different tank regions, allowing the tank to locally absorb impact energy without compromising overall structural integrity or pressure containment capability
Solution Approach 2:
The patent employs composite materials by combining thermoplastic materials with different elasticity characteristics in a single tank structure. The tank body comprises multiple materials with varying elastic moduli, creating a composite structure that optimizes both structural strength for pressure containment and crash strength for impact absorption, preventing force concentration while maintaining stability
2Strength
If the tank body is made from a single thermoplastic material with high structural strength, then internal pressure resistance is improved, but the tank cannot non-destructively absorb impact-related deformation forces
Solution Approach 1:
The patent applies parameter changes by varying the elasticity modulus of thermoplastic materials in different tank regions. The elastic elasticity modulus varies by at least one order of magnitude between different materials used, allowing certain regions to be highly rigid for pressure resistance while other regions are highly elastic for impact absorption. This parameter variation enables the tank to handle both internal pressure and external impact forces effectively
3Stability of the object's composition
If structural reinforcements are added to the tank body, then stability is improved, but the tank complexity and weight increase
Solution Approach 1:
The patent merges the structural reinforcement function with the tank shell itself by integrating elastically deformable regions directly into the tank body structure. Instead of adding separate supports, tie rods, or reinforcement elements, the tank shell is formed with varying material properties that provide both structural stability and impact absorption in a unified structure, reducing overall complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the tank's ability to absorb deformation forces and ice pressure without plastic deformation, ensuring non-destructive impact resistance and improved assembly flexibility, while maintaining tightness and stability.
Implementation Method 1
at least one elastically deformable region made of an injected or molded-on thermoplastic elastomer
Implementation Method 2
at least one shell is formed at least in certain regions from thermoplastic materials of differing strengths and/or elasticity
Data Source
AI summary
The invention relates to an operating fluid tank (1) for a motor vehicle, comprising a tank body which is composed of two mutually complementary, injection-molded shells (2) which are made of thermoplastic material and which are welded circumferentially to one another to form a substantially closed hollow body, wherein at least one shell (2a, 2b) is formed at least in certain regions from thermoplastic materials of differing strength and/or elasticity, wherein at least one partial region is formed from a thermoplastic material which is elastically deformable, and wherein the shell (2a, 2b) has been obtained by a co-injection process during injection molding.