Composite Fuel Tank Bracket with Flexible Mounting
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Solution Overview
Problem
The increasing demand for high-pressure storage of alternative fuels like natural gas and hydrogen in vehicles poses challenges for fuel tank design, requiring tanks to withstand high pressures and be suitable in size and weight for vehicle mounting, while existing solutions fail to efficiently accommodate pressure changes and structural integration.
Innovation Solution
A fuel tank assembly using composite materials with embedded fibers, featuring a flexible and resilient bracket system that can adapt to changing fuel pressures and integrate with the vehicle's structural frame, reducing the need for additional structural members and offering weight and cost savings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If higher tank pressures are used to provide desired stored volume of compressed gaseous fuel, then the stored volume or capacity of fuel is improved, but the tank weight and structural complexity increase
Solution Approach 1:
The fuel tank is constructed using composite materials consisting of multiple layers including an inner liner, intermediate layers, and outer layers. This composite structure provides the necessary strength to withstand high pressures while maintaining a lighter weight compared to traditional single-material tanks, thereby resolving the contradiction between storing more fuel at high pressure and keeping the tank weight manageable.
2Reliability
If the bracket is made rigid to securely mount the fuel tank, then the mounting reliability is improved, but the ability to accommodate pressure-induced shape changes deteriorates
Solution Approach 1:
The bracket is designed with flexible and resilient characteristics, allowing it to dynamically adapt to shape changes in the fuel tank caused by pressure variations. This dynamic design maintains secure mounting (reliability) while accommodating the tank's deformation (adaptability), resolving the contradiction between rigidity and flexibility.
Solution Approach 2:
The bracket's physical parameters such as thickness, material composition, and geometric configuration are optimized to provide appropriate flexibility. By carefully controlling these parameters, the bracket achieves a balance between maintaining secure attachment and accommodating pressure-induced dimensional changes in the tank.
3Strength
If additional structural members are added to the vehicle frame to support the fuel tank, then the structural strength is improved, but the vehicle weight and complexity increase
Solution Approach 1:
The fuel tank assembly is integrated with the vehicle frame structure by directly mounting the flexible bracket to frame members. This merging of the fuel tank support system with the existing frame structure eliminates the need for additional dedicated structural members, thereby maintaining structural strength while reducing overall complexity and weight.
Solution Approach 2:
The vehicle frame members serve dual functions: providing structural support for the vehicle and serving as mounting points for the fuel tank bracket. This multi-functionality approach allows the frame to fulfill both structural and mounting roles, reducing the need for separate components and simplifying the overall design.
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
The solution enables the efficient storage of high-pressure fuels by providing a durable, adaptable fuel tank system that can accommodate pressure changes and function as a structural member of the vehicle, resulting in weight and cost reductions.
Implementation Method 1
the bracket is flexible and resilient in at least one direction to accommodate changes in the shape or dimensions of the fuel tank such as may occur due to the changing fuel pressure within the fuel tank in use
Data Source
AI summary
A fuel tank assembly includes a fuel tank, a bracket carried by the fuel tank and having a portion accessible from the outside of the fuel tank to permit the assembly to be mounted to a vehicle, and an outer layer disposed around at least part of the fuel tank and a portion of the bracket to connect the bracket to the fuel tank. In one implementation, the fuel tank includes layers of composite material that have fibers embedded in resin or the like. The bracket is carried or trapped between adjacent layers of the composite material so that the bracket is fixed to the tank. The bracket preferably is connected to the tank at one end and is flexible in at least one direction to accommodate changes in the shape or dimensions of the fuel tank.