Conductive Polymer Earthing Strap for Fuel Filler Pipe
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Solution Overview
Problem
Existing earthing elements for fuel container filler pipes, typically made of copper wires, suffer from contact corrosion, leading to reduced conductivity and increased costs due to complex and expensive mounting processes.
Innovation Solution
An earthing element composed of an electrically conductive polymer, such as carbon-black-filled polyamide, with integrally formed fastening means like hooks or clips, eliminating contact corrosion and allowing for simple and cost-effective injection molding production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper wires with clamped-on contact shoes are used for earthing, then electrical conductivity is achieved, but contact corrosion occurs reducing conductivity over time and mounting becomes complex and expensive
Solution Approach 1:
The patent combines the earthing function and fastening function into a single integrated polymer component. The earthing element with integrally formed fastening means eliminates the need for separate contact shoes and clamping mechanisms, thereby reducing mounting complexity while maintaining reliable electrical conductivity through the continuous conductive polymer structure
Solution Approach 2:
The patent employs a composite material structure consisting of a polymer matrix combined with conductive particles (such as carbon black or metal particles). This composite provides both the mechanical properties needed for fastening and the electrical conductivity required for earthing, eliminating corrosion issues associated with traditional copper-wire constructions while maintaining electrical performance
2Reliability
If copper wires with contact shoes are used for earthing, then electrical connection is established, but contact corrosion occurs leading to reduced conductivity
Solution Approach 1:
The patent uses a composite material comprising a polymer matrix with embedded conductive particles (carbon black or metal particles). This composite structure provides inherent corrosion resistance while maintaining electrical conductivity, eliminating the contact corrosion problem that plagues traditional copper wire with contact shoe configurations and thereby extending service life
Solution Approach 2:
The patent changes the material parameter from traditional copper wire to a conductive polymer composite. This material substitution fundamentally alters the corrosion behavior, transforming the earthing element from a corrosion-prone metal construction to a corrosion-resistant polymer-based structure that maintains conductivity over time
3Reliability
If traditional copper wires are used for earthing, then electrical conductivity is provided, but manufacturing costs increase due to complex mounting processes
Solution Approach 1:
The patent merges multiple functions (earthing, fastening, and structural support) into a single integrated polymer component. This consolidation eliminates the need for separate contact shoes, clamps, and assembly operations, thereby reducing manufacturing complexity and cost while maintaining the essential earthing function through the conductive polymer material
Solution Approach 2:
The earthing element with integrally formed fastening means is designed to be self-installing, eliminating the need for separate mounting operations. The component can be directly attached to the fuel filler pipe without requiring additional contact shoes or clamping mechanisms, thereby simplifying the manufacturing process and reducing overall system cost
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 provides a reliable, corrosion-free earthing connection that withstands increased pull-off forces, maintaining conductivity and reducing costs through simplified manufacturing and reduced risk of corrosion.
Implementation Method 1
The earthing element can, for example, be in the form of an injection-moulded strap with a thermoplastic matrix and conductive particles embedded in the matrix
Data Source
AI summary
The invention relates to an earthing element for the filler pipe of a motor vehicle, and also to a mouthpiece on a filler pipe of a motor vehicle. The earthing element is in the form of an earthing strap (7) which is composed of an electrically conductive polymer.