Deployable Fuel Tank Baffle for Noise Reduction
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Solution Overview
Problem
Existing methods for producing hollow plastic fuel tanks with integrated noise-reducing components are costly, inefficient, and compromise the permeability of the tank, with challenges in inserting components during molding and maintaining productivity.
Innovation Solution
A deployable baffle assembly with a main body and auxiliary structures that are initially compact for installation and expand for operation, integrated into the fuel tank through a blow molding process using mold cores and a carrier system, allowing for efficient noise reduction without affecting permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a baffle is inserted into a fuel tank to reduce noise, then noise propagation is reduced, but the permeability of the fuel tank is adversely affected and productivity is reduced
Solution Approach 1:
The baffle is constructed with a porous structure that allows fuel vapor to pass through while still effectively reducing noise propagation. The porous nature of the baffle material enables vapor permeation while the physical structure absorbs and dampens noise from fuel movement.
2Object-affected harmful factors
If components are inserted into a hollow plastic article after molding, then noise reduction functionality is added, but the process becomes cost prohibitive and productivity is negatively impacted
Solution Approach 1:
The baffle is integrated directly into the fuel tank molding process rather than being inserted separately. The baffle and tank are formed as a single integrated component through co-molding, eliminating separate insertion steps and associated costs while maintaining productivity.
Solution Approach 2:
The baffle is pre-formed and positioned within the mold cavity before the fuel tank material is injected. This preliminary positioning allows the baffle to be automatically incorporated during the molding process itself, eliminating post-molding insertion operations.
3Ease of manufacture
If a twin-sheet forming process is used to insert components between half-shells, then component integration is possible, but additional time and energy are required for heating and welding
Solution Approach 1:
The baffle and fuel tank are formed and bonded in a single integrated molding process without requiring separate heating and welding operations. The co-molding process creates a unified structure that eliminates the energy-intensive post-forming operations of twin-sheet processes.
4Object-affected harmful factors
If a deployable auxiliary baffle structure is used to increase operational width, then noise reduction effectiveness is improved, but the complexity of the baffle assembly increases
Solution Approach 1:
The auxiliary baffle structure is designed to be deployable or adjustable, allowing it to transition from a compact state during installation to an extended state during operation. This dynamic configuration enables the baffle to achieve optimal noise reduction performance while maintaining ease of installation.
Data Source
AI summary
A fuel tank baffle assembly is provided for installation in a fuel tank, the baffle assembly comprising a main body having a first end section, a second end section, and an intermediate section interconnecting the first and second end sections. Operably associated with the main body is at least one deployable auxiliary baffle structure. The auxiliary baffle structure is configured to be positioned in an undeployed state during installation into a fuel tank, thereby defining a first installation width of the baffle assembly. Following installation, the auxiliary baffle structure is deployed into an extended position, thereby defining an operational width for subsequent usage. The operational width is greater than the installation width.