Fiber Reinforced Plastic Protector with Metal Collar Sealing
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Solution Overview
Problem
Existing protectors for high-pressure fuel pumps in internal combustion engines face challenges with sealing performance due to creep deformation under high temperatures, thermal expansion, and potential oil or rainwater ingress, which can lead to bolt loosening and reduced sealing efficacy.
Innovation Solution
A protector made of fiber reinforced plastic with metal collars, featuring an uneven and smooth portion design on the outer circumferential surface of the collar, where the uneven portion restricts collar removal and the smooth portion ensures sealing by preventing oil or rainwater ingress, while carbon fiber reinforced plastic is used to reduce weight and enhance specific strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a smooth surface is provided on the entire outer circumferential surface of the collar to ensure sealing performance, then sealing performance is improved, but the collar can be easily removed from the protector
Solution Approach 1:
The outer circumferential surface of the collar is divided into two distinct regions: a smooth portion (first region) that ensures sealing performance by preventing oil or rainwater ingress, and an uneven portion (second region) with protrusions that restrict collar removal. This local differentiation allows each region to fulfill its specific function without compromising the other.
2Weight of moving object
If the protector is made of fiber reinforced plastic to reduce weight, then weight is reduced, but creep deformation occurs under high temperature causing bolt loosening
Solution Approach 1:
The protector employs a composite structure combining fiber reinforced plastic for the main body (achieving weight reduction) with metal collars for fastening portions (providing creep resistance). This material composition allows the plastic portion to be lightweight while the metal collar maintains fastening reliability under high temperature conditions.
3Stability of the object's composition
If reinforcing fibers are laminated in the thickness direction to prevent thermal expansion, then thermal expansion is restricted, but gaps form at the front and rear surfaces allowing oil or rainwater ingress
Solution Approach 1:
The collar surface is differentiated into a smooth portion that prevents oil or rainwater ingress and an uneven portion that accommodates thermal expansion differences between metal and plastic. The uneven portion with protrusions allows the collar to maintain engagement with the protector body even when gaps form due to thermal expansion, while the smooth portion ensures sealing at critical locations.
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 effectively maintains sealing performance and prevents collar removal, even under thermal expansion differences, while reducing the engine's weight and operating noise through the use of carbon fiber reinforced plastic and metal collars, ensuring reliable protection for the high-pressure fuel pump.
Implementation Method 1
a metal collar insert-molded into the fiber reinforced plastic portion
Implementation Method 2
The uneven portion includes recesses and projections arranged alternately in a thickness direction of the fiber reinforced plastic portion
Implementation Method 3
the smooth portion includes a smooth surface parallel to the thickness direction. The smooth portion and the plastic portion are in close contact with each other at the smooth portion
Implementation Method 4
the protector may be made of reinforced fiber plastic, which has a higher specific strength than, for example, cast iron
Implementation Method 5
A protector according to one aspect of the present disclosure includes a plate-shaped fiber reinforced plastic portion made of a fiber reinforced plastic
Implementation Method 6
When the plastic protector is fastened by bolts and used under a high-temperature environment, the portions of the protector that are fastened by the bolts may undergo creep deformation
Data Source
AI summary
A protector protects a high-pressure fuel pump for an internal combustion engine. A metal collar is insert-molded into a plate-shaped fiber reinforced plastic portion made of a fiber reinforced plastic of the protector. An outer circumferential surface of the collar includes an uneven portion and a smooth surface. The uneven portion includes recesses and projections arranged alternately in a thickness direction of the fiber reinforced plastic portion. The smooth portion includes a smooth surface parallel to the thickness direction of the fiber reinforced plastic portion. The uneven portion and the smooth portion are arranged in the thickness direction on the outer circumferential surface of the collar.