Fibre-Reinforced Thermoplastic Operating-Fluid Container
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Solution Overview
Problem
Existing operating-fluid containers for motor vehicles face challenges in meeting safety requirements for stability and tightness, particularly in withstanding deformation forces during crashes and freezing pressures, while maintaining interior volume and avoiding bulging or sagging, especially when filled with fuels or aqueous liquids.
Innovation Solution
The use of fibre-reinforced thermoplastic materials in injection-moulded shells, with specific reinforcement in critical regions and multi-layered constructions, including co-injection moulding and integrally moulded retaining lugs, to enhance structural strength and stability without compromising interior volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If supports, tie rods, or similar internal reinforcements are provided inside the container, then structural strength and stability are improved, but interior volume is reduced
Solution Approach 1:
The patent applies composite materials by integrating fibre-reinforced thermoplastic material directly into the container shells during injection moulding. The fibres (glass, carbon, aramid, or polyamide) are embedded in the thermoplastic matrix to create a composite structure that provides enhanced strength and stiffness without requiring separate internal reinforcement elements, thus avoiding interior volume loss.
Solution Approach 2:
The patent implements local quality by selectively reinforcing specific critical regions of the container shells with fibre-reinforced material. The fibre reinforcement can be concentrated in areas subjected to highest stresses (such as corners, connection points, or structurally critical zones) while leaving other regions with standard material composition, thereby optimizing strength-to-volume ratio.
2Strength
If container shells are manufactured from composite materials using extrusion blow-moulding or vacuum forming, then structural strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent uses composite materials consisting of thermoplastic material reinforced with fibres (glass, carbon, aramid, or polyamide). The fibres are incorporated into the thermoplastic matrix during injection moulding to create a composite structure that provides enhanced strength and stiffness while maintaining processability.
Solution Approach 2:
The patent changes the material parameters by incorporating fibres with specific properties (length, diameter, material type) into the thermoplastic matrix. The fibre content, length, and orientation are controlled during injection moulding to achieve the desired mechanical properties while maintaining manufacturing feasibility.
3Reliability
If the container is designed to withstand deformation forces and freezing pressures, then safety and stability are improved, but material requirements and structural complexity increase
Solution Approach 1:
The patent employs composite materials with fibre reinforcement to achieve the required strength and deformation resistance. The fibres provide enhanced mechanical properties that enable the container to withstand crash forces and freezing pressures without requiring complex structural designs or additional reinforcement elements.
Solution Approach 2:
The patent applies fibre reinforcement selectively in critical regions where deformation forces and freezing pressures are most severe. This localized approach provides the necessary safety and stability while avoiding the need for uniform thickening or additional structural elements throughout the entire container.
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 results in a container that meets higher strength requirements with targeted reinforcement, reduced need for metallic fasteners, and improved resistance to deformation and freezing pressures, while maintaining container shape and preventing environmental leaks.
Implementation Method 1
at least in regions, a fibre-reinforced thermoplastic material has been injection-moulded in the container body
Implementation Method 2
welded together in an encircling manner to form a substantially closed hollow body
Implementation Method 3
a fibre-reinforced thermoplastic material has been injection-moulded in the container body. In this manner, fibre-reinforced regions and non-fibre-reinforced regions result, such that the container can be reinforced in a targeted manner in regions which are particularly critical with respect to the deformation behaviour of the container
Data Source
Figure 1
Figure 2~4
AI summary
The invention relates to an operating-fluid container (1) for a motor vehicle, comprising a container body which is assembled from two mutually complementary injection-moulded shells (2a, 2b) which consist of thermoplastic material and are welded together in an encircling manner to form a substantially closed hollow body, wherein at least one shell (2a, 2b) is at least in regions formed from thermoplastic materials having different strengths, wherein at least one part-region consists of a thermoplastic material having a fibrous filling, wherein the shell (2a, 2b) has been obtained by way of a co-injection process during injection moulding.