Foldable Tank Baffle Assembly for Sloshing Noise Reduction
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Solution Overview
Problem
Existing methods for inserting noise-reducing baffles into vehicle fuel tanks are complex, expensive, and difficult for baffles with complex shapes, especially when multiple openings are minimized to control evaporative losses.
Innovation Solution
A noise-reducing baffle with at least two panels and a hinge, allowing it to be folded for easy insertion through a single opening, and automatically fixing to the tank wall in its final configuration, reducing the need for multiple openings and attachment points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a complex-shaped baffle is manufactured and installed during tank production by extruding and blow-molding a tubular parison around the baffle, then the baffle can be incorporated into the tank, but the manufacturing process becomes complex and expensive
Solution Approach 1:
The baffle is divided into multiple detachable panels (first panel, second panel, third panel) that can be assembled separately and then installed as a complete unit. This segmentation allows the complex-shaped baffle to be manufactured using simple injection molding processes for each panel, rather than requiring complex co-molding of the entire assembly with the tank.
Solution Approach 2:
The detachable panels are designed to nest within each other during storage and transport, with each panel fitting into the previous one. This nesting arrangement minimizes storage space requirements and simplifies logistics, while allowing the complete baffle assembly to be installed through a single opening in the tank after assembly.
2Ease of manufacture
If a complex-shaped baffle is manufactured and installed during tank production by extruding and blow-molding a tubular parison around the baffle, then the baffle can be incorporated into the tank, but the manufacturing cost increases
Solution Approach 1:
The baffle is divided into multiple detachable panels that can be manufactured using simple injection molding processes. Each panel is produced separately using cost-effective molding techniques, avoiding the need for expensive multi-cavity molds or complex co-molding processes required for integrated complex-shaped baffles.
Solution Approach 2:
The invention changes the manufacturing parameters from complex extrusion and blow-molding processes to simpler injection molding processes for individual panels. This parameter change reduces tooling costs, manufacturing complexity, and overall production expenses while maintaining the ability to create complex three-dimensional baffle shapes.
3Object-affected harmful factors
If the baffle is designed with complex shapes to reduce sloshing noise, then noise reduction effectiveness is improved, but the baffle weight increases
Solution Approach 1:
The baffle is segmented into multiple thin-walled panels that can be assembled to form complex three-dimensional noise-reducing structures. Each panel uses minimal material while the collective assembly creates the necessary complex geometry for effective sloshing noise reduction, reducing overall weight compared to a solid complex-shaped baffle.
Solution Approach 2:
Each baffle panel is constructed as a thin-walled structure that provides the necessary structural integrity and noise-reducing geometry while minimizing material usage. The thin-walled panels form complex three-dimensional shapes that effectively reduce sloshing noise without the weight penalty of solid structures.
4Ease of operation
If multiple openings are made in the tank wall for baffle insertion, then baffle installation is simplified, but evaporative losses increase
Solution Approach 1:
The detachable panels are designed to nest within each other, allowing the complete baffle assembly to be collapsed into a compact form that fits through a single opening in the tank wall. After insertion, the panels are assembled into their final three-dimensional configuration inside the tank, eliminating the need for multiple openings and preventing evaporative losses.
Data Source
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AI summary
The invention relates to a noise attenuation device (1) for a motor vehicle tank intended to receive an operating fluid of the vehicle, wherein the noise attenuation device (1) comprises: - at least two panels (13, 15, 17), - at least one hinge (19) integrally moulded with the other parts of the noise attenuation device (1), the noise attenuation device (1) being deformable between: - an initial configuration, wherein the noise attenuation device (1) is not folded along the at least one hinge (19), - a folded configuration, wherein the noise attenuation device (1) is folded along the at least one hinge (19), and - a final configuration, wherein the noise attenuation device (1) is unfolded along the at least one hinge (19), such that, in the folded configuration, the noise attenuation device (1) can be inserted into the tank via an opening of the tank.