Integrated Fuel Filter Box with Injection-Molded Screens
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Solution Overview
Problem
The existing fuel delivery devices for motor vehicles have complex assembly processes due to close tolerances required between the base and cup-shaped components of the fuel filter, making production intricate and costly.
Innovation Solution
A fuel filter design featuring an open box with a channel connected to a connecting piece, where both screens are made in one piece from plastic, allowing for simplified manufacturing through injection molding and eliminating the need for rework or assembly prior to installation, with features like multiple openings and ribs to enhance filtration and structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fuel filter uses a pot-shaped component closed with a base plate requiring close tolerances, then the filtration function is achieved, but the assembly complexity and production cost increase significantly
Solution Approach 1:
The patent merges the box and filter element into a single integrated component manufactured as one piece. The box wall itself forms the filter element with openings, eliminating the need for separate base plate and pot-shaped component assembly. This integration resolves the contradiction by maintaining filtration function while dramatically reducing assembly complexity.
Solution Approach 2:
The box structure serves multiple functions simultaneously: it contains the fuel filter, provides structural support, and forms the filter element itself through its wall openings. This multi-functionality eliminates the need for separate specialized components, reducing both device complexity and production costs while maintaining reliable filtration.
2Reliability
If the base plate and pot-shaped component require close tolerances to prevent unfiltered fuel flow, then filtration reliability is improved, but manufacturing complexity increases
Solution Approach 1:
By combining the base plate and pot-shaped component into a single integrated box structure manufactured as one piece, the patent eliminates the interface between components where tolerances would be required. The filter element is formed directly in the box wall, ensuring proper filtration without complex tolerance specifications.
3Reliability
If multiple separate components are used in the fuel filter assembly, then filtration function is achieved, but production time and cost increase
Solution Approach 1:
The patent combines multiple functional components into a single integrated box structure that is manufactured as one piece using injection molding. This eliminates assembly steps and reduces production time while maintaining the filtration function through the openings in the box wall.
Solution Approach 2:
The filter element is pre-formed as an integral part of the box structure during the initial molding process, rather than requiring subsequent assembly operations. This preliminary integration of functions streamlines production and increases manufacturing efficiency.
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 design simplifies the manufacturing process, reduces production costs, and maintains a high filter effect while minimizing clogging risks, resulting in a more efficient and cost-effective fuel filter production.
Implementation Method 1
a first screen (14) on the box (11) and a second screen (18) on the channel (17) is arranged
Implementation Method 2
a suction unit (3) for drawing in fuel from a fuel tank (2)
Data Source
Figure 1~2
Figure 3~4
AI summary
The system has a supplying unit for supplying fuel, and a fuel filter casing (11) arranged at a base of a fuel tank. A connection fitting (12) connects a fuel filter (9) at an intake line, and the fuel filter casing is opened on one side. The fuel filter casing has a channel connected with the connection fitting and is prestressed against the base of the fuel tank with the opened side. The fuel filter has two filter units (14), which are provided at the fuel filter casing and the channel, respectively and are made of plastic as a single piece.