In-Tank Fuel Module Electrostatic Charge Control

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Solution Overview

Problem

In-tank fuel modules with non-conductive or insulated conductive components face challenges in dissipating electrostatic charges, leading to potential accumulation and interference, as existing solutions do not effectively provide a ground path for charge dissipation.

Innovation Solution

The integration of conductive pathways using metallic float arms, conductive polymeric materials, and conductive strands or wires connects components to the vehicle's ground plane, ensuring safe dissipation of electrostatic charges through the fuel level sensor assembly and other critical components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If non-conductive materials are used for component bodies, then insulation and structural integrity are improved, but electrostatic charge dissipation capability deteriorates

Engineering Contradiction:

Improvestructural integrityVSAvoidelectrostatic charge dissipation

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent applies composite materials by integrating conductive elements (metallic float arms, conductive polymeric materials, conductive strands) within or on non-conductive component bodies. This creates a hybrid structure where the non-conductive material provides structural integrity and insulation, while the conductive elements provide electrostatic charge dissipation pathways to ground.

Inventive Principle:

Principle #40Composite materials

2Reliability

If conductive elements are insulated from ground, then electrical isolation is improved, but electrostatic charge accumulation increases

Engineering Contradiction:

Improveelectrical isolationVSAvoidelectrostatic charge accumulation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent uses conductive strands and conductive polymeric materials as intermediary elements that bridge the gap between insulated conductive components and the ground plane. These intermediaries provide a controlled path for electrostatic charge dissipation while maintaining electrical isolation for operational circuits.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If metal wires are used to connect components to ground, then electrostatic charge dissipation is improved, but device complexity increases

Engineering Contradiction:

Improveelectrostatic charge dissipationVSAvoidground connection structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the ground connection function with existing structural components. Conductive polymeric materials are integrated into component bodies during molding, and conductive strands are embedded within housing structures, eliminating the need for separate metal wire connections and reducing overall device complexity.

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If conductive polymeric materials are used, then electrostatic charge dissipation is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improveelectrostatic charge dissipationVSAvoidconductive pathway continuity

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent utilizes the inherent properties of conductive polymeric materials that can be adjusted during the molding process. By controlling parameters such as conductive filler concentration, distribution, and material formulation, the patent achieves reliable electrostatic charge dissipation while maintaining compatibility with standard manufacturing processes.

Inventive Principle:

Principle #35Parameter changes

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 solution effectively prevents electrostatic charge accumulation, ensuring reliable operation of in-tank fuel module components by providing a direct path to ground, thereby enhancing safety and performance.

Implementation Method 1

providing an electrostatic discharge path to ground of various components within a vehicular in-tank fuel module

Methodology Applied

Scientific EffectElectrostatic discharge: Electrostatic Discharge

Implementation Method 2

integration of conductive pathways using metallic float arms, conductive polymeric materials, and conductive strands or wires connects components to the vehicle's ground plane

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS7467549B2Electrostatic charge control for in-tank fuel module components

Publication Date: 2008.12.23 TI GROUP AUTOMOTIVE SYSTEMS LLC

AI summary

A grounding arrangement for an in-tank fuel system includes a fuel level sensor assembly of a fuel module comprising a conductive card body and a resister card supported on the conductive card body. The resister card includes a conductive trace in conductive contact with the conductive card body. The card body is conductively connected to a conductive fuel module component. The trace is adapted to be connected to the ground plane of a vehicle. Other traces on the resister card are in the electrical circuit of the fuel level sensor assembly. The fuel module further includes a conductive blade having a knife edge and in conductive contact with a conductive fuel module component. The knife edge cuts through the insulation of an insulated conductor to allow the knife edge to be in contact with the conductive element of the conductor.