Fuel Pump Flange Adhesion Enhancing Member
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Solution Overview
Problem
The existing flange designs for fuel pump modules face issues with adhesion between the power supply terminal and the resin material, leading to gaps that compromise sealing performance and airtightness, especially under temperature changes, which can result in fuel or gas leakage and fail to meet strict exhaust gas regulations.
Innovation Solution
An adhesion enhancing member, such as a thermosetting adhesive tape, is formed on the power supply terminal and heat-hardened to increase adhesion with the resin material, preventing gaps and enhancing sealing performance during the injection molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a resin material with high melting point is used to resist heat, then heat resistance is improved, but adhesion between the power supply terminal and resin decreases due to drastic temperature changes
Solution Approach 1:
An adhesion enhancing member is introduced as an intermediary between the power supply terminal and the resin material. This mediator maintains reliable adhesion even when the resin undergoes drastic temperature changes during injection molding, preventing gaps while allowing the use of high-temperature resistant resin materials.
Solution Approach 2:
The adhesion enhancing member is designed with specific physical and chemical parameters that differ from both the power supply terminal and resin material. By changing parameters such as thermal expansion coefficient, melting point, and adhesion properties, the intermediate layer accommodates temperature variations and maintains bonding reliability.
2Ease of manufacture
If the adhesion between power supply terminal and resin is weak, then manufacturing is easier, but gaps are created compromising sealing performance
Solution Approach 1:
The adhesion enhancing member serves as a mediator that ensures strong bonding between the power supply terminal and resin material during injection molding. This prevents gap formation and maintains sealing performance without complicating the manufacturing process.
Solution Approach 2:
The adhesion enhancing member is prepared in advance and attached to the power supply terminal before the injection molding process. This preliminary action ensures that the bonding interface is optimized for adhesion, preventing gaps during the subsequent molding and cooling processes.
3Reliability
If gaps are created between power supply terminal and resin, then airtightness deteriorates, but detecting these gaps is difficult
Solution Approach 1:
The adhesion enhancing member acts as a visible intermediary layer between the power supply terminal and resin material. Its presence makes the bonding interface observable, allowing easy detection of any gaps or adhesion failures, thereby improving quality control for airtightness.
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 prevents fuel or gas leakage from the fuel tank, meeting strict exhaust gas regulations by ensuring a strong bond between the power supply terminal and the resin material, thereby improving manufacturing efficiency and sealing performance.
Implementation Method 1
the adhesion enhancing member may comprise a thermosetting material, and the method may further comprise heat-hardening the adhesion enhancing member so as to increase bondability between the adhesion enhancing member and the power supply terminal
Implementation Method 2
increasing the force of adhesion between the power supply terminal and a resin material for forming a flange and preventing the probability of creating a gap between them
Data Source
AI summary
Disclosed is a flange for a fuel pump module, which includes an adhesion enhancing member so that there is no gap between a power supply terminal and a resin material for forming a flange, thus further increasing injection efficiency and sealing performance. A method of manufacturing such a flange is also provided.