Plastic Fuel Tank Noise Baffle With Interference Sections

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Solution Overview

Problem

Existing plastic fuel tank designs with noise reduction baffles face challenges in accommodating negative pressure tests without reducing internal volume or increasing weight, and offer limited shape and material options due to molded baffle structures.

Innovation Solution

A plastic fuel tank design incorporating a noise reduction baffle and interference sections that project inward from the upper and lower surfaces, with one section serving as a fixation device to secure the baffle, allowing for flexible installation and resistance to negative pressure without occupying additional volume or weight, using thermoplastic materials like HDPE and POM for the baffle and fixation device respectively.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If noise reduction baffles are molded from the tank wall, then noise suppression is achieved, but the internal volume of the tank is reduced

Engineering Contradiction:

Improveslosh noiseVSAvoidinternal volume

Core Design Contradiction:

Object-affected harmful factorsVSVolume of stationary object

Solution Approach 1:

The baffle is separated from the tank wall structure, allowing it to be installed independently inside the tank rather than being molded as an integrated part of the tank wall. This segmentation enables the baffle to occupy space that would otherwise be available for fuel storage, thus preserving internal volume while still achieving noise suppression functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A fixation device acts as an intermediary element between the baffle and the tank wall, providing a mounting mechanism that does not require the baffle to be molded from the tank wall. This intermediary fixation system allows the baffle to be positioned and secured without compromising the tank's internal volume.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If noise reduction baffles are molded from the tank wall, then noise suppression is achieved, but the overall weight of the tank increases

Engineering Contradiction:

Improveslosh noiseVSAvoidtank weight

Core Design Contradiction:

Object-affected harmful factorsVSWeight of stationary object

Solution Approach 1:

By segmenting the baffle from the tank wall structure, the design allows for optimized material selection and weight distribution. The baffle can be made from lighter materials or thinner sections since it doesn't need to be structurally integrated into the tank wall, thereby reducing overall tank weight while maintaining noise suppression effectiveness.

Inventive Principle:

Principle #1Segmentation

3Object-affected harmful factors

If noise reduction baffles are molded from the tank wall, then noise suppression is achieved, but shape and material options are limited

Engineering Contradiction:

Improveslosh noiseVSAvoidshape and material options

Core Design Contradiction:

Object-affected harmful factorsVSAdaptability or versatility

Solution Approach 1:

Segmenting the baffle from the tank wall allows it to be manufactured separately using different materials and shapes that are optimized for noise suppression performance. This independence enables selection from a wider range of materials (such as flexible polymers, foams, or composite materials) and geometric configurations without being constrained by the tank wall molding process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The separation of the baffle from the tank wall structure enables changes in material parameters (density, elasticity, damping properties) and geometric parameters (shape, size, positioning) to be optimized independently for noise suppression, providing greater versatility in design options.

Inventive Principle:

Principle #35Parameter changes

4Reliability

If interference sections are provided for negative pressure resistance, then tank integrity is maintained, but the internal volume is reduced

Engineering Contradiction:

Improvetank integrity under negative pressureVSAvoidinternal volume

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The fixation device that secures the baffle is merged with one of the interference sections required for negative pressure resistance. This combination means that the same structural element serves dual purposes: providing mechanical support for the baffle and maintaining tank integrity under vacuum conditions, thereby avoiding additional volume occupation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The interference section is designed to perform multiple functions: it provides structural reinforcement for negative pressure resistance and simultaneously serves as a fixation device for mounting the baffle. This multi-functionality eliminates the need for separate components, preserving internal volume while ensuring both tank integrity and noise suppression.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS9168830B2Plastic fuel tank comprising a noise reduction baffle and process for manufacturing it

Publication Date: 2015.10.27 PLASTIC OMNIUM ADVANCED INNOVATION & RES SA

AI summary

Plastic fuel tank comprising a noise reduction baffle and interference sections for suppressing tank deformation in the case of application of negative pressure to said tank, the interference sections projecting inward in the tank from an upper surface and a lower surface thereof respectively, and being disposed so as to be substantially opposed with a specified interval between them, one of these sections being part of a fixation device which secures the baffle to the tank wall.