Fuel Tank Moulding with Core-Positioned Accessories
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Solution Overview
Problem
The challenge lies in producing a fuel tank with internal accessories that are optimally located and easily integrated during the moulding process, while maintaining leakproofness and minimizing the number and size of openings in the tank wall to reduce evaporation losses and prevent siphon formation in fuel systems.
Innovation Solution
A method utilizing a single core to position and fasten accessories in an ideal layout within the tank, allowing for a single-step integration of components like ventilation and fuel supply lines, and creating fluid communication through a reduced-dimension opening that can be freely chosen to prevent siphons and detours, using a parison and blow moulding techniques with a core that preheats and positions accessories for optimal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the number and size of openings in the tank wall are reduced to reduce evaporation losses, then evaporation losses are reduced, but it becomes more difficult to insert and position components inside the tank
Solution Approach 1:
The patent applies preliminary action by introducing accessories into the parison during the moulding process before the tank wall is fully formed. The accessories are positioned inside the parison while it is still pliable, allowing for optimal placement without requiring large openings in the finished tank wall. This preliminary positioning resolves the contradiction by enabling component insertion before the structural integrity and leakproof requirements are finalized.
Solution Approach 2:
The patent implements nesting by placing accessories inside the parison (a nested structure) during moulding. The accessories are inserted into the parison before the tank wall is formed, effectively nesting the components within the forming structure. This eliminates the need for separate insertion operations through the finished tank wall, reducing both evaporation losses and manufacturing complexity.
2Ease of manufacture
If accessories are placed inside the tank after moulding by separate operations, then accessories can be attached, but the process takes time and labour and is costly
Solution Approach 1:
The patent merges the accessory attachment operation with the tank moulding process. Instead of performing separate operations after moulding, the accessories are introduced and attached during the moulding cycle itself. This combining of operations eliminates additional assembly time and labour costs while maintaining proper accessory placement, directly resolving the contradiction between ease of manufacture and time loss.
3Ease of operation
If openings are made in the tank wall to introduce accessories, then accessories can be positioned, but the location may create siphons or unnecessary pipe length
Solution Approach 1:
The patent applies preliminary action by determining and establishing the optimal location for accessories during the moulding process design phase. The parison is configured with accessories positioned at ideal locations before moulding, ensuring that when the tank is formed, the accessories are already at their optimal positions. This preliminary positioning eliminates the need for post-moulding location adjustments and prevents siphon formation and unnecessary pipe length issues.
Solution Approach 2:
The patent implements local quality by optimizing the specific location of each accessory based on its functional requirements. Different accessories are positioned at different optimal locations within the parison during moulding, allowing each component to be placed where it performs best functionally. This localized optimization prevents harmful effects like siphons while maintaining ease of operation for each specific accessory.
4Productivity
If a single core is used to position accessories during moulding, then integration is simplified and time is reduced, but the process complexity increases
Solution Approach 1:
The patent applies universality by designing a single core that performs multiple functions: it serves as the support structure for the parison, the positioning mechanism for accessories, and the attachment tool during moulding. This multi-functional core consolidates what would otherwise require multiple separate devices or operations, increasing productivity while actually reducing overall process complexity through consolidation rather than addition of components.
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 approach enables the production of a fuel tank with optimized accessory placement, reduced assembly time and costs, and leakproof fluid communication, while minimizing the number of steps and ensuring efficient fluid transfer without siphon formation or unnecessary pipe length.
Implementation Method 1
a method for moulding a fuel tank using a parison in several parts so as to be able to insert the accessories into the tank at the same time as it is moulded
Implementation Method 2
using a parison and blow moulding techniques with a core
Data Source
Figure 1~3
AI summary
Method for producing a fuel tank provided with internal accessories (2, 3) and having a wall (1) made of plastic made in a single piece by moulding a split parison or a parison in at least two parts, said method comprising the following steps: a) the parison is introduced in the heat-softened state into a mould comprising dies; b) a core on which the accessories (2, 3) are placed is introduced inside the parison; c) the parison is pressed onto the dies of the mould; d) the accessories (2, 3) are fastened to the parison with the aid of the core in an ideal layout; e) the core is withdrawn and the mould is closed; f) the tank is moulded from the parison; and g) the tank is removed from the mould.