Plastic Fuel Tank Component Integration via Molding Core
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Solution Overview
Problem
Existing processes for manufacturing plastic fuel tanks face challenges in achieving rapid, precise, and leak-free installation of components, often resulting in labor costs and scrap due to manual assembly errors and potential damage to the tank during component insertion.
Innovation Solution
A process involving molding a parison using a mold with two impressions and a core, where the core is fitted with components, allowing for leaktight contact and pressing of the parison to form a pocket for component installation, eliminating manual assembly risks and ensuring precise component placement without damaging the tank.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If components are fastened to the tank after molding by making openings and using compression seals, then components can be installed inside the tank, but sealing and permeability problems occur near the openings and manual assembly increases labor costs and scrap
Solution Approach 1:
The component is pre-positioned on the core before the parison is molded, allowing the component to be integrated into the tank wall during the molding process itself rather than requiring post-molding installation. This preliminary positioning ensures proper sealing and eliminates the need for separate fastening operations.
Solution Approach 2:
The component fastening process is merged with the tank molding process. By positioning the component on the core and molding the parison around it, the component becomes an integrated part of the tank structure, combining two separate operations (component installation and tank molding) into one simultaneous process.
2Reliability
If a core is used to position components on the parison during molding, then components can be fastened without piercing the parison, but the process requires manual assembly steps or deformation of the parison which risks damaging the parison
Solution Approach 1:
The component is pre-positioned on the core with precise location features before the parison is molded. This preliminary positioning ensures that the component will be accurately placed in the final tank without requiring post-molding adjustment or manual assembly, thereby maintaining parison integrity while improving assembly precision and speed.
Solution Approach 2:
The core serves as an intermediary device that temporarily holds the component in the correct position during molding. The core transfers the positioning function from a potentially damaging post-molding operation to a controlled pre-molding setup, allowing the parison to be molded around the component without piercing or deformation.
3Ease of manufacture
If the parison is deformed by piercing to allow component passage, then components can be installed through the tank wall, but the parison may be damaged and the EVOH layer may break compromising impermeabilization
Solution Approach 1:
Instead of piercing the parison after molding to install components, the component is pre-positioned on the core before molding begins. This allows the parison to be molded around the component in its entirety, completely avoiding any piercing or deformation of the parison and preserving the integrity of the EVOH impermeabilization layer.
4Adaptability or versatility
If manual assembly is used after molding to install components, then components can be positioned on the tank, but labor costs increase and human error may generate scrap
Solution Approach 1:
The component is pre-positioned on the core with precise location features before the molding process begins. This eliminates the need for manual assembly after molding, as the component is automatically positioned correctly during the molding process itself, thereby reducing labor costs and eliminating human error while maintaining positioning flexibility through the core design.
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 process enables rapid, precise, and reproducible installation of communication components within the tank, reducing production costs and increasing quality by eliminating leakage risks and component damage, while maintaining tank impermeability.
Implementation Method 1
pressing of the parison against the impressions by blowing through the core and/or applying a vacuum behind the impressions
Implementation Method 2
pressing of the parison against the impressions by blowing through the core and/or applying a vacuum behind the impressions
Implementation Method 3
installation of the communication component comprises its fastening, in this pocket, by welding of at least one portion of its side wall to at least one portion of the side wall of the pocket
Data Source
AI summary
Process and device for manufacturing a plastic fuel tank equipped with at least one communication component, by molding a parison using a mold comprising two impressions and a core, said process comprising the pressing of the parison against the impressions and formation of a pocket in this parison, the communication component being fastened in this pocket by welding of at least one portion of its side wall to at least one portion of the side wall of the pocket.