Fuel Tank Float With Integrated Magnetized Particles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing fuel tank systems face design constraints due to the need for thick, buoyant floats with stand-alone magnets, limiting the possibility of manufacturing floats with smaller thickness, smaller overall size, or complex shapes that can still activate reed switches on printed circuit boards.
Innovation Solution
A float manufactured with magnetized particles interspersed throughout and incorporating a foaming agent to create air voids, allowing for a thin wall thickness and small size while maintaining magnetic properties, enabling activation of reed switches without a stand-alone magnet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a stand-alone magnet is secured on the float, then the magnetic field strength is sufficient to activate reed switches, but the float thickness and overall size must be increased
Solution Approach 1:
The patent combines the magnetic particles directly into the float material matrix, merging the magnetic function with the float structure itself. This eliminates the need for a separate stand-alone magnet and its associated mounting requirements, allowing thinner float designs while maintaining sufficient magnetic field strength for reed switch activation.
Solution Approach 2:
The float is constructed using composite material containing magnetized particles dispersed throughout the material matrix. This composite structure provides both the structural integrity of the float and the magnetic properties needed for sensor activation, resolving the contradiction between size reduction and magnetic field maintenance.
2Length of moving object
If the float thickness is reduced, then the float size is decreased, but the float can no longer support a stand-alone magnet
Solution Approach 1:
The magnetic functionality is merged into the float material itself through incorporation of magnetized particles during manufacturing. This eliminates the need for separate magnet mounting operations, simplifying the manufacturing process while enabling thinner float designs that would otherwise be incapable of supporting a stand-alone magnet.
Solution Approach 2:
The patent changes the magnetic parameter distribution from a concentrated stand-alone magnet to a distributed arrangement of magnetized particles throughout the float material. This parameter change allows the float to maintain magnetic functionality at reduced thicknesses where a stand-alone magnet could not be mounted.
3Force
If a foaming agent is added to the float material, then the buoyancy is increased, but the material composition becomes more complex
Solution Approach 1:
The patent employs porous material structure created by incorporating a foaming agent during float manufacturing. The resulting air-filled voids within the float material increase buoyancy forces without requiring additional structural complexity, as the porosity is integrated into the base material formulation rather than requiring separate buoyancy enhancement mechanisms.
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
Enables the production of floats with a small footprint and custom shapes that can move freely within fuel tanks, providing accurate fuel level sensing without the weight and size constraints of traditional designs.
Implementation Method 1
the float may be manufactured of a material having magnetized particles interspersed throughout the float such that the float does not require a stand alone magnet secured thereon
Implementation Method 2
the float may be manufactured of a material having a foaming agent added thereto so as to provide a finished product with air filled voids positioned throughout the float to increase the buoyancy of the finished float product
Data Source
AI summary
One embodiment of a fuel tank assembly includes a fuel sending unit having a float with a small thickness, which heretofore has been too thin to secure a stand-alone magnet thereon. The float may be manufactured in a complex shape or in a small size. In one embodiment the float may be manufactured of a material having magnetized particles interspersed throughout the float such that the float does not require a stand alone magnet secured thereon. The float may be manufactured of a material having a foaming agent added thereto so as to provide a finished product with air filled voids positioned throughout the float to increase the buoyancy of the finished float product.