Motorcycle Fuel Tank with Integrated Injection-Molded Compartments
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing fuel tanks for motor vehicles, particularly motorcycles, are limited in shaping flexibility, integration of additional components, and surface quality, making them unsuitable for use as visible parts and lacking additional functions beyond fuel storage.
Innovation Solution
A fuel tank design featuring two injection-molded partial bodies with physically separated receiving chambers, including a fuel chamber and additional compartments like air filters or storage, integrated with reinforcing elements for enhanced rigidity and strength, allowing for the integration of various components and improved manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If blow molding or rotational molding is used to produce fuel tanks, then production is possible, but shaping flexibility is extremely limited and surface quality is inadequate for visible parts
Solution Approach 1:
The patent replaces traditional mechanical molding methods (blow molding, rotational molding) with injection molding technology. This substitution enables precise shaping and high surface quality suitable for visible parts while maintaining manufacturing efficiency. The injection molding process allows for complex geometries and integrated components that were not achievable with conventional methods.
2Productivity
If traditional molding methods are used, then fuel tanks can be produced, but integration of further components is possible only to a very limited extent
Solution Approach 1:
The patent combines multiple components and functions into a single integrated fuel tank structure produced by injection molding. The tank can incorporate mounting brackets, fluid conduits, reinforcement elements, and multiple receiving chambers all in one manufacturing process. This merging approach maintains high productivity while dramatically improving integration capability compared to traditional multi-step assembly methods.
Solution Approach 2:
The fuel tank is designed as a multi-functional component that not only stores fuel but also provides structural support, mounting points for other components, fluid management pathways, and reinforcement structures. This universal design allows a single part to perform multiple functions that previously required separate components, enhancing adaptability without compromising manufacturing efficiency.
3Adaptability or versatility
If fuel tanks are designed with additional functions and integrated components, then versatility improves, but device complexity increases
Solution Approach 1:
The patent divides the fuel tank into multiple receiving chambers (first receiving chamber for fuel, second receiving chamber for other purposes) separated by internal partitions. This segmentation allows different functions to be housed within a single integrated structure, increasing versatility while managing complexity through organized compartmentalization rather than multiple separate components.
Solution Approach 2:
The design embeds additional components and structures within the fuel tank walls and chambers. Reinforcement elements are integrated into the tank walls, mounting points are formed as part of the tank structure, and multiple receiving chambers are nested within the overall tank geometry. This nesting approach adds functionality while minimizing increases in external dimensions and overall structural complexity.
Data Source
AI summary
A fuel tank for a motor vehicle includes at least two parts that are joined together, each part being formed by an injection moulding process. The two parts form a receiving chamber for receiving fuel and form at least one other receiving chamber, the receiving chamber and the other receiving chamber being spatially separated by a portion of at least one part.