Fuel Tank Module Sealed Design for Racing Vehicle Safety

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Passenger motor vehicles used for racing sports face safety risks due to fuel tank modules located in the passenger compartment, where fuel lines are prone to damage in accidents, and incomplete emptying of fuel tanks leads to residual quantities.

Innovation Solution

A fuel tank module with a sealed design, divided into two chambers - one for the tank bladder and another for the fuel pump unit, filter, and regulator - where fuel lines are external to the passenger compartment, ensuring no fuel leakage ignites within the compartment and allowing for complete emptying by transferring fuel from the main tank to a smaller catch tank.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If fuel lines are guided through the passenger compartment to the fuel tank module, then the fuel tank module can be positioned in the passenger compartment to increase range, but the fuel lines may be damaged during an accident creating safety risks

Engineering Contradiction:

Improvefuel capacityVSAvoidsafety risk from fuel leakage

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The fuel lines are extracted from the passenger compartment and routed externally through the vehicle body. The fuel tank module is positioned in the passenger compartment but connected to the engine via fuel lines that pass through openings in the vehicle body, keeping the fuel lines outside the passenger compartment to eliminate fire hazards while maintaining the extended range benefit.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The fuel system is segmented into distinct zones: the fuel tank module in the passenger compartment, the fuel lines routed externally through the vehicle body, and the engine in the engine compartment. This spatial segmentation isolates the fuel lines from the passenger compartment, reducing safety risks while preserving fuel capacity benefits.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If a simple container design is used for the fuel tank module, then manufacturing is easier, but complete emptying of the container is not possible leaving residual fuel quantities

Engineering Contradiction:

Improvecontainer design simplicityVSAvoidresidual fuel quantity

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The fuel tank module is segmented into two functional chambers: a storage chamber for the expandable bladder and a dispensing chamber containing the fuel pump. This segmentation allows the pump to access and empty residual fuel from the storage chamber, achieving complete emptying while maintaining a simple overall container design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The fuel pump acts as an intermediary mechanism between the storage chamber and the external fuel line. It actively transfers residual fuel from the storage chamber through the dispensing chamber to the external fuel line, enabling complete emptying of the container while keeping the container design simple.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Volume of moving object

If the fuel tank module is positioned in the passenger compartment, then range is increased, but the module poses an elevated risk to the driver in case of accident

Engineering Contradiction:

Improvefuel capacityVSAvoidoccupant safety

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The fuel lines are extracted from the passenger compartment and routed externally through the vehicle body. The fuel tank module remains in the passenger compartment to maintain range, but the fuel lines pass through openings in the vehicle body, keeping them outside the passenger compartment to eliminate fire hazards while preserving the extended range benefit.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The potential harm of having the fuel tank module in the passenger compartment is converted into a benefit by routing the fuel lines externally. The module position enables extended range, and the external fuel line routing eliminates the associated fire hazard, transforming the safety risk into a safe configuration.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Data Source

PatentUS8282132B2Passenger motor vehicle with fuel module arranged within a passenger compartment

Publication Date: 2012.10.09 DR ING H C F PORSCHE AG

AI summary

A passenger motor vehicle (1) has a passenger compartment (3) and a fuel tank module (4) is in the passenger compartment (3). The module (4) has first and second chambers (19, 20). The first chamber (19) holds a tank bladder and a catch tank (32) is arranged within the tank bladder. The second chamber (20) holds a fuel pump unit (33). The module (4) is sealed off from remaining areas of the passenger compartment (3), and fuel lines to the module (4) and from the module (4) to the internal combustion engine are arranged outside the passenger compartment (3). Thus, a high level of safety for the vehicle occupant is ensured despite the accommodation of the fuel module in the passenger compartment, and substantially complete emptying of the fuel in the fuel module is possible.