Vehicle Fuel Tank Crashworthiness via Nested Shell Design
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Solution Overview
Problem
Conventional fuel tanks in vehicles are prone to rupture and fuel spillage during crashes, leading to increased risks of fires and explosions due to their exposure and construction, which do not effectively manage impact energy to relocate the tank away from the point of impact.
Innovation Solution
A fuel tank design featuring a protective outer shell and a deformable crush sleeve that isolates an inner shell, allowing the inner shell to move axially and/or radially during an impact, positioning it further from the point of impact or protecting it with the vehicle's chassis, thereby reducing the likelihood of failure and spillage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the fuel tank is positioned outside the frame rails for easy access and installation, then the ease of operation is improved, but the tank becomes exposed to crushing during crashes, increasing the risk of fuel spillage and fire
Solution Approach 1:
The patent employs a nested structure where the inner fuel tank is housed within an outer protective shell. The outer shell acts as a sacrificial protective layer that absorbs impact forces during crashes, while the inner tank remains protected. This nested configuration allows the fuel tank system to maintain ease of installation while significantly reducing crash exposure risks.
2Device complexity
If conventional fixed fuel tank construction is used, then the device complexity is reduced, but the tank cannot move away from the impact path during collision, increasing the likelihood of rupture
Solution Approach 1:
The patent transforms the fixed fuel tank structure into a dynamic system where the inner tank can move relative to the outer shell during impact events. The inner tank is designed to slide or shift away from the impact path when subjected to crash forces, allowing the system to adapt to collision conditions. This dynamic capability significantly improves crashworthiness while maintaining relatively simple construction through the use of sliding surfaces and clearance spaces.
3Weight of moving object
If thin wall aluminum or steel tanks are used for fuel storage, then the weight is reduced, but the tanks are more susceptible to punctures and seam failure during impacts
Solution Approach 1:
The patent employs a composite structure consisting of multiple material layers and components. The outer shell provides a protective barrier, the crush sleeve offers sacrificial energy absorption, and the inner tank contains the fuel. This composite construction allows the use of lighter materials for the inner tank while maintaining overall impact resistance through the combined protective system. The different layers serve complementary functions, achieving both weight reduction and enhanced strength.
Solution Approach 2:
The patent incorporates a crush sleeve made of energy-absorbing material positioned between the outer shell and inner tank. This crush sleeve is designed to deform and absorb impact energy before it reaches the inner fuel tank, providing beforehand cushioning against punctures and seam failures. This pre-positioned protective element significantly enhances impact resistance while allowing the inner tank to remain lightweight.
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
The design enhances crashworthiness by managing impact energy to minimize tank failure, fuel spillage, and the risk of fires or explosions, improving the safety of fuel storage during collisions.
Implementation Method 1
the force of the impact causes the outer shell and the crush sleeve to deform and the inner shell to move relative to the outer shell
Implementation Method 2
the force of the impact causes the outer shell and the crush sleeve to deform
Data Source
AI summary
A fuel tank in a vehicle. The fuel tank includes a protective outer shell, an inner shell and a crush sleeve. The protective outer shell defines an outer tank. The inner shell defines an inner tank which holds fuel. The inner shell is housed in the outer shell and is isolated from the outer shell by a space. The crush sleeve is provided in the space between the outer shell and the inner shell. The crush sleeve supports the inner shell and maintains the inner shell in position relative to the outer shell. Wherein during an impact to the vehicle, the force of the impact causes the outer shell and the crush sleeve to deform and the inner shell to move relative to the outer shell.