Plastic Fuel Tank Pot-Like Installation Body Undercut Engagement
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Solution Overview
Problem
Existing methods for securing a tank module with a fuel pump in a plastic fuel tank often require complex installation processes or additional components, and may result in issues like dry running of the pump at low fuel levels or pumping gaps.
Innovation Solution
A ring body with retaining ribs is engaged in an undercut section of the tank wall, and the installation body is securely fastened within the ring body, using a method where the undercut section is produced during blow molding, either by sliders or a molded part, ensuring a secure attachment without play.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing methods are used to secure the tank module, then the fuel pump can be mounted, but the installation process becomes complex and requires additional components
Solution Approach 1:
The ring body is nested within the undercut section of the tank wall, while the installation body is simultaneously nested within the ring body. This nested arrangement allows both components to be securely integrated without requiring additional fastening elements or complex assembly procedures, thus ensuring reliable attachment while maintaining simplicity.
Solution Approach 2:
The undercut section of the tank wall is designed to automatically engage and secure the ring body through its geometric shape alone, without requiring separate fastening mechanisms. The ring body's retaining ribs interact with the undercut geometry to provide self-securing functionality, eliminating the need for additional components and simplifying the installation process.
2Reliability
If existing methods are used to secure the tank module, then the fuel pump can be mounted, but extensive installation effort is required
Solution Approach 1:
The undercut section is pre-formed in the tank wall during the molding process, and the ring body is pre-designed with retaining ribs that match this geometry. This preliminary preparation allows for rapid assembly during installation, as the components are already configured to fit together without requiring complex assembly steps or additional fastening operations.
Solution Approach 2:
The nested arrangement of the ring body within the undercut section and the installation body within the ring body creates a self-contained assembly unit. This integration reduces the number of separate installation steps required, as the components are designed to be assembled together in a single operational sequence, thereby reducing installation effort and time.
3Reliability
If the installation body is secured in the tank, then the fuel pump operates reliably, but plastic welding processes are required
Solution Approach 1:
The mechanical fastening system replaces plastic welding processes by using the geometric interaction between the undercut section and the ring body's retaining ribs. This mechanical engagement provides secure attachment through friction and geometric interlocking alone, eliminating the need for thermal welding operations and their associated complexity.
Solution Approach 2:
The welding process is extracted and removed from the assembly process entirely. Instead of requiring plastic welding to secure the installation body, the design extracts the fastening function and implements it through pure mechanical means via the undercut-section engagement, thereby simplifying the manufacturing process.
Data Source
AI summary
The present disclosure relates to a plastic tank, particularly a plastic fuel tank, with a pot-like installation body arranged on the inside of the tank, as well as a method for producing the same. According to the present disclosure, a ring body is provided which is arranged on an end portion of the installation body, wherein the ring body is engaged in an undercut section in the tank wall, and the installation body is engaged in the ring body.