Thermoplastic Fuel Tank Seam Integration for Leakage Reduction
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Solution Overview
Problem
Existing fuel tanks made of thermoplastic face challenges in minimizing the number of orifices in the tank wall, which can lead to potential leakage points for hydrocarbons, especially around seams, connectors, and fittings, and there is a need to reduce the size and number of these openings to minimize hydrocarbon emissions and ensure leaktightness.
Innovation Solution
A fuel tank design featuring a continuous seam with integrated leadthroughs for fluid and electrical lines, where these lines pass through the seam or filler neck, eliminating the need for additional orifices in the tank wall, and using a multilayer coextrudate with a hydrocarbon barrier layer to enhance leaktightness, with connection elements like pine-tree profile nipples welded into the tank wall for fluid lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple orifices are provided in the tank wall for fuel conveying unit, venting lines, and electrical connections, then the tank can accommodate all necessary functional connections, but the number of potential leakage points increases and hydrocarbon emissions increase
Solution Approach 1:
The patent combines multiple separate connection functions into a single integrated seam structure. The seam serves simultaneously as the welding joint between tank halves, the passage for fuel lines, the route for electrical cables, and the location for venting connections. This merging of multiple functions into one location eliminates the need for multiple separate orifices, thereby reducing leakage points while maintaining all necessary functional connections.
Solution Approach 2:
The seam structure is designed as a multi-functional element that performs multiple roles: structural joining of tank halves, fluid passage for fuel extraction and return lines, electrical conduit for cables, and mounting location for venting components. This universal seam design allows the tank wall to accommodate all necessary connections without creating additional perforations, thus minimizing hydrocarbon emission pathways.
2Object-generated harmful factors
If the tank wall is made intact without orifices to minimize leakage, then hydrocarbon emissions are reduced, but it becomes difficult to provide necessary connections for fuel conveying unit and other functional groups
Solution Approach 1:
The patent integrates all necessary functional connections into the seam structure itself, rather than creating separate orifices. The fuel extraction line, return line, electrical cables, and venting connections are all routed through or integrated with the seam, allowing the tank wall to remain substantially intact while providing all required functional access points.
Solution Approach 2:
The seam acts as an intermediary structure that mediates between the requirement for an intact tank wall and the need for functional connections. By incorporating connection elements within the seam itself, the seam serves as a mediator that allows fluid and electrical passages without requiring separate perforations through the tank wall, thus maintaining wall integrity while enabling necessary connections.
3Ease of repair
If inspection orifices are provided for accessing the fuel conveying unit, then maintenance and repair become easier, but the number of leakage points increases
Solution Approach 1:
The patent combines the inspection/maintenance access function with the existing seam structure. The seam, which already requires access for connection installation, is designed to also serve as the access point for maintenance activities. Connection elements are positioned within the seam such that the same access provided for installing connections also enables maintenance and inspection, eliminating the need for separate inspection orifices.
4Ease of manufacture
If connection elements are welded into the tank wall through separate orifices, then fluid lines can be connected, but additional leakage points are created in the tank wall
Solution Approach 1:
The patent merges the connection installation process with the seam welding process. Connection elements are positioned and welded into the seam structure itself during the same manufacturing operation used to join the tank halves. This integration means that connection installation does not require separate orifices or additional penetration of the tank wall, thereby eliminating additional leakage points while maintaining ease of connection installation.
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
This design minimizes potential leakage paths and hydrocarbon emissions by eliminating unnecessary orifices, ensuring a sealed tank wall with integrated leadthroughs and connection elements, maintaining the integrity of the tank wall while allowing necessary fluid and electrical connections.
Implementation Method 1
modern fuel tanks are produced from plastic consisting of multilayer coextrudates which contain barrier layers for hydrocarbons. The permeation leaktightness of the tank wall therefore usually does not present any problem.
Implementation Method 2
connection elements like pine-tree profile nipples welded into the tank wall for fluid lines
Data Source
AI summary
The invention relates to a fuel tank (1) consisting of thermoplastic, with at least one continuous seam (3), with a filler orifice, with means for aeration and venting and with means for the conveyance and extraction of fuel which are in the form of at least one fuel conveying unit (11) arranged inside the fuel tank (1). In the fuel tank (1) according to the invention, with the exception of the filler orifice, no orifices or perforations which are substantially larger than the diameter of the line to be led through are provided in the tank wall, instead the fluid lines and/or electrical lines led out of or into the fuel tank (1) pass through the seam (3) of the fuel tank (1) so as to extend at an angle with respect to the profile of the seam (3), and/or are led partially through the filler orifice and, if appropriate, a filler neck adjoining the filler orifice.