Plastic Fuel Tank Support Flange for Weld-Free Stiffness
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Solution Overview
Problem
Existing plastic fuel tanks with supporting elements face challenges in manufacturing efficiency and cost due to sensitive welding processes during the connection of supporting elements to the tank body, and they lack sufficient mechanical stiffness.
Innovation Solution
A plastic fuel tank design with integrated receiving structures for supporting elements, allowing stable attachment without welding the outer surfaces, featuring a flange that fits within stepped cavities to simplify manufacturing and enhance mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If supporting elements are welded to the fuel tank body, then mechanical stiffness is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical joining) with a mechanical insertion system. The flange of the supporting element is inserted into a receiving structure with a stepped cavity, eliminating the need for welding operations. This substitution reduces manufacturing complexity while maintaining the mechanical stiffness provided by the supporting elements.
Solution Approach 2:
The receiving structure with stepped cavity acts as an intermediary component that facilitates the connection between the supporting element and the fuel tank body. The flange fits into the stepped cavity, providing a stable mechanical interface that replaces the direct welding connection, thereby simplifying the manufacturing process.
2Strength
If supporting elements are welded to the fuel tank body, then mechanical stiffness is improved, but manufacturing time increases
Solution Approach 1:
By replacing the welding process with a mechanical insertion system, the patent eliminates the time-consuming welding operations. The flange can be inserted into the receiving structure more quickly and with less precision requirements, thereby increasing manufacturing velocity while maintaining mechanical stiffness.
Solution Approach 2:
The receiving structure is pre-formed with a stepped cavity that guides and positions the flange during insertion. This preliminary preparation of the receiving structure allows for faster assembly of the supporting elements, as the positioning and alignment are already built into the mold design, reducing assembly time.
3Reliability
If supporting elements are welded to the fuel tank body, then connection stability is improved, but sensitivity to movements during manufacturing increases
Solution Approach 1:
The patent replaces the welding process, which requires high positioning precision and is sensitive to movements, with a mechanical insertion system. The stepped cavity in the receiving structure provides mechanical guidance and positioning for the flange, making the connection process less sensitive to movements during manufacturing while maintaining connection stability.
Solution Approach 2:
The flange is nested within the stepped cavity of the receiving structure, creating a fitted connection. This nesting arrangement provides inherent positioning and stability, as the flange is contained within the cavity, reducing sensitivity to manufacturing variations and improving connection reliability.
Data Source
AI summary
A plastic fuel tank for a vehicle, the plastic fuel tank including a bottom part and a top part; at least one side wall extending between the bottom part to the top part; at least one supporting element. The at least one supporting element has an elongated shape and includes a longitudinal axis, includes a first end side and a second end side in its axial ends, includes a flange at the first end side or the second end side. The flange includes a flange width, and is arranged between the bottom part and the top part; wherein the top part or the bottom part includes an integrated receiving structure for receiving the flange of the supporting element. The receiving structure is formed by the top part or the bottom part, and forms a stepped cavity including a first cavity and a second cavity.