Fuel Tank Functional Component Support Stiffness
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Solution Overview
Problem
Conventional fuel tanks face challenges in ensuring secure and rigid positioning of functional components due to the elastically compliant nature of the functional component support, which can lead to insecure positioning and potential damage during the blow molding process.
Innovation Solution
A functional component support is rigidly connected to the fuel tank's inner wall via supporting legs, forming a dimensionally stable node location with increased stiffness, allowing for direct fastening of components and using a baffle wall with a flat, plate-shaped supporting leg and latching elements for secure assembly without tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the functional component support is made from thermoplastic resin with low material thickness to achieve elastic compliance, then the support can be easily manufactured and integrated, but the positioning security of functional components deteriorates
Solution Approach 1:
The supporting leg is designed with non-uniform thickness: a first region with lower material thickness for elastic compliance and a second region with increased material thickness for rigidity. This local quality variation allows the support to be both easy to manufacture and reliable in positioning functional components.
Solution Approach 2:
The material thickness parameter is changed along the length of the supporting leg. The transition from thinner to thicker sections modifies the mechanical properties from compliant to rigid, resolving the contradiction between ease of manufacture and positioning security.
2Device complexity
If the functional component support is made elastically compliant with low inherent stiffness for easy integration, then manufacturing is simplified, but the secure positioning of functional components deteriorates
Solution Approach 1:
The supporting leg incorporates a localized thickened region that provides high stiffness specifically where functional components are mounted, while the rest of the structure remains thin and compliant. This reduces overall device complexity while ensuring positioning security at critical locations.
Solution Approach 2:
The supporting leg is segmented into functionally distinct regions: a compliant region for energy absorption and a rigid region for secure component positioning. This segmentation allows the structure to achieve both low complexity and high reliability.
3Productivity
If the supporting leg is made thin-walled for easy assembly, then assembly efficiency improves, but the dimensional stability and force transfer capability deteriorates
Solution Approach 1:
The supporting leg features a localized thickened section at the node location where dimensional stability is critical for force transfer to the fuel tank wall. The thin-walled sections maintain assembly efficiency while the thickened region ensures compositional stability.
4Ease of manufacture
If the functional component support is designed with low inherent stiffness for compliant arrangement, then integration with fuel tank is easier, but the torsion-proof and tilt-proof positioning deteriorates
Solution Approach 1:
The supporting leg is designed with a thickened region specifically at the connection point where functional components are positioned. This local quality enhancement provides the necessary manufacturing precision for secure positioning while keeping the overall structure easy to manufacture.
Solution Approach 2:
The thickened region is pre-formed in the supporting leg structure before component assembly, ensuring that positioning precision is built into the support itself rather than requiring additional adjustment or assembly steps.
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 solution ensures secure and precise positioning of functional components within the fuel tank, enhancing dimensional stability and preventing collisions during the blow molding process, thereby improving the reliability and assembly efficiency of the fuel tank.
Implementation Method 1
During the blow molding process, the functional component support is also welded or glued to the inside of the fuel tank in the region of its supporting legs
Data Source
AI summary
A fuel tank and a method for producing a fuel tank for a motor vehicle. The fuel tank is designed as a blow-molded hollow plastic member, into the interior of which a functional component support is introduced. The support, to which functional components, such as a fuel pump, a level indicator or valves can be secured, includes at least one supporting leg to be supported on an inner face of the hollow plastic member delimiting the interior thereof. The supporting leg of the functional component support is designed to include a connection point to which a functional component can be connected.