Integrally Cast Double-Walled Fuel Line Element
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Solution Overview
Problem
Existing double-walled fuel supply systems face challenges in precision manufacturing and high fault potential due to multiple welded seams, and they are not effective in preventing fuel vaporization emissions when using plastic inner fuel lines, which can lead to leakage and environmental contamination.
Innovation Solution
A double-walled fuel supply line element is integrally cast using materials like non-alloyed cast steel, alloyed cast steel, or cast iron, with a connecting structure that forms a hollow space between the inner and outer line elements, ensuring a secure and gas-tight connection without the need for multiple welded seams, and allowing for the use of non-plastic inner lines to prevent fuel vaporization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple welded seams are used to assemble double-walled fuel supply line elements, then the structural integrity and gas-tightness are improved, but the fault potential increases and manufacturing precision becomes more difficult to maintain
Solution Approach 1:
The patent merges multiple separate components (inner line element, outer line element, and connecting structure) into a single integrally casted piece. This eliminates the need for welded seams between these components, thereby maintaining gas-tightness and structural integrity while eliminating the manufacturing precision issues and fault potential associated with multiple welded joints.
Solution Approach 2:
While the overall structure is integrated, the patent maintains functional segmentation through the hollow space between the inner and outer line elements. This allows the structure to serve multiple functions (fuel transport, leak detection, structural support) while being manufactured as a single piece, avoiding the problems of welded assemblies.
2Strength
If multiple welded seams are used to create T-shaped connection elements, then the structural strength is improved, but the production effort and monitoring requirements increase
Solution Approach 1:
The T-shaped connection element is manufactured as a single integrally casted piece rather than being assembled from multiple welded components. This maintains the required structural strength for T-shaped connections while dramatically reducing production effort by eliminating multiple welding operations and the associated monitoring and quality control requirements.
3Ease of manufacture
If plastic inner fuel lines are used in double-walled configurations, then the manufacturing cost is reduced, but fuel vaporization emissions occur due to porosity
Solution Approach 1:
The patent employs a composite material structure where the inner line element is made from non-plastic material (such as metal) that is non-porous and prevents fuel vaporization emissions. This may be combined with the outer plastic line element, creating a composite structure that maintains both the cost benefits of plastic components and the emission-prevention properties of non-plastic materials.
4Manufacturing precision
If integrally casted double-walled line elements are used, then the fault potential is reduced and manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
The complex geometry of the double-walled structure, including the hollow space and connecting structures, is prepared in advance through specially designed molds and core elements. By performing the complex shaping work during the casting process rather than through subsequent assembly operations, the patent achieves high manufacturing precision while managing device complexity through preliminary mold design.
Data Source
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AI summary
The present disclosure generally refers to a double-walled fuel supply line element (5) configured to be used in a fuel supply system (100) of e.g. middle to large-sized internal combustion engines and a method for manufacturing such a fuel supply-line element (5). The double-walled fuel supply line element (5) may comprise an inner line element (10), an outer line element (40), and a connecting structure (70) configured to fixedly arrange the outer line element (40) around the inner line element (10) such that a tubular hollow space (50) is provided between the inner line element (10) and the outer line element (40). The inner line element (10), the outer line element (40), and the connecting structure (70) may be integrally casted.