Integrated Fuel Tank Assembly for Commercial Vehicles
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Solution Overview
Problem
Prior art fuel tank assemblies for commercial vehicles require extensive installation time and space due to multiple separately mounted components, which are not cost-effective and lack structural integrity.
Innovation Solution
An integrated fuel tank assembly is manufactured as a single extruded device incorporating a fuel draw line, auxiliary fuel line, fuel return line, level sending unit cavity, rollover vent, coolant inlet, and coolant outlet, allowing all components to be secured with a single flange and manufactured from a single piece of material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple components are separately mounted on the fuel tank, then each component can be independently manufactured and installed, but the installation time and space requirements increase extensively
Solution Approach 1:
The patent combines multiple separately mounted components (draw tube, return tube, level sending unit, vent, pressure valve) into a single integrated assembly that is extruded as one piece. This merging eliminates the need to install multiple separate components, dramatically reducing installation time while maintaining the functional independence of each component through precise integration during the extrusion process
2Ease of manufacture
If multiple components are separately mounted on the fuel tank, then each component can be independently installed, but the space requirements on the fuel tank increase extensively
Solution Approach 1:
The integrated assembly merges all fuel management components into a single compact unit that mounts to the fuel tank as one piece. This consolidation reduces the total surface area required on the fuel tank compared to having multiple separate mounting locations, while still providing all necessary functions through the integrated design
3Ease of operation
If multiple components are separately mounted on the fuel tank, then installation flexibility is maintained, but the structural integrity and sturdiness decrease
Solution Approach 1:
The patent creates a single integrated assembly where all components are structurally unified through the extrusion process. This merging provides inherent structural integrity and sturdiness that cannot be achieved with separately mounted components, as the entire assembly acts as one rigid unit that resists vibration and environmental stresses better than multiple loose components
Solution Approach 2:
The integrated assembly performs multiple functions (fuel draw, return, level sensing, venting, pressure regulation) within a single multi-functional structure. This universal design maintains installation flexibility while achieving superior structural integrity through the unified construction that withstands harsh commercial trucking environments
4Ease of repair
If multiple components are separately mounted on the fuel tank, then component replacement is simplified, but manufacturing cost and complexity increase
Solution Approach 1:
The integrated assembly combines all components into one unit, reducing device complexity from multiple separate parts to a single assembly. While this may seem to reduce ease of repair, the unified structure actually simplifies the overall system and reduces the number of separate mounting operations and potential failure points associated with multiple separate components
Data Source
AI summary
The present invention relates to an integrated fuel tank assembly, and a process of manufacturing the same, for use in commercial vehicles, and more particularly, to an integrated fuel tank assembly that allows multiple components to be manufactured as a single integral structure, such as a single extruded device including a draw tube, a return tube, a fuel sender device, and a vent, for example.