Liquid Tank Baffle Bracket Design for Stability
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Solution Overview
Problem
Existing liquid tanks for motor vehicles, particularly fuel tanks, face challenges in achieving targeted strength reinforcement and stability due to limitations in blow molding techniques, which result in inefficient material usage and limited design flexibility, as well as increased risk of baffle breakage when filled with water.
Innovation Solution
A liquid tank design featuring a columnar baffle bracket integrated into the tank shell, allowing for radial attachment of baffles that enhance stability and noise reduction, with the baffle mount connecting to another shell section for increased structural integrity, and formed as a one-piece plastic part for simplified manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If blow molding technique is used for manufacturing liquid tanks, then manufacturing simplicity is improved, but targeted reinforcement of individual tank areas becomes limited
Solution Approach 1:
The patent applies local quality by varying the wall thickness in specific areas of the tank shell to provide targeted reinforcement where needed. The blow molding process is modified to create local thickening zones that strengthen specific regions without requiring additional structural elements, thus maintaining manufacturing simplicity while achieving area-specific strength enhancement.
2Ease of manufacture
If additional structural elements such as baffles are attached individually using additional welds, then baffle installation is achieved, but accessibility during assembly is severely limited
Solution Approach 1:
The patent merges the baffle structure with the tank shell by integrating baffles into the shell during the blow molding process itself. This combination eliminates the need for separate attachment operations and welds, allowing baffles to be formed simultaneously with the shell in a single manufacturing step, thereby resolving the accessibility problem during assembly.
3Strength
If wall thickness is generally increased to improve strength, then strength properties are enhanced, but material waste increases significantly
Solution Approach 1:
The patent implements local quality by creating variable wall thickness distribution through controlled thickening in specific regions rather than uniformly increasing wall thickness throughout the entire tank. This approach provides necessary strength enhancement only where structurally required, minimizing material usage and reducing waste while maintaining overall tank performance.
4Adaptability or versatility
If geometric jumps are attempted in blow molding processes, then design flexibility is improved, but manufacturing reliability deteriorates
Solution Approach 1:
The patent applies dynamics by using a multi-stage blow molding process with controlled pressure and temperature variations that dynamically adapt to create complex geometric features. The process parameters are adjusted in different stages to reliably form geometric jumps and intricate tank shell shapes without compromising manufacturing precision, enabling design flexibility while maintaining forming reliability.
Data Source
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AI summary
The tank (100) has a gush wall bracket extending along an inner wall of a liquid tank shell (101) i.e. plastic mold part. A gush wall is provided in the gush wall bracket. The gush wall bracket connects the liquid tank shell with another liquid tank shell (109). The gush wall bracket is arranged in a pillared portion of the former liquid tank shell. Halt ribs stabilize the gush wall bracket. The former liquid tank shell and the gush wall bracket are formed by an injection molded part. An aperture is formed in the gush wall.