Plastic Fuel Tank Reinforcing Profiles for Deformation Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional plastic fuel tanks in motor vehicles experience significant deformations due to pressure and temperature peaks, leading to relative movements of tank shells, which existing supporting concepts fail to adequately address without reducing tank volume or causing reinforcing components to detach.
Innovation Solution
A plastic tank design featuring elongate reinforcing profiles with a retaining geometry on the outer side, where the tank wall material engages with the profiles through openings, creating a positive retention mechanism to prevent detachment and enhance structural integrity without significantly reducing tank volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional supporting concepts (fixed support points) are used to limit deformations of tank walls, then deformation is reduced, but these measures are insufficient for pressurized tank systems and additional measures are required
Solution Approach 1:
The tank wall is divided into multiple zones by introducing longitudinal and transverse reinforcing profiles that segment the shell into smaller panels. This segmentation allows each panel to better resist deformation under pressure while maintaining overall tank integrity.
Solution Approach 2:
The invention transitions from point-based support (0D) to line-based reinforcement (1D) by introducing elongate reinforcing profiles that run longitudinally and transversely across the tank wall, adding dimensional complexity to the support structure.
2Strength
If shell thickness of the tank bladder is increased to limit deformation, then deformation resistance improves, but tank volume is significantly reduced
Solution Approach 1:
The tank wall is constructed as a composite structure combining the plastic tank bladder with separate reinforcing profile elements. This composite approach provides enhanced deformation resistance without requiring increased thickness of the tank wall material itself, thereby preserving tank volume.
Solution Approach 2:
Instead of uniformly increasing shell thickness, the reinforcement is segmented into discrete profile elements positioned at critical locations, providing structural support only where needed and maintaining maximum tank volume.
3Strength
If reinforcing welded-on components are used to limit deformation, then deformation resistance improves, but the reinforcing components may become detached during use
Solution Approach 1:
The tank wall and reinforcing profiles are merged into a single integrated component through co-molding, eliminating separate attachment operations and potential failure points. The profiles and tank wall become structurally unified, ensuring long-term reliability under dynamic loading conditions.
4Strength
If additional reinforcing measures are employed to reduce deformations, then deformation resistance improves, but device complexity increases
Solution Approach 1:
The reinforcing profiles serve multiple functions simultaneously: they provide deformation resistance, maintain tank volume, ensure attachment reliability through integrated design, and can be manufactured in a single process. This multi-functionality reduces overall system complexity despite the added structural features.
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
The solution effectively minimizes unwanted deformations in plastic tanks, ensuring long-term reliability and structural integrity while maintaining tank volume, by forming a materially bonded connection between the tank wall and reinforcing profiles during production.
Implementation Method 1
the material of the tank wall engages around the reinforcing profile, at least in some region or regions, with the result that there is positive retention between the tank wall and the reinforcing profile
Data Source
AI summary
A tank that includes a tank wall composed of a plastic material, and at least one reinforcing profile member configured to minimize deformation of the plastic tank. The at least one reinforcing profile member is configured for arrangement on an outer side of the tank wall to be engaged by the tank wall and establish a positive material bond connection therewith. The at least one reinforcing profile member has a retaining geometry region with a plurality of openings through and/or into which material of the tank wall extends and onto a rear side of the reinforcing profile member facing away from the tank wall to thereby establish the positive material bond connection between the tank wall and the at least one reinforcing profile member at the retaining geometry region.