Segmented Thermoplastic Tank Reinforcement for Impact Stress
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Solution Overview
Problem
Thermoplastic fuel tanks in hybrid cars face breaking constraints during high energy impacts due to stress from overpressure or underpressure, leading to potential fuel leakage, as existing internal reinforcement elements are either too rigid or lack a preferential breaking section.
Innovation Solution
An internal reinforcement element for thermoplastic tanks comprising multiple external parts connected by intermediate units with limited side and face area connections, featuring a blade-shaped design with varying section dimensions and strategically located weak points, allowing for controlled stress distribution and earlier stress release during impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the internal reinforcement element is made rigid to resist overpressure and underpressure, then pressure resistance is improved, but the tank may break during high energy impact due to excessive stress
Solution Approach 1:
The internal reinforcement element is divided into multiple intermediate units (at least 3) connected by connection means, creating a segmented structure. This segmentation allows the element to flex during high energy impacts while maintaining pressure resistance, as the segments can move independently to absorb impact energy rather than transmitting it all to the tank wall.
Solution Approach 2:
The connection means between intermediate units allow relative movement and independent displacement during overpressure events. This dynamic capability enables the reinforcement element to adapt its rigidity - maintaining structural integrity for pressure resistance while allowing controlled movement to reduce stress during high energy impacts.
2Reliability
If the internal reinforcement element is made flexible to prevent tank breaking during impact, then impact resistance is improved, but pressure resistance decreases
Solution Approach 1:
The reinforcement element consists of multiple intermediate units (at least 3) connected by connection means, creating a segmented structure that can maintain overall rigidity for pressure resistance while allowing controlled flexibility through the connection points between segments.
Solution Approach 2:
The connection means are designed to allow independent displacement of intermediate units during overpressure events, providing dynamic adaptability. This enables the structure to maintain sufficient rigidity for pressure containment while allowing controlled movement to absorb impact energy during high energy events.
3Strength
If the internal reinforcement element lacks a preferential breaking section to maintain structural integrity, then strength is improved, but the tank may break before the reinforcement element during high energy impact
Solution Approach 1:
The reinforcement element is segmented into multiple intermediate units connected by connection means, creating natural weak points at the connections. These segmented connection points serve as preferential breaking sections that can fail independently to absorb impact energy and protect the tank from breaking.
Solution Approach 2:
The connection means between intermediate units are designed as sacrificial elements that can break during high energy impacts. These connection points act as disposable weak points that fail first to absorb impact energy, protecting the more critical tank structure from breaking while maintaining pressure resistance capability.
4Strength
If the internal reinforcement element uses solid profile without preferential breaking sections to maintain rigidity, then pressure resistance is improved, but the element cannot release stress early during impact
Solution Approach 1:
The reinforcement element is divided into multiple intermediate units (at least 3) connected by connection means, creating segmented sections with defined weak points. This segmentation enables controlled stress release at the connection points during impact while maintaining overall structural rigidity for pressure resistance through the solid profile of each intermediate unit.
Solution Approach 2:
The connection means between intermediate units provide dynamic stress release capability during overpressure events. The intermediate units can move independently through the connection means, allowing controlled stress release during high energy impacts while maintaining sufficient rigidity for pressure containment through the solid profile of each segment.
Data Source
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AI summary
The present invention relates to an internal reinforcement element (1 ) for a thermoplastic tank comprising at least two external parts (11, 12), said at least two external parts (11, 12) being connected by at least n intermediate units (13) with n being an integer greater or equal to 3, said intermediate units (13) being connected together by less than 40%, of their mutual sides length and/or faces area. The invention relates also to the method for manufacturing said internal reinforcement element, to the thermoplastic tank comprises said internal reinforcement element and to the method for manufacturing said tank