Two-Tiered Filler Pipe Bracket for Aluminum Pickup Trucks
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Solution Overview
Problem
Aluminum pickup truck box components face challenges in structural reinforcement due to the limited formability of aluminum sheet metal compared to steel, requiring additional structural support for filler pipes, particularly in mounting scenarios.
Innovation Solution
A filler pipe bracket assembly for aluminum pickup trucks featuring a two-tiered body with angled side members and mount flanges that secure to the inner box frame, allowing for the mounting of diesel fuel and diesel exhaust fluid pipes, with the bracket positioned adjacent to the C-pillar region and accessible via a fuel door opening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If aluminum sheet metal is used instead of steel sheet metal, then weight is reduced, but formability and structural reinforcement capability deteriorate
Solution Approach 1:
The bracket assembly combines aluminum material with strategic reinforcement features including integrated ribs, flanges, and mounting structures. This composite approach maintains the weight advantage of aluminum while incorporating structural elements that provide the necessary reinforcement and formability characteristics typically associated with steel.
2Strength
If additional structural reinforcement is added to aluminum components, then structural integrity is improved, but device complexity increases
Solution Approach 1:
The bracket integrates multiple functions into a single consolidated component. The mounting bracket combines support structures, reinforcement ribs, flanges for attachment, and pipe support features all in one piece. This merging approach provides the necessary structural reinforcement while actually reducing overall device complexity by eliminating the need for separate reinforcement components.
Solution Approach 2:
The bracket is designed with segmented functional zones including distinct mounting flanges, reinforcement ribs, and pipe support areas. This segmentation allows each region to be optimized for its specific function while maintaining overall structural integrity without requiring a completely complex monolithic design.
3Strength
If filler pipes are mounted in the C-pillar region, then structural support is improved, but accessibility for maintenance deteriorates
Solution Approach 1:
The fuel filler pipe and diesel exhaust fluid pipe are extracted from the main bracket structure and routed through dedicated openings in the outer body panel. This extraction allows the pipes to be accessible from the exterior of the vehicle for maintenance and refilling operations while the bracket itself remains securely mounted in the structurally optimal C-pillar region.
Solution Approach 2:
The outer body panel serves as an intermediary element between the internally mounted bracket and the external environment. It provides structural support when closed while incorporating openings that allow access to the pipe apertures for maintenance operations, thus mediating between the conflicting requirements of structural integrity and accessibility.
Data Source
AI summary
A filler pipe bracket of an aluminum pickup truck includes a two-tiered body, a first side member, and a second side member. The two-tiered body includes a first layer defining a first pipe aperture and a second layer defining a second pipe aperture. The first side member extends from the first layer and includes a first mount flange oriented for securing to a portion of an inner pickup box frame. The second side member extends from the second layer and includes a second mount flange for fastening to another portion of the inner pickup box frame. The first pipe aperture may be sized to receive a diesel fuel pipe and the second pipe aperture may be sized to receive a diesel exhaust fluid pipe.