Urea Container with Plastic Sintered Layer for Metal Ion Leakage Prevention
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Solution Overview
Problem
Conventional fuel containers for commercial vehicles are not environmentally compatible with chemically aggressive media like urea, leading to issues such as metal ion leakage and inadequate adaptability to diverse vehicle geometries.
Innovation Solution
A container with a metallic carrying structure partially covered by a thin plastic sintered layer, which is applied through a sintering process, providing chemical stability and mechanical reinforcement, allowing for lightweight and rigid construction, and enabling adaptation to various frame geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional metal container is used to carry operating media like urea, then the container provides structural strength and rigidity, but the metal ions leak into the chemically aggressive operating media causing contamination and reliability issues
Solution Approach 1:
The patent applies a plastic sintered layer coating on the inner surface of the metal container, creating a composite structure where the metal provides structural strength and the plastic layer provides chemical inertness. This composite approach prevents metal ion leakage while maintaining the required mechanical strength of the container.
2Object-generated harmful factors
If a thick plastic coating is applied to prevent metal ion leakage, then chemical stability is improved, but the container weight increases and interior space is reduced
Solution Approach 1:
The patent uses a sintered plastic layer with controlled porosity that provides adequate chemical protection while maintaining thin thickness. The sintered structure creates a tortuous path for potential ion migration while allowing the layer to remain thin, thus preventing metal ion leakage without significantly increasing weight or reducing interior space.
3Object-generated harmful factors
If a conventional plastic container is used to avoid metal ion leakage, then chemical stability is improved, but the container lacks the rigidity and structural strength required for commercial vehicle applications
Solution Approach 1:
The patent creates a composite container where the outer metal structure provides the required structural rigidity and strength for commercial vehicle applications, while the inner plastic sintered layer provides chemical stability. This composite design allows the container to meet both mechanical and chemical requirements that neither material could satisfy alone.
4Strength
If conventional riveted or welded containers are used, then structural strength is achieved, but the production complexity and time increase
Solution Approach 1:
The patent applies the plastic sintered layer coating during the container manufacturing process itself, using the container as its own sintering tool. This preliminary action of coating during production eliminates the need for separate coating operations and reduces production time while maintaining structural integrity.
5Strength
If conventional plastic containers are placed inside outer stabilizing sheaths, then structural stability is improved, but the interior space utilization is significantly reduced
Solution Approach 1:
The patent integrates the stabilizing function directly into the metal container structure and applies the plastic coating on the inner surface, eliminating the need for a separate outer sheath. This integrated composite design maintains structural stability while maximizing the usable interior space of the container.
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 prevents metal ion leakage, reduces weight, and simplifies production and installation by providing a chemically inert and adaptable container suitable for carrying fuels and additives like urea, while allowing for integrated multiple container designs and reduced fixation needs.
Implementation Method 1
a plastic powder is subsequently introduced into its interior, where it melts on the hot carrying structure and consequently forms the layer mentioned
Implementation Method 2
the container as a whole is heated, and a plastic powder is subsequently introduced into its interior, where it melts on the hot carrying structure and consequently forms the layer mentioned
Data Source
AI summary
A container for operating media of motor vehicles which is chemically stable both in respect of the fuel carried and in respect of additives.