Method of producing a deflector device for fuel-refilling systems and construction kit with prefabricated components for producing a deflector device prototype

Abstract

A method of producing a deflector device for a fuel tank system comprising producing a deflector device prototype from prefabricated components of a construction kit, performing fuel-refilling tests using the deflector device prototype, optionally modifying the deflector device prototype, creating a construction model for the deflector device prototype, producing a deflector device according to the construction model, optionally performing fuel-refilling tests with the deflector device produced according to the construction model and optionally producing the deflector device according to the construction model. The disclosure further provides a construction kit with prefabricated components for producing the prototype of the deflector device for the fuel tank system.

Claims

1. A method of producing a deflector device for a fuel tank system comprising the following steps: producing a deflector device prototype from prefabricated deflector device components of a construction kit, performing fuel-refilling tests using the deflector device prototype, determining a position of each of the prefabricated components of the construction kit used to produce the deflector device prototype relative to one another using a scale having a plurality of marking lines arranged circumferentially on one of the prefabricated components, creating a construction model for the deflector device prototype, producing at least one deflector device according to the construction model, wherein the prefabricated components of the construction kit comprise at least two prefabricated deflector base bodies, at least two prefabricated inserts for the deflector base bodies designed to receive a filler neck and at least two prefabricated bends, wherein the at least two prefabricated bends have at least one of different radii and different lengths.

2. The method according to claim 1, wherein the prefabricated components of the construction kit are made of at least one of plastic, metal, casting resin and glass.

3. The method according to claim 1, wherein the prefabricated components of the construction kit are produced by at least one of stereolithography, injection moulding, milling, turning, vacuum blowing and laser sintering.

4. The method according to claim 1, wherein the prefabricated components of the construction kit each have a construction model and the construction models for the prefabricated components of the construction kit are stored on a computer facility, wherein the construction model of the deflector device prototype is created using the construction models of the prefabricated components of the construction kit used to produce the deflector device prototype.

5. The method according to claim 1, wherein the prefabricated components of the construction kit are provided with grid lines on at least part of their surface.

6. The method according to claim 5, further comprising modifying the prefabricated components of the construction kit, and wherein the modifications to the prefabricated components of the construction kit are transferrable to the construction model for the deflector device prototype by using the grid lines.

7. The method according to claim 1, wherein determining the position of each of the prefabricated components of the construction kit used to produce the deflector device prototype relative to one another further comprises using a marking applied to another of the prefabricated components connected thereto.

8. The method according to claim 1, wherein the prefabricated components of the construction kit used to produce the prototype are detachably connected to one another.

9. The method according to claim 1, further comprising modifying the deflector device prototype after performing fuel-refilling tests using the deflector device prototype and before creating a model for the deflector device prototype.

10. The method according to claim 1, further comprising performing fuel-refilling tests with the at least one deflector device produced according to the construction model after producing the at least one deflector device according to the construction model.

11. The method according to claim 1, further comprising producing a plurality of deflector devices according to the construction model.

Description

(1) The invention is explained in greater detail below with the help of the exemplary embodiments shown in the figures.

(2) In the figures:

(3) FIG. 1 shows a flow diagram of a method according to the invention,

(4) FIGS. 2a to 2c show prefabricated components of a construction kit according to the invention and

(5) FIG. 3 shows a prototype of a deflector device made up of prefabricated components from a construction kit.

(6) FIG. 1 shows the flow of a method 1 according to the invention for producing a deflector device for fuel tank systems. At a first stage 2 a prototype 14 of a deflector device is produced from prefabricated components 10, 11, 12 from a construction kit 9. Fuel-refilling tests 3 are then conducted using the prototypes 14 of the deflector device. If the prototype 14 of the deflector device should fail to meet all the requirements for the deflector device, said prototype 14 of the deflector device is adapted 4 until it meets all the requirements for the deflector device in the tank-refilling tests 3 performed. For prototypes 14 of the deflector device, which satisfy all requirements for the deflector device, a construction model 5 is created. Using the construction model, a deflector device is produced 6 which is optionally rechecked by conducting further fuel-refilling tests 7, to see whether all requirements for deflector devices have been fulfilled.

(7) With the help of the construction model created, series production 8 of the deflector device according to the construction model may preferably take place.

(8) The advantageous feature of the method 1 according to the invention is that the prototype 14 of the deflector device is made 2 of prefabricated components 10, 11, 12 from a construction kit 9. The prefabricated components 10, 11, 12 from the construction kit 9 are configured such that the prototype 14 produced therefrom is producible in production terms by means of injection moulding, for example. It is thereby achieved that the deflector device produced according to the construction model for the prototype 14 of the deflector device corresponds to the prototype and does not require modification on account of production requirements. This results in a significant reduction in development time for the deflector device for fuel tank systems.

(9) The construction kit 9 for production 2 of the prototype 14 of the deflector device exhibits prefabricated deflector base bodies 10, prefabricated inserts 11 for the deflector base body 10 for receiving a filler neck and prefabricated bends 12 with different radii and/or lengths.

(10) The prefabricated components 10, 11, 12 of the construction kit 9 are produced from plastic, metal or casting compound such as epoxy resin, for example, or glass, according to a rapid prototyping method, for example, such as stereolithography, injection moulding, milling, turning, vacuum blowing and/or laser sintering.

(11) Construction models for the prefabricated components 10, 11, 12 of the construction kit 9 are preferably stored in a computer facility, wherein the construction model for the prototype 14 of the deflector device is created by means of the construction models of the prefabricated components 10, 11, 12 from the construction kit 9, which were used for production 2 of the prototype 14 of the deflector device. Since a construction model is stored in the computer facility for each prefabricated component 10, 11, 12 of the construction kit 9, the construction model for the prototype 14 of the deflector device can easily be created by combining the construction models for the prefabricated components 10, 11, 12 from the construction kit 9, which were used in the production 2 of the prototype 14 of the deflector device.

(12) The prefabricated components 10, 11, 12 of the construction kit 9 are provided with grid lines 13, at least in part. By means of these grid lines 13, modifications to the prefabricated components 10, 11, 12 of the construction kit 9 can be transferred to the construction model for the prototype. Modifications of this kind to the prefabricated components 10, 11, 12 of the construction kit 9 may, for example, be openings in the peripheral walls.

(13) The position of the prefabricated components 10, 11, 12 of the construction kit 9 relative to one another, which were used to produce 2 the prototype 14 of the deflector device, is determined by means of a scale 15 applied to a prefabricated component 10, 11, 12, such as the deflector base body 10, for example, and a marking applied to a component 10, 11, 12 connected thereto, such as a bend 12, for example. This alignment of the prefabricated components 10, 11, 12 from the construction kit 9, which were used to produce 2 the prototype 14 of the deflector device, may be transferred into the construction model for the prototype 14.

(14) The prefabricated components 10, 11, 12 from the construction kit used to produce 2 the prototype 14 are detachably connected to one another using the tongue-and-groove principle, for example. The prototype 14 of the deflector device can thereby be easily adapted 4.

(15) Illustrated in FIGS. 2a to 2c is a construction kit 9 according to the invention with prefabricated components 10, 11, 12 for the production of a prototype of a deflector device for fuel tank systems. The prototype 14 of the deflector device for fuel tank systems is preferably produced according to the method described above in this case. The construction kit 9 comprises at least two prefabricated deflector base bodies 10, wherein an exemplary prefabricated deflector base body 10 is illustrated in FIG. 2a. The deflector base body 10 exhibits an upper expanded area in which an insert 11 can be used. The deflector base body 10 subsequently exhibits a conical area and a lower cylindrical area.

(16) The construction kit 9 according to the invention further comprises at least two prefabricated inserts 11 for the deflector base body 10 configured to receive a filler neck. An exemplary insert 11 for the deflector base body 10 is depicted in FIG. 2b.

(17) The internal geometry of the deflector base body 10 and the external geometry of the inserts 11 are preferably coordinated with one another in this case, such that all prefabricated inserts 11 can be used in all prefabricated deflector base bodies 10.

(18) The construction kit 9 according to the invention further comprises at least two prefabricated bends 12 with different radii and/or lengths. Exemplary prefabricated bends 12 are depicted in FIG. 2c.

(19) By means of the construction kit 9 according to the invention with prefabricated components 10, 11, 12, shown in FIGS. 2a to 2c, a prototype 14 of a deflector device for fuel tank systems can be created, as with the implementation of the previously described method according to the invention.

(20) The prefabricated components 10, 11, 12 of the construction kit 9 may be made of plastic, metal, a casting compound such as epoxy resin, for example, or glass and depending on the material used are produced by a rapid prototyping method such as stereolithography, injection moulding, milling, turning, vacuum blowing and/or laser sintering, for example.

(21) FIG. 3 shows a prototype 14 of a deflector device for fuel tank systems. The prototype 14 is made up of a prefabricated deflector base body 10, a prefabricated insert 11 and a prefabricated bend 12 from the construction kit 9 according to the invention.

(22) As shown in FIG. 3, the components 10, 11, 12 of the construction kit 9 comprise grid lines on their surface, at least in part. By means of the grid lines 13 on the surface of the prefabricated components 10, 11, 12 of the construction kit 9, modifications to the prefabricated components 10, 11, 12 of the construction kit 9 can be transferred to the construction model for the prototype 14 of the deflector device.

(23) The components 10, 11, 12 of the construction kit 9 exhibit at least in part a scale 15 or a marking 16, wherein the marking 16 of the one component 12 is disposed following assembly with a further component 10 in close proximity to the scale 15 of said further component 10. As shown in FIG. 3, the deflector base body 10 exhibits a scale 15 on the end, which is connected to a bend 12 and the bend 12 exhibits a marking 16 on the end, which is connected to the deflector base body 10. The position of the deflector base body 10 in relation to the bend 12 can therefore be determined using the scale 15 and the marking and transferred to the construction model for the prototype 14.

(24) The components 10, 11, 12 of the construction kit 9 according to the invention are configured such that they can be detachably connected to one another, for example by means of a tongue-and-groove system. Consequently, a prototype created by means of components 10, 11, 12 from the construction kit 9 according to the invention, as shown in FIG. 3, for example, can be adapted by exchanging individual components 10, 11, 12 of the construction kit 9.

REFERENCE NUMBER LIST

(25) 1. Method

(26) 2. Production of a prototype

(27) 3. Fuel-refilling tests

(28) 4. Possible modification of the prototype

(29) 5. Creation of a construction model

(30) 6. Production of a deflector device

(31) 7. Optional fuel-refilling tests

(32) 8. Series production

(33) 9. Construction kit with prefabricated components

(34) 10. Deflector base body

(35) 11. Insert for deflector base body

(36) 12. Bend

(37) 13. Grid lines

(38) 14. Prototype

(39) 15. Scale

(40) 16. Marking