Watch the quick video to see the impact that hybrid applications has on a standard plastic tank. To the left is a conventional tank without the added Next Generation Tank Stiffener (NGTS®) elements. To the right is Kautex's all-plastic pressurized fuel tank - withstanding the challenges of a pressurized environment.
NGFS®: A technology enabler for future growth
Our NGFS® technology, also known as “twin sheet” technology helps reduce emissions and weight while potentially increasing volume depending on tank design. It also serves as the basis for our lightweight hybrid fuel tank.
NGFS® is produced by lowering two sheets of multi-layered parison through the blow molder extruders. The "twin sheet" design allows easy access for components to be integrated directly into the plastic shell, thus eliminating the need for cutting and welding and reducing emissions.
The two half shells, with their associated components in place, are then molded together before being removed from the bold molder.
NGFS® Component Integration
The twin-sheet design allows for quick and easy access to place internal components during the blow molding process. This reduces the amount of cutting or welding on the tank thereby reducing emissions. Examples of pre-placed components incldue:
- Internal venting systems
- Low emissions connections
- Delivery and indication elements
- Anti-slosh elements (baffles)
- Internal tank stiffeners for hybrid tank applications
ANOTHER INDUSTRY FIRST: KAUTEX'S ALL-PLASTIC HYBRID FUEL TANK
Sustainability is a key focus at Kautex, as it is with many of our global customers. The continued focus on carbon-dioxide (CO2) reduction is driving many OEMs to look at the electrification of vehicles in the form of hybrid-electric vehicles (HEVs) and plug-in hybrid electric vehicles (PHEVs).
These more complex fuel tank applications require closed fuel systems with a higher internal pressure which causes massive deformations on un-reinforced plastic tanks. The first generation of fuel systems hybrid technology was equipped with a thick-wall steel tank because standard plastic tanks could not handle the impact of the pressurization (see video below).
In 2015, Kautex was first to market with two plastic tank solutions that met the pressuirization requirements. These systems boasted a reduction in weight of more than five kilograms when compared to pressurized steel tanks.
Our lightweight pressurized fuel tanks are created using Kautex’s NGFS® twin sheet technology, adding patented stiffening elements to withstand the pressure/vacuum requirements needed for hybrid applications and eliminating the need for steel support.
Inside our hybrid fuel tank
In a Kautex lightweight, high pressure fuel tank you will find:
1) Welded tanks stiffeners using our NGTS® technology to reduce deformation under high pressure conditions
2) Internal anti-slosh walls to reduce slosh noise (the sound of fuel moving back and forth in a tank) – important during silent electrical driving or in start/stop conditions
3) Internal venting systems to keep the liquid inside the tank and achieve excellent hydrocarbon (HC) emission results as the tank wall's highly efficient multi-layer structure is not destroyed during assembly operations