초록 ▼

A manufacturing process for reverse building complex-shaped vehicle fuel tanks using complementary female mold half sections which, when joined together about their mating peripheral edges, exactly duplicate the fuel cavity framework of the vehicle into which the completed tanks are to be mounted. W

A manufacturing process for reverse building complex-shaped vehicle fuel tanks using complementary female mold half sections which, when joined together about their mating peripheral edges, exactly duplicate the fuel cavity framework of the vehicle into which the completed tanks are to be mounted. Whereas previous reverse building processes employed light weight, air-curable, non-tear fabric such as nylon fabric reinforcement to both halves of the female molds, such fabric is applied only to the mold for the top half of the fuel tank of the present invention. Self-sealing, autoclave curable materials are used in the bottom half of the fuel tank, thereby providing improved ballistic protection to the lower portion of the tank.

대표청구항 ▼

[ What is claimed is:] [1.] A method for manufacturing at least a portion of a complex-shaped, elastomeric fuel tank for installation into a vehicle body cavity, comprising the steps of:providing a female mold section exactly duplicating a plurality of complex contours of at least part of the vehicl

[ What is claimed is:] [1.] A method for manufacturing at least a portion of a complex-shaped, elastomeric fuel tank for installation into a vehicle body cavity, comprising the steps of:providing a female mold section exactly duplicating a plurality of complex contours of at least part of the vehicle body cavity into which the fuel tank will be mounted;coating a first ply of urethane elastomer onto the female mold section;applying a plurality of layers of self-sealing material over the first ply in the female mold section;applying vacuum pressure to the plurality of layers;curing the plurality of layers while still in the female mold section at a temperature of at least 220.degree. F. and a pressure of at least 15 psi;coating a second ply of urethane elastomer over the plurality of layers of self-sealing material to encase the plurality of layers of self-sealing material between the first ply and the second ply;applying a fuel-resistant film over the second ply after the plurality of layers have been cured to provide a barrier to hydrocarbon fuels;coating a third ply of urethane elastomer onto the fuel-resistant film to form a liner; andremoving the first ply from the female mold section after forming the liner, thereby forming said at least a portion of the fuel tank.