A great deal of innovative design and materials work is going into vehicle fuel tank systems. It is area that is coming under increasing pressure from legislation on both sides of the Atlantic. Matthew Beecham reports.
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The main factors driving fuel tank innovation are legislation, weight, packaging, safety and cost. “We’re also seeing a continued demand for fuel tank range and fuel economy,” said Doug Johnston, fuel storage and delivery product line manager for Visteon. “More complex shapes and geometries are also emerging, particularly driven by the all/rear wheel drive increase in smaller car segments. This creates a rather unique packaging environment that influences the design selection and requirement for those programmes.”
In the 1970s, all fuel tanks were made of steel. Today, about 85% of newly registered vehicles in Europe are equipped with plastic tanks while over 70% of cars built for North American roads have plastic tanks. European carmakers sourcing plastic fuel tanks include BMW, DaimlerChrysler, Fiat, Ford, Opel, Peugeot Citroen, Porsche, Renault, MG Rover, Toyota and Volkswagen.
While the angular shape of modern plastic fuel tanks may appear a little strange, the blow-moulded design allows maximum fuel holding capacity in a minimum amount of space. Plastic tanks are also considered more crashworthy because of their seamless design and ability to deform.
Although plastic seems to have become the material of choice, steel makers raise concerns that they cannot meet the California Partial Zero Emission Vehicle legislation (PZEV) emissions regulations. It is certainly true that plastic PZEV fuel tanks have yet to appear on American roads. In the US, the Californian Air Resources Board (CARB) certified 23 car models in 2004 as PZEV vehicles: all of these used steel fuel tanks. But all that is about to change.
Inergy recently won a contract to supply its so-called Super Ultra Low Emission Vehicle (SULEV) fuel system for an unspecified Nissan car platform in North America. Following the contract win with Nissan, Inergy was then awarded two new PZEV plastic fuel system programmes for two future GM vehicles. The new PZEV requirements stipulate that fuel emissions must drop below 54 mg, down from an equivalent of 600 mg in 2001. The company claims that its SULEV system outperforms Californian standards, as it emits less than 15 mg.
Visteon has also developed an integrated plastic fuel tank system designed to help carmakers meet the PZEV standards. The tank integrates the fuel delivery module, fuel filter and fuel/vapour lines. The tank wall geometry is constructed from a six-layer, high-density polyethylene with an ethylene vinyl alcohol barrier. Visteon says this tank will enter production for a 2007 model year programme. The supplier expects to see its market position advance over the next few years, thanks to its new order book and the roll out of its PZEV tank.
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By GlobalDataAlthough steel industry sources concede a shrinking steel tank market, they believe that the environmental and cost issues will eventually win back a larger share of the fuel tank business. They reckon that they can make steel tanks with the same amount of design flexibility as plastic. Modern fabricating methods such as hydroforming, allow steel to be manipulated into equally complex shapes. They also believe that as zero emission legislation spreads beyond Californian borders, demand for steel tanks could increase.
International steel specialist Corus reckons the tide is turning. Corus has won a contract to supply Ford with its advanced, fully recyclable, Neotec steel for fuel tanks in the Ka and StreetKa. The new lead-free metallic-coated steel was launched in February 2003 just in time for the ELV (End of Vehicle Life) European directive, which swung into force in six months later. Neotec has been specifically designed to help vehicle manufacturers meet future environmental legislation that requires emission-free fuel tanks, and sets recycling targets for vehicles at the end of their life.
MG Rover is already fitting the new steel tank on its Rover 25 and 45 and MG ZR and ZS models. “As far as MG Rover were concerned, the Neotec fuel tank was an improved replacement for its predecessor, the lead-zinc coated –Ternex steel tank,” said Jonathan Parkes, commercial manager for Corus Strip Products UK. “Rover didn’t have to change their press lines or welding equipment. And the paint adhesion was equally as good for Neotec as it had been for the Ternex tank. So from the OEM’s point of view, it was a dead cert. It meant a changeover from a very good product that no longer complies with European legislation to a product that performs even better in terms of corrosion and is just as easy to manufacture. The carmaker using Neotec fuel tanks can rest assured that by using steel, they will fulfill their responsibility to comply with the latest emission and recycling legislation.”
Corus has just taken orders from Proton in Malaysia, too. “There are two new Proton models next year set to use the Neotec steel fuel tank. And we are also getting a lot of interest from around the world, especially China. It is really starting to take off. The potential is huge.”
On balance, just-auto estimate that approximately 85% of vehicles built for Western Europe were fitted with plastic fuel tanks in 2003. That figure should exceed 90% by the end of the decade. Despite the initial concerns that plastic tanks could not meet the PZEV requirements, manufacturers have proved otherwise with their latest offerings. In North America, just-auto see plastic fuel tank fitment reaching 91% by 2010, up from 71% in 2003. The fastest growing market, however, is Japan. Just a few years ago, steel tanks represented well over 90% of the market. But by the end of this decade, the proportion of steel tanks is expected to shrink to just 40%. Overall, plastic fuel tanks are fitted to nearly two-thirds of the world’s annual vehicle production.
Steel vs plastic fuel tanks
Benefits of steel fuel tanks:
- Non-permeable to hydrocarbons — said to be favoured for PZEV.
- Cost competitive (depending on volumes).
- Easier to recycle, arguably.
Benefits of plastic fuel tanks:
- Greater shape flexibility thereby extending capacity.
- Corrosion resistant.
- Better crashworthiness.
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