Fuel Supply Module Housing for the Four Stroke Marine Outboard Engine
Judge's Award
Molder: Pyramid Plastics Inc.
Moldmaker: Industrial Molds Inc.
Material Supplier: DuPont Automotive
Designer: Magneti Marelli Powertrain USA
OEM: Mercury Marine
Description
Lightweight, rugged housing molded from high performance polyamide protects and provides structural support for the moduleís internal components. It resists seawater, fuel and cleaning agents while preventing water intrusion into the fuel reservoir. There are numerous molded-in features for fuel and cooling water, power supply, assembly and mounting.
Why is this Part Innovative?
The module has been awarded a U.S. patent for unique design location of component enabled by polymer technology. The worldís first thermoplastic fuel supply module for marine use. Feature integration has eliminated 31 fuel leak paths and increased assembly reliability. As molded sealing geometry eliminates machining of precision tolerance features.
Process
Injection Molded- due to high dimensional tolerances and extreme structural performance requirements. RJG Decoupled Molding Techniques ensure consistent part quality. The added tooling complexity decreased labor and defects. The result is a highly competitive and cost effective domestic made product. This proves that U.S. injection molding companies can be competitive in the global market.
Design
Due to the structural requirements of this design CAD, Mold Flow and FEA were utilized. A reduction of 13% was attained in cost and 35% reduction in weight.
Tooling
The module features innovative quick connect fitting mold design with stepped parting line. This tooling design eliminates flash and mismatch at o-ring surface.
Material
High performance semi-aromatic nylon was selected for resistance to corrosion, fuel, water and impact. The housings structural demands include impact resistance to accelerations in excess of 230 Gís.
Finishing
No finishing required eliminating toxic metals and hexavalent chromate.
