Inergy�s Innovative New Twin Sheet Blow Molding Process Set To Go Into Production

Inergy Automotive Systems, leading global Tier 1 supplier of integrated plastic Fuel Systems to the automobile industry, sees its revolutionary Twin Sheet Blow Molding (TSBMä) process hit the road in some of the world’s finest vehicles next year.

INERGY has always held a pre-emptive position in automotive innovation, anticipating and exceeding the industry’s specifications.  Now, this recognized pathfinder takes production processes to another level of development with Twin Sheet Blow Molding (TSBMä), a technique that combines the advantages of half-shell processes with blowmolding and allows Fuel Systems to be produced in a single stage, along with their various functional components.

In just about the same time as a standard blow-molding process, TSBMä requires only some modifications to the existing blow molding machine yet allows for a major manufacturing innovation – the integration of components (baffle, gauge, valves, jet pumps, lines, fuel modules, canister).  The parison is cut in half when it comes out of the extrusion head, to create two sheets.  A central core, supporting the components, is inserted between the two halves, which are each blown onto the corresponding mold half while components are mechanically anchored onto the inner tank surface.  Then the core is removed before the mold re-closes and finalizes the blowing cycle.

There are hardly any finishing operations, such as welding or cutting of holes, except for the sender opening. The process advantages are numerous: easy set-up, no increased thickness required for welding and use of known technologies.

The result is an advanced ultra low emission Fuel System, TSBM™ allows for new architecture possibilities like the easy integration and free positioning of components, fuel tank volume optimization and reduced slosh noise.  TSBMä is the most advanced Fuel System production process available, delivering value-added customer benefits that give INERGY a distinct competitive advantage in today’s increasingly tough market. 

After more than two years of intensive and dedicated research, INERGY has been awarded its first business with TSBM™ technology by a major OEM.

With environmental regulations, like PZEV, applying to an increasing number of vehicles on the North American market and end-user demands for non-polluting vehicles on the increase, the race is on between automotive industry suppliers to design and manufacture environmentally sound solutions.  Inergy Automotive Systems is a recognized pioneer in this field and remains on the forefront of technology and production process innovation.  From the Fuel System development to its industrialization and until the end-of-life stage, INERGY responds with products and solutions relied on by the world’s major OEMs.