Chloe Zhang
Plastic gas tanks have become an increasingly popular alternative to steel tanks in the automotive industry. Before 1990, most car gas tanks were made of steel. However, by 1996, plastic had replaced steel in a quarter of fuel tanks manufactured in North America. As of 2019, 98% of vehicles in Europe and 75% in the US had plastic gas tanks. Plastic tanks are favoured for their flexibility, durability, weight reduction, noise attenuation, and safety. However, steel tanks remain preferable in certain applications, especially where weight and space are not primary concerns.
| Characteristics | Values |
|---|---|
| Year plastic gas tanks became mainstream | 1996 |
| Percentage of plastic gas tanks in North America by 1996 | 28% |
| Percentage of plastic gas tanks in the worldwide market by 2000 | 50% |
| Percentage of plastic gas tanks in the North American market by 2000 | 50% |
| Percentage of vehicles in Europe with plastic gas tanks | 98-99% |
| Percentage of vehicles in the US with plastic gas tanks | 72-75% |
| Main benefits of plastic gas tanks | Lighter weight, more flexible, durable, affordable, safer, less corrosion |
| Main drawbacks of plastic gas tanks | Higher manufacturing cost, recyclability issues, lower permeability |
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What You'll Learn
- Plastic gas tanks offer benefits over steel including being more lightweight, durable, and flexible
- They are safer and more cost-effective to produce
- Plastic tanks are better at reducing fuel slosh noise
- Plastic tanks are more environmentally friendly, with new technologies meeting EPA regulations
- Plastic tanks are more prone to cracking
Plastic gas tanks offer benefits over steel including being more lightweight, durable, and flexible
Plastic gas tanks started to become mainstream in the 1990s, with plastic replacing steel in one out of four fuel tanks manufactured in North America by 1996. As of 2019, 75% of US vehicles have plastic gas tanks, and this figure is even higher in Europe, at 98% or 99% according to different sources.
Plastic gas tanks offer several benefits over steel. Firstly, they are more lightweight, which increases vehicle efficiency as less fuel is burned. Plastic tanks can also be more durable, as steel tanks are susceptible to interior corrosion from fuel and exterior corrosion from elements such as road chemicals, salt, mud, and gravel. Plastic tanks are also more flexible in terms of design, being easier to mould into the odd saddle-shaped tanks used in some vehicles.
However, steel tanks have their own advantages. They are more resistant to fire and explosions, making them ideal for industrial settings. Steel tanks are also more impermeable to gasoline, alcohol, diesel, and biodiesel, making them better for low evaporative emission requirements. Steel is also more proven, with a longer track record than plastic.
The choice between plastic and steel gas tanks ultimately depends on the specific needs and budget of the user, as well as any applicable regulations. For example, some areas prohibit the use of plastic tanks for certain types of fuel, such as diesel.
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They are safer and more cost-effective to produce
Plastic gas tanks became mainstream in the mid-1990s, with plastic replacing steel in one out of four fuel tanks manufactured in North America by 1996. Automakers favoured plastic tanks because they are lighter and more flexible to mould into the odd saddle shapes used in some vehicles.
Safer
Plastic fuel tanks can provide safe storage and transportation of flammable substances. They can also be used to gauge substance levels, venting, feeding the engine, and anticipating potential harm. HDPE gas tanks are inert to corrosive environments, whereas zinc-coated products that replace terne plates are susceptible to corrosion.
Cost-effective to produce
Plastic gas tanks are cost-effective to produce because they are lighter in weight, which saves on costs. They are also recyclable, which is an important criterion for automotive-design engineers to meet. Recycled plastics are not cost-competitive with virgin plastics, but the recycling of HDPE gas tanks is easier in terms of dismantling and avoiding type mixing.
However, it is important to note that some experts believe that multilayer plastic tanks, which are required to meet stricter permeation standards, will be more expensive to manufacture and harder to recycle.
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Plastic tanks are better at reducing fuel slosh noise
The use of plastic gas tanks in vehicles has been a growing trend since the 1990s. Before this time, most car gas tanks were made of steel. By 1996, plastic had replaced steel in a quarter of fuel tanks manufactured in North America, and by 2019, 75% of US vehicles were fitted with plastic tanks. This shift can be attributed to the many benefits offered by plastic tanks, including their lightweight nature, flexibility in design, and durability.
One specific advantage of plastic tanks is their ability to reduce fuel slosh noise. Fuel slosh noise occurs when fuel moves around inside the tank, creating an unpleasant sound. This noise has become more noticeable with the increasing efficiency of plug-in hybrid electric vehicles (PHEV), which can run for longer periods in electric-only mode, thus reducing the sound of the engine that would otherwise mask the fuel sloshing.
Additionally, plastic tanks offer improved safety features compared to steel tanks. Steel tanks are susceptible to interior corrosion from fuel and exterior corrosion from elements such as road chemicals, salt, mud, and gravel. Plastic tanks are more resistant to corrosion and are also impermeable to gasoline, alcohol, diesel, and biodiesel, making them ideal for meeting low evaporative emission requirements.
While plastic tanks have faced challenges due to stricter permeation and emission standards, advancements in technology have addressed these concerns. For example, the emergence of multilayer and barrier tank technologies has enabled plastic tanks to meet more stringent emission standards while still providing the benefits of weight reduction and noise attenuation.
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Plastic tanks are more environmentally friendly, with new technologies meeting EPA regulations
Plastic gas tanks started to replace steel ones in the 1970s, with VW introducing the Passat with mass-produced plastic fuel tanks in 1972. By 1996, plastic had replaced steel in a quarter of fuel tanks manufactured in North America, and by 2019, 75% of US vehicles had plastic fuel tanks.
Plastic tanks are more environmentally friendly than steel tanks, and new technologies are ensuring that plastic tanks meet EPA regulations. The US Environmental Protection Agency (EPA) has implemented various regulations and standards to reduce the environmental impact of fuel tanks. One example is the mandate for sealed fuel systems introduced in 1971 to reduce hydrocarbon emissions from vehicles. To comply with these stricter standards, designers of plastic gas tanks have adopted more complex multi-layer tanks that prevent gasoline from seeping into the atmosphere.
The emergence of new technologies, such as multilayer and barrier tank types, has facilitated the increased use of plastic gas tanks. Multilayer tank technology, in particular, is seen by some manufacturers as a solution to stricter emission standards. For instance, Chrysler switched to multilayered HDPE tanks in 1995 to meet the more stringent SHED test.
While plastic tanks offer advantages in weight reduction and design flexibility, there are concerns about their recyclability and disposal. The Delphi VII report highlights the higher manufacturing cost and recyclability issues of multilayer plastic tanks required to meet permeation standards. However, some experts believe that advancements in plastic technology will lead to commercially feasible operations, making plastic tanks more environmentally sustainable.
The EPA has also published the "National Strategy to Prevent Plastic Pollution," which aims to prevent the release of plastic pollution into the environment. This strategy addresses the challenges of managing plastic waste and promotes increased recycling rates and reduced plastic consumption. Additionally, the EPA has established guidelines and regulations for septic tanks to ensure they are environmentally friendly and safe for public health. These regulations focus on the design, installation, and maintenance of septic systems, with regular inspections to ensure proper functioning.
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Plastic tanks are more prone to cracking
The use of plastic gas tanks in vehicles became mainstream in the 1990s. Before 1990, most car gas tanks were made of steel. By 1996, plastic had replaced steel in one out of four fuel tanks manufactured in North America. This shift was driven by the need to meet stricter emissions regulations and reduce the weight of vehicles.
While plastic gas tanks offer several advantages, they are more prone to cracking than their steel counterparts. Plastic tanks can become brittle and more susceptible to physical damage when exposed to low temperatures. This can lead to cracks and splits, especially in single-skinned tanks without an outer layer of protection. Additionally, an uneven base can cause the plastic to stretch and eventually crack under pressure.
To prevent cracking, it is essential to maintain and service plastic tanks regularly. This includes visual inspections during winter to monitor for any signs of damage and ensuring the tank is installed on a level surface.
If a plastic gas tank develops a crack, it can be challenging to repair. Traditional adhesives like fiberglass resin and common epoxies are ineffective on plastic, especially High-Density Polyethylene (HDPE) tanks, which are commonly used in vehicles. Some methods for repairing cracks in plastic tanks include:
- Drilling small holes at both ends of the crack to prevent it from spreading further.
- Plastic welding using a soldering iron or gun to melt the crack and seal it.
- Using a glue gun with a hot tip to melt the original plastic and blend it with the new plastic.
- Applying a coating of JB Weld, a two-part epoxy specifically designed for plastic, to seal the crack.
While these repair methods can be effective, they may not provide a permanent solution, and in some cases, replacing the damaged tank with a new one may be necessary to ensure safety and prevent fuel leaks.
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Frequently asked questions
Plastic gas tanks became mainstream in the 1990s. Before 1990, most car gas tanks were made of steel. By 1996, plastic had replaced steel in one out of four fuel tanks manufactured in North America.
Plastic gas tanks offer several benefits over steel, including durability, weight reduction, design freedom, noise attenuation, and safety. Plastic is also lighter in weight and more flexible to mould into odd saddle-shaped tanks used in some vehicles.
Recent research indicates that 98% of all vehicles in Europe are outfitted with plastic gas tanks.
High-density polyethylene (HDPE) has been the resin of choice for plastic gas tanks.
