The news that the fuel tanks for Volkswagen Group´s new Passat will be supplied by Visteon Corporation (HQ: Dearborn, Michigan / USA; www.visteon.com) should cause quite a stir among German and European plastics suppliers to the automotive industry. The company has plans for the construction of two special production and assembly facilities with in-line-vehicle sequencing to deliver fuel tank systems in close proximity to the Volkswagen production locations of Emden in the north of Germany and Mosel (near Zwickau in Saxony). Series production of fuel tanks for the new Volkswagen Passat will start at the end of 2004.

Visteon is among the first automotive suppliers to introduce a new “Twin Sheet” thermoformed plastic fuel tank system. The new production method allows the fuel tanks to accommodate even unusual car body contours. With their vapour-tightness, the new systems comply with future evaporative emission standards for plastic fuel tanks.

The twin sheet production method developed by Visteon offers two major advantages: With its more filigree contour, the fuel tank is more adaptable in size and shape to optimally use the space inside the car body. Conventional fuel tanks, e.g. those made of steel or blow-moulded plastic are claimed to be less adaptable. Moreover, thermoformed tanks have a higher weight-saving potential and offer more process safety than conventional plastic tanks.

The system integrates a fuel pump delivery module, fuel filters, fuel/vapour lines and an on-board recovery system into the tank. The tank wall is constructed from a six-layer high-density polyethylene with an ethylene vinyl alcohol (EVOH) barrier against carbohydrate emission. A main advantage of Visteon´s thermoformed fuel tanks is their safe integration of system components during the thermoforming process. The integrated components minimise vapour fuel emissions. The tank´s emission levels below the European limit are also claimed to contribute to a cleaner environment.

“Our investment in two new locations close to our customer´s Passat production plants shows that, despite being a relatively young company, Visteon has already succeeded in entering into a long-term partnership with the Volkwagen Group”, says Dr. Wilfried Janke who is co-ordinating the partnership with Volkswagen as Visteon Corporation´s vice president and managing director for Germany. Visteon is a leading full-service supplier of automotive components and systems to car manufacturers and within the global aftermarket. The company has about 77,000 employees and a global delivery system of more than 180 technical, manufacturing, sales and service facilities located in 25 countries.

• Plasteurope.com Service: Detailed information on Visteon´s blow-moulded fuel tank systems (broshure): PIE-No. 45876.