Fuel pump driven by an electric motor

Abstract

A fuel pump includes a pump holder having a sidewall extending from a first end to a second end which is closed off by an end wall, the pump holder having a fuel inlet. An upper plate located within the sidewall has an upper plate flow channel. A lower plate located within the sidewall has a lower plate flow channel and an outlet chamber is formed between the lower plate and the end wall. An outlet passage extends from the lower plate flow channel to a lower surface of the lower plate. A pumping element located between the upper plate and the lower plate is rotated by an electric motor such that fuel is drawn through the fuel inlet into, and pressurized within, the upper plate flow channel and the lower plate flow channel and discharged into the outlet chamber through the outlet passage.

Description

TECHNICAL FIELD OF INVENTION

The present invention relates to a fuel pump and more particularly to a fuel pump which is driven by an electric motor.

BACKGROUND OF INVENTION

In-tank fuel pumps which supply fuel, for example, gasoline, diesel fuel, alcohol, ethanol, and the like, and blends thereof to an internal combustion engine, for example an internal combustion engine of a motor vehicle, have been widely used for many years where such fuel pumps are submersed in the fuel within the fuel tank. One example is illustrated in U.S. Pat. No. 5,452,701 to Tuckey. Such fuel pumps are typically driven by an electric motor which is an integral element of the fuel pump. Furthermore, it is typical that the electric motor is enclosed within a sealed portion of the fuel pump through which the pressurized fuel passes as the fuel is communicated to the internal combustion engine. As a result of the electric motor being in the pressurized portion of the fuel pump, pressure-tight interfaces are required around the electric motor in order to prevent flow loss outside of the fuel circuit going to the internal combustion engine. These pressure-tight interfaces include interfaces of the elements which enclose the electric motor as well as interfaces of the electrical circuit which supplies electricity to the electric motor. Costs are associated with providing these pressure-tight interfaces, not only in the product itself but also in the required manufacturing processes, and as a result, the pressure-tight interfaces are not desirable. Not only is there a cost impact, but there is also an increase in axial length which is not desirable, particularly in applications where space is limited. Also as a result of the electric motor being in the pressurized portion of the fuel pump, a high flow of fuel flows through the electric motor which results in a viscous torque drag on a rotating armature of the electric motor. This viscous torque drag results in energy loss. Furthermore, the pressure on the electric motor creates an axial force on the armature that adds to reactive forces on a thrust bearing which results in additional energy loss due to added friction.

What is needed is a fuel pump which minimizes or eliminates one or more of the shortcomings as set forth above.

SUMMARY OF THE INVENTION

Briefly described, a fuel pump includes a pump holder having a pump holder sidewall extending along an axis from a first end to a second end, the pump holder sidewall being annular in shape and surrounding the axis such that the second end is closed off by a pump holder end wall which is transverse to the axis, the pump holder having a fuel inlet and a fuel outlet; an electric motor which rotates when an electric current is applied thereto; an upper plate which is received within the pump holder sidewall and which is proximal to the electric motor, the upper plate having an upper plate flow channel formed in a lower surface thereof; a lower plate which is located within the pump holder sidewall and which is distal from the electric motor such that the upper plate is located axially between the electric motor and the lower plate and such that an outlet chamber is formed axially between the lower plate and the pump holder end wall, the lower plate having a lower plate flow channel formed in an upper surface thereof such that the upper surface of the lower plate faces toward the lower surface of the upper plate, the lower plate also having a lower plate outlet passage which extends from the lower plate flow channel to a lower surface thereof; and a pumping element located axially between the upper plate and the lower plate and rotationally coupled to the electric motor such that rotation of the pumping element by the electric motor causes fuel to be drawn through the fuel inlet into, and pressurized within, the upper plate flow channel and the lower plate flow channel and discharged into the outlet chamber through the lower plate outlet passage such that fuel under pressure within the outlet chamber urges the lower plate toward the upper plate. The fuel pump as described herein minimizes cost, simplifies manufacturing, minimizes axial length, and maximizes efficiency since the electric motor is not in the pressurized path of fuel.

BRIEF DESCRIPTION OF DRAWINGS

This invention will be further described with reference to the accompanying drawings in which:

FIG. 1 is a schematic view of a fuel system in accordance with the present disclosure;

FIG. 2 is an exploded isometric view of a fuel pump in accordance with the present disclosure;

FIGS. 3 and 4 are cross-sectional views of the fuel pump taken through two different sectioning planes;

FIG. 5 is an isometric view of a lower plate of a pumping section of the fuel pump;

FIG. 6 is an isometric view of an upper plate of the pumping section; and

FIGS. 7 and 8 are isometric views of the fuel pump where FIG. 7 shows an electric motor partially installed and FIG. 8 shows the electric motor fully installed.

DETAILED DESCRIPTION OF INVENTION

Referring initially to FIG. 1, a fuel system 10 is shown in accordance with the present disclosure for supplying fuel to a fuel consuming device, illustrated by way of non-limiting example only, as an internal combustion engine 12. The fuel of fuel system 10 may be any liquid fuel customarily used, for example only, gasoline, diesel fuel, alcohol, ethanol, and the like, and blends thereof.

Fuel system 10 includes a fuel tank 14 for storing a quantity of fuel and a fuel pump 16 for pumping fuel from fuel tank 14 to internal combustion engine 12. Fuel that is pumped by fuel pump 16 is communicated to internal combustion engine 12 through a fuel supply line 18. Fuel pump 16 is an electric fuel pump which will be described in greater detail in the paragraphs that follow.

Additional reference will now be made to FIGS. 2-4 where FIG. 2 is an exploded isometric view of fuel pump 16 and FIGS. 3 and 4 are axial cross-sectional views of fuel pump 16 taken through different sectioning planes. Fuel pump 16 generally includes a pump holder 20, a pumping section 22 received within pump holder 20, and an electric motor 24 which is fixed to pump holder 20 and which rotates a portion of pumping section 22, thereby pumping fuel from fuel tank 14 to internal combustion engine 12.

Pump holder 20 includes a pump holder sidewall 20a which is centered about, and extends along, an axis 26 from a first end 20b to a second end 20c such that a pump holder sidewall 20a is annular in shape and surrounds axis 26. Second end 20c is closed off by a pump holder end wall 20d which is transverse to axis 26. The inner periphery of pump holder sidewall 20a is stepped in diameter, thereby forming a shoulder 20e which is annular in shape and which faces away from a pump holder end wall 20d. An inlet port 20f is provided on the outer periphery of pump holder sidewall 20a such that inlet port 20f is tubular and serves as a fuel inlet through which fuel enters fuel pump 16 from fuel tank 14. A pump holder inlet passage 20g extends through a pump holder sidewall 20a such that pump holder inlet passage 20g provides fluid communication between the interior of inlet port 20f and the inner periphery of pump holder sidewall 20a. While one pump holder inlet passage 20g has been illustrated herein, it should be understood that a greater quantity may be provided. Pump holder 20 also includes an outlet port 20h which is tubular and which serves as a fuel outlet through which fuel exits fuel pump 16. An outlet passage 20i extends through either pump holder sidewall 20a or pump holder end wall 20d, however, for illustrative purposes, outlet passage 20i has been illustrated herein as extending through pump holder sidewall 20a. Outlet passage 20i provides fluid communication between the inner periphery of pump holder sidewall 20a and the interior of outlet port 20h. As illustrated herein, outlet port 20h is provided on the outer periphery of pump holder sidewall 20a, however, outlet port 20h may alternatively be provided on pump holder end wall 20d if outlet passage 20i extends through pump holder end wall 20d. Providing outlet port 20h on the pump holder end wall 20d may be desirable, for example, to accommodate mounting fuel pump 16 vertically rather than horizontally as shown in FIG. 1.

In order to retain electric motor 24 to pump holder 20, pump holder sidewall 20a includes a plurality of retention windows 20j which extend radially therethrough such that retention windows 20j are circumferentially spaced around pump holder sidewall 20a and are located proximal to first end 20b, but spaced away from first end 20b in a direction toward second end 20c. While four retention windows 20j have been illustrated herein, a lesser quantity or a greater quantity of retention windows 20j may be provided depending on the retention needs. In order to increase the flexibility of pump holder sidewall 20a, thereby aiding in assembly of electric motor 24 to pump holder 20, pump holder sidewall 20a may include a plurality of slots 20k which extend from first end 20b toward second end 20c. One or more slots 20k are located between adjacent pairs of retention windows 20j and extend toward second end 20c slightly further than retention windows 20j, however, the extent to which slots 20k extend may be tailored in order to provide different magnitudes of flexibility to pump holder sidewall 20a depending on the retention requirements. As illustrated in the figures, eight slots 20k have been illustrated, however, a lesser quantity or a greater quantity of slots 20k may be provided.

A pressure regulator holder 28 may be integrally formed with pump holder 20 in order to hold a pressure regulator 30 which regulates the pressure of fuel supplied to internal combustion engine 12. Pressure regulator holder 28 includes a pressure regulator holder sidewall 28a which is centered about, and extends along, an axis 32 from a first end 28b to a second end 28c such that pressure regulator holder sidewall 28a is annular in shape and surrounds axis 32. Axis 26 and axis 32 may be parallel to, and laterally offset from, each other such that the integral nature of pump holder 20 and pressure regulator holder 28 results in a portion of pump holder sidewall 20a and a portion of pressure regulator holder sidewall 28a being integrally formed and being common to both pump holder 20 and pressure regulator holder 28 which may be most easily viewed in FIGS. 2 and 3. Second end 28c is closed off by a pressure regulator holder end wall 28d which is transverse to axis 32. A pressure regulation passage 34 extends through the common portion of pump holder sidewall 20a and pressure regulator holder sidewall 28a, thereby providing fluid communication between the interior of pump holder 20 and the interior of pressure regulator holder 28. While pump holder 20 and pressure regulator holder 28 have been illustrated herein as being arranged laterally relative to each other, other respective orientations are also anticipated, for example to accommodate different fuel tank environments. In one example, pump holder 20 and pressure regulator holder 28 may each be arranged axially relative to each other such that pump holder 20 and pressure regulator holder 28 include pump holder end wall 20d in common and such that pressure regulation passage 34 extends through pump holder end wall 20d. In another example, axis 26 and axis 32 may be not be parallel and may alternatively be perpendicular to each other or arranged at some other angle relative to each other.

Pumping section 22 includes a lower plate 36, a pumping element illustrated as impeller 38, and an upper plate 40, each of which is located within pump holder sidewall 20a. Lower plate 36 is disposed at the end of pumping section 22 that is proximal to pump holder end wall 20d and distal from electric motor 24 while upper plate 40 is disposed at the end of pumping section 22 that is distal from pump holder end wall 20d and proximal to electric motor 24. Both lower plate 36 and upper plate 40 are fixed relative to pump holder 20 in order to prevent relative movement between lower plate 36 and upper plate 40 with respect to pump holder 20. Upper plate 40 defines a spacer ring 42 on the side of upper plate 40 that faces toward lower plate 36. Impeller 38 is disposed axially between lower plate 36 and upper plate 40 such that impeller 38 is radially surrounded by spacer ring 42. Spacer ring 42 is dimensioned to be slightly thicker than the dimension of impeller 38 in the direction of axis 26, i.e. the dimension of spacer ring 42 in the direction of axis 26 is greater than the dimension of impeller 38 in the direction of axis 26. Spacer ring 42 is also dimensioned to have an inside diameter that is larger than the outside diameter of impeller 38 to allow impeller 38 to rotate freely within spacer ring 42 and axially between lower plate 36 and upper plate 40. Impeller 38 is rotationally coupled to electric motor 24, and rotates about axis 26 between lower plate 36 and upper plate 40. While the pumping element has been illustrated as impeller 38, it should now be understood that other pumping elements may alternatively be used, by way of non-limiting example only, a gerotor, gears, or roller vanes. Furthermore, while spacer ring 42 is illustrated as being made as a single piece with upper plate 40, it should be understood that spacer ring 42 may alternatively be made as a separate piece that is captured axially between lower plate 36 and upper plate 40 or may be made as a single piece with lower plate 36.

Lower plate 36 is generally cylindrical in shape and extends along axis 26 from a lower surface 36a, which is proximal to pump holder end wall 20d, to an upper surface 36b which contacts impeller 38. Lower plate 36 includes a lower plate flow channel 36c formed in upper surface 36b. Lower plate 36 also includes a lower plate inlet passage 36d that extends radially inward from the outer periphery of lower plate 36 such that lower plate inlet passage 36d connects to lower plate flow channel 36c at one end thereof as can be seen in FIG. 5. Lower plate inlet passage 36d is aligned with pump holder inlet passage 20g of pump holder 20, and in this way, lower plate inlet passage 36d provides fluid communication from pump holder inlet passage 20g of pump holder 20 to lower plate flow channel 36c. Lower plate 36 also includes a lower plate outlet passage 36e which extends to lower surface 36a from the end of lower plate flow channel 36c which is opposite from lower plate inlet passage 36d. Lower surface 36a of lower plate 36 is spaced axially apart from pump holder end wall 20d such that an outlet chamber 44 is formed axially between lower plate 36 and pump holder end wall 20d which is in fluid communication with lower plate outlet passage 36e. Lower plate 36 also includes a central recess 36g which extends axially into lower plate 36 from upper surface 36b such that central recess 36g is centered about axis 26 and such that central recess 36g terminates axially at a thrust surface 36h.

As can be seen in FIG. 3, the outer periphery of lower plate 36 is stepped such that a lower plate shoulder 36f is formed which faces toward pump holder end wall 20d. A sealing ring 46 is captured axially between lower plate shoulder 36f and shoulder 20e of pump holder 20 and is captured radially between the inner periphery of pump holder sidewall 20a the outer periphery of lower plate 36. Sealing ring 46 prevents pressurized fuel within outlet chamber 44 from escaping radially between lower plate 36 and pump holder 20. It should also be noted that sealing ring 46 is held in axial compression between lower plate shoulder 36f and shoulder 20e of pump holder 20 and therefore also urges lower plate 36 into contact with upper plate 40, thereby maintaining a close clearance between impeller 38 and lower plate 36 and between impeller 38 and upper plate 40 which is necessary for maintaining pumping efficiency, particularly when fuel pump 16 is initially started and pressure within outlet chamber 44 is low.

Upper plate 40 is generally cylindrical in shape and extends along axis 26 from a lower surface 40a, which contacts impeller 38, to an upper surface 40b which is proximal to electric motor 24. Upper plate 40 includes an upper plate flow channel 40c formed in lower surface 40a. Upper plate 40 also includes an upper plate inlet passage 40d that extends radially inward from the outer periphery of upper plate 40 such that upper plate inlet passage 40d connects to upper plate flow channel 40c at one end thereof as can be seen in FIG. 6 where it should be noted that upper plate 40 is shown inverted from the orientation shown in FIGS. 3 and 4. Upper plate inlet passage 40d is aligned with pump holder inlet passage 20g of pump holder 20, and in this way, upper plate inlet passage 40d provides fluid communication from pump holder inlet passage 20g of pump holder 20 to upper plate flow channel 40c. Upper plate 40 also includes a vapor bleed passage 40e which extends to upper surface 40b of upper plate 40 from upper plate flow channel 40c. Vapor bleed passage 40e provides a path to purge fuel vapor which aids in priming and provides cooling and lubrication to electric motor 24 by directing a flow of fuel at electric motor 24. Upper plate 40 also includes a central aperture 40f which extends axially therethrough from upper surface 40b to lower surface 40a such that central aperture 40f is centered about axis 26. Central aperture 40f provides a bearing surface to electric motor 24 as will be described in greater detail later.

Impeller 38 includes a plurality of impeller blades 38a arranged in a polar array radially surrounding and centered about axis 26 such that impeller blades 38a are aligned with lower plate flow channel 36c and upper plate flow channel 40c. Impeller blades 38a are each separated from each other by respective impeller blade chambers 38b that pass through impeller 38 in the general direction of axis 26. Impeller 38 may be made, for example only, by a plastic injection molding process in which the preceding features of impeller 38 are integrally molded as a single piece of plastic.

Electric motor 24 includes a rotor or armature 48 which rotates about axis 26, a motor frame 50, and a flux carrier 52. One of armature 48 and motor frame 50 includes a plurality of circumferentially spaced motor windings and the other of armature 48 and motor frame 50 includes a plurality of magnets. As embodied herein, armature 48 includes a plurality of motor windings 54 which are circumferentially spaced around armature 48 and motor frame 50 includes a pair of magnets 56 which are each in the shape of a segment of a hollow cylinder; however, it should be understood that this arrangement may alternatively be reversed. In order to switch electric current through motor windings 54, armature 48 also includes a commutator portion 58. Armature 48 also includes a motor shaft 60 which is centered about axis 26 and which extends axially from both ends of armature 48. The lower end of motor shaft 60 extends through central aperture 40f of upper plate 40 such that motor shaft 60 is sized relative to central aperture 40f to allow motor shaft 60 to rotate freely therein while limiting movement of motor shaft 60 laterally relative to axis 26. The lower end of motor shaft 60 is also rotationally coupled to impeller 38, for example through complementary geometries of motor shaft 60 and impeller 38, thereby causing impeller 38 to rotate together with armature 48 and motor shaft 60. Axial movement of motor shaft 60 toward lower plate 36 is limited by motor shaft 60 abutting thrust surface 36h in a direction downward as oriented in FIG. 3.

Motor frame 50 includes a top section 50a which is distal from pumping section 22, a plurality of circumferentially spaced legs 50b extending axially from top section 50a toward pumping section 22, and a base section 50c axially spaced apart from top section 50a by legs 50b. Top section 50a, legs 50b, and base section 50c are preferably integrally formed from a single piece of plastic, for example only, by a plastic injection molding process.

Top section 50a of motor frame 50 includes a first brush holder 50d and a second brush holder 50e which are each hollow and which each extend in a direction parallel to axis 26. A first carbon brush 62 is disposed within first brush holder 50d and is urged into contact with commutator portion 58 of armature 48 by a first brush spring 62a. First brush holder 50d includes an axially extending slot which allows a first shunt wire 62b to extend out of first brush holder 50d and accommodates movement of first carbon brush 62. A second carbon brush 64 is disposed within second brush holder 50e and is urged into contact with commutator portion 58 of armature 48 by a second brush spring 64a. Second brush holder 50e includes an axially extending slot which allows a second shunt wire 64b to extend out of second brush holder 50e and accommodates movement of second carbon brush 64. First carbon brush 62 and second carbon brush 64 deliver electrical power to motor windings 54 through first shunt wire 62b and second shunt wire 64b respectively and via commutator portion 58, thereby rotating armature 48 and motor shaft 60 about axis 26. A brush retainer 65 closes off the ends of first brush holder 50d and second brush holder 50e which are distal from commutator portion 58, thereby capturing first carbon brush 62 and second carbon brush 64 within first brush holder 50d and second brush holder 50e respectively and providing a surface for first brush spring 62a and second brush spring 64a to push against in order to urge first carbon brush 62 and second carbon brush 64 into contact with commutator portion 58. Brush retainer 65 is fixed to first brush holder 50d and second brush holder 50e, for example, with one or more of adhesive, welding, heat staking, mechanical fasteners, interlocking features, and the like.

Top section 50a of motor frame 50 defines an upper aperture 50f therein which radially supports an upper end of motor shaft 60. Motor shaft 60 and upper aperture 50f are sized in order to allow motor shaft 60 to rotate freely within upper aperture 50f while limiting movement of motor shaft 60 laterally relative to axis 26. Axial movement of motor shaft 60 away from pumping section 22 is limited by motor shaft 60 abutting an upper thrust surface, which terminates upper aperture 50f, in a direction upward as oriented in FIG. 3.

Legs 50b are preferably equally circumferentially spaced around top section 50a and base section 50c and define motor frame openings 50g between legs 50b. Motor frame openings 50g extend axially from top section 50a to base section 50c. One magnet 56 is disposed within each motor frame opening 50g. Magnets 56 may be inserted within respective motor frame openings 50g after motor frame 50 has been formed. Alternatively, magnets 56 may be insert molded with motor frame 50 when motor frame 50 is formed by a plastic injection molding process. In this way, magnets 56 and legs 50b radially surround armature 48. While two legs 50b and two magnets 56 have been illustrated, it should be understood that other quantities of legs 50b and magnets 56 may be included.

Base section 50c is annular in shape and connects legs 50b to each other. Base section 50c is coaxial with upper aperture 50f and receives a portion of upper plate 40 closely therein such that radial movement of upper plate 40 within base section 50c is substantially prevented. Since base section 50c is coaxial with upper aperture 50f, a coaxial relationship is maintained between upper aperture 50f and central aperture 40f of upper plate 40. The outer periphery of base section 50c includes a plurality of retention tabs 50h which are circumferentially spaced around axis 26 to be complementary to retention windows 20j of pump holder 20. Retention tabs 50h are tapered outward in a direction moving from base section 50c toward top section 50a. Consequently, when base section 50c is inserted into pump holder 20, retention tabs 50h cause the portion of pump holder sidewall 20a containing retention windows 20j to be elastically deformed outward. When base section 50c is inserted sufficiently far to allow retention tabs 50h to be aligned with retention windows 20j, pump holder sidewall 20a rebounds to is original state, i.e. pre-elastic deformation, thereby causing retention tabs 50h to be captured within retention windows 20j and retain electric motor 24 to pump holder 20. For clarity, FIG. 7 shows electric motor 24 being installed and just before retention tabs 50h cause the portion of pump holder sidewall 20a containing retention windows 20j to be elastically deformed outward and FIG. 8 shows electric motor 24 being completely installed such that retention tabs 50h are captured within retention windows 20j and retain electric motor 24 to pump holder 20. While retention of electric motor 24 to pump holder 20 has been illustrated herein as being accomplished through retention tabs 50h interlocking with retention windows 20j, it should be understood that retention may additionally or alternatively be accomplished through one or more of crimping, adhesive, welding, heat staking, or mechanical fasteners such as a retention clip. It should also be noted that the outer periphery of base section 50c mates with the inner periphery of pump holder sidewall 20a in an interference fit in order to prevent fuel from entering pumping section 22 without passing through inlet port 20f. This interference fit may be provided by a sealing bead 50i which protrudes radially outward from the outer periphery of base section 50c.

Flux carrier 52 is made of a ferromagnetic material and may take the form of a cylindrical tube. Flux carrier 52 may be made, for example only, from a sheet of ferromagnetic material formed to shape by a rolling process. Flux carrier 52 closely radially surrounds legs 50b of motor frame 50 and magnets 56 and axially abuts base section 50c. Retention of flux carrier 52 is accomplished by way of interference fit with one or more of motor frame 50 and magnets 56.

Pressure regulator 30 includes a housing 66 which is received within pressure regulator holder sidewall 28a, a valve member 68 located within housing 66, a valve spring 70 which biases valve member 68 toward a closed position (shown without section lines in FIG. 3), and a spring retainer 72. The elements of pressure regulator 30 will be described in greater detail in the paragraphs that follow.

Housing 66 is centered about, and extends along, axis 32 from a first end 66a which is distal from pressure regulator holder end wall 28d to a second end 66b which is proximal to pressure regulator holder end wall 28d. A central passage, which is stepped in diameter, extends through housing 66 from first end 66a to second end 66b such that a central passage first section 66c extends into housing 66 from first end 66a and such that a central passage second section 66d, which is smaller in diameter than central passage first section 66c, extends from central passage first section 66c to second end 66b. A housing shoulder 66e, which is transverse to axis 32, is formed where central passage first section 66c meets central passage second section 66d. The outer periphery of housing 66 is sealed to the inner periphery of pressure regulator holder sidewall 28a, for example by interference fit, adhesive, or mechanical seals, thereby preventing fuel from passing out from pressure regulator holder sidewall 28a radially between housing 66 and pressure regulator holder sidewall 28a. When a mechanical seal is used, a groove on the outer periphery of housing 66 may carry the mechanical seal in the form of an O-ring.

Valve member 68 is located within central passage first section 66c and selectively opens and closes central passage second section 66d. As illustrated herein, valve member 68 may be disk shaped such that valve member 68 engages housing shoulder 68e in order to block central passage first section 66c (shown without section lines in FIG. 3), thereby preventing fuel flow through housing 66 and such that valve member 68 is spaced apart from housing shoulder 68e (shown with section lines in FIG. 3), thereby allowing fuel flow through housing 66. However, it should be understood that valve member 68 may take other forms, which may be by way of non-limiting example only conical, frustoconical, spherical, or frustospherical. Spring retainer 72 is fixed within central passage first section 66c and proximal to first end 66a such that valve spring 70 is held in compression between valve member 68 and spring retainer 72. Compression of valve spring 70 is set by inserting spring retainer 72 within central passage first section 66c sufficiently far so as to require a predetermined force to cause valve member 68 to be separated from housing shoulder 68e. Spring retainer 72 is fixed within central passage first section 66c, by way of non-limiting example only through one or more of interference fit, adhesive, welding, heat staking, or mechanical fasteners. Spring retainer 72 includes a flow passage 72a extending axially therethrough which allow fuel to flow therethrough.

Fuel pump 16 is mounted near the bottom of fuel tank 14 and may be mounted to a fuel tank cover 74 which closes a fuel tank opening 14a of fuel tank 14 which allows fuel pump 16 to be installed within fuel tank 14. While fuel tank opening 14a has been illustrated herein at the bottom of fuel tank 14, it should be understood that fuel tank opening 14a may alternatively be at the top of fuel tank 14 or even on the side of fuel tank 14.

In operation, electric motor 24 is supplied with electricity, and as a result, armature 48, including motor shaft 60, rotates about axis 26. Since impeller 38 is rotationally coupled to motor shaft 60, impeller 38 also rotates about axis 26. Rotation of impeller 38 about axis 26 causes fuel to be drawn into lower plate flow channel 36c and upper plate flow channel 40c through a fuel strainer 76 which is attached to inlet port 20f, through inlet port 20f and pump holder inlet passage 20g. Fuel strainer 76 prevents solid foreign matter from entering fuel pump 16 in order to prevent premature wear of the moving parts. After being drawn into lower plate flow channel 36c and upper plate flow channel 40c, the fuel is pressurized within lower plate flow channel 36c and upper plate flow channel 40c as the fuel passes along each of lower plate flow channel 36c and upper plate flow channel 40c. A portion of the fuel that is pressurized is expelled through vapor bleed passage 40e which is directed toward electric motor 24. The fuel that is expelled through vapor bleed passage 40e flows between armature 48 and legs 50b/magnets 56 and exits at top section 50a, thereby providing lubrication and cooling, particularly to the interface between commutator portion 58 and first carbon brush 62/second carbon brush 64 and to the interface between motor shaft 60 and upper aperture 50f. However, it should be noted electric motor 24 is not a sealed container, and consequently, the fuel expelled through vapor bleed passage 40e is depressurized and merely flows through electric motor 24 where it mixes with the other fuel within fuel tank 14. It should be noted that a portion of this fuel flow exits electric motor 24 through first brush holder 50d and through second brush holder 50e. The remaining portion of fuel that is pressurized within lower plate flow channel 36c and upper plate flow channel 40c passes through lower plate outlet passage 36e and into outlet chamber 44. From outlet chamber 44, the pressurized fuel passes through outlet passage 20i and outlet port 20h where it is delivered to internal combustion engine 12. It should be noted that since outlet chamber 44 is pressurized with fuel, this pressure will force lower plate 36 into contact with upper plate 40, thereby maintaining a close clearance between impeller 38 and lower plate 36 and between impeller 38 and upper plate 40 which is necessary for maintaining pumping efficiency. In order to maintain pressure within fuel supply line 18 when fuel pump 16 is not operating, thereby aiding in restarting internal combustion engine 12, a check valve 78 may be provided within lower plate outlet passage 36e. Check valve 78 allows flow of fuel from lower plate flow channel 36c to outlet chamber 44 but prevents flow of fuel from outlet chamber 44 to lower plate flow channel 36c. It is important to note that by providing check valve 78 within lower plate outlet passage 36e, pressure regulator 30 is available to prevent excessive pressure from building within fuel supply line 18 which can result from the fuel heating and expanding when fuel pump 16 is not operating. This is importance because if excessive pressure in fuel supply line 18 is not prevented, fuel can be forced from fuel injectors of internal combustion engine 12 which is undesirable for emissions output of internal combustion engine 12. Check valve 78 may take many forms, however, for illustrative purposes, check valve 78 has been shown as a plunger which is biased into a closed position by a spring. When fuel pump 16 is operated, the pressure of fuel pumped by pumping section 22 overcomes the force of the spring, thereby opening the plunger. Check valve 78 may be omitted in systems where backflow of fuel to fuel pump 16 is not a concern, for example, when fuel pump 16 is located higher than internal combustion engine 12.

Pressure regulator 30 is exposed to the same pressure as within outlet chamber 44 due to fluid communication through pressure regulation passage 34. Consequently, pressure regulator 30 limits the pressure of fuel being supplied to internal combustion engine 12 by opening valve member 68. More specifically, when the pressure within outlet chamber 44 exceeds a predetermined threshold, the force acting on valve member 68 due to fuel pressure exceeds the force of valve spring 70 acting on valve member 68, thereby causing valve member 68 to open and allowing fuel to flow out through central passage second section 68d, central passage first section 66c, and flow passage 72a where the fuel mixes with the other fuel within fuel tank 14. After the pressure within outlet chamber 44 falls below the predetermined threshold, the force acting on valve member 68 due to fuel pressure no longer exceeds the force of valve spring 70, thereby causing valve spring 70 to close valve member 68.

Fuel pump 16 as described herein provides advantages over known fuel pumps. Since electric motor 24 is not a pressurized container, i.e. is not within a sealed portion of fuel pump 16 through which pressurized fuel passes, pressure-tight interfaces normally associated with the electric motor are not required, thereby minimizing cost, simplifying manufacturing, and minimizing axial length. Furthermore, energy efficiency is maximized since there is less viscous torque drag as a result of only a low flow of fuel (from vapor bleed passage 40e) passing between the pressurized fuel and armature 48 and since there is no pressure acting on electric motor 24 which would translate into increased axial thrust pressure between motor shaft 60 and thrust surface 36h, thereby minimizing friction.

While this invention has been described in terms of preferred embodiments thereof, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow.

Claims

1. A fuel pump comprising: a pump holder having a pump holder sidewall extending along an axis from a first end to a second end, said pump holder sidewall being annular in shape and surrounding said axis such that said second end is closed off by a pump holder end wall which is transverse to said axis, said pump holder having a fuel inlet and a fuel outlet;an electric motor which rotates when an electric current is applied thereto;an upper plate which is received within said pump holder sidewall and which is proximal to said electric motor, said upper plate having an upper plate flow channel formed in a lower surface thereof;a lower plate which is located within said pump holder sidewall and which is distal from said electric motor such that said upper plate is located axially between said electric motor and said lower plate and such that an outlet chamber is formed axially between said lower plate and said pump holder end wall, said lower plate having a lower plate flow channel formed in an upper surface thereof such that said upper surface of said lower plate faces toward said lower surface of said upper plate, said lower plate also having a lower plate outlet passage which extends from said lower plate flow channel to a lower surface thereof; anda pumping element located axially between said upper plate and said lower plate and rotationally coupled to said electric motor such that rotation of said pumping element by said electric motor causes fuel to be drawn through said fuel inlet into, and pressurized within, said upper plate flow channel and said lower plate flow channel and discharged into said outlet chamber through said lower plate outlet passage such that fuel under pressure within said outlet chamber urges said lower plate toward said upper plate.

2. A fuel pump as in claim 1, wherein said fuel outlet is located on one of 1) said pump holder sidewall between said lower plate and said pump holder end wall and 2) said pump holder end wall.

3. A fuel pump as in claim 1, wherein: said pump holder sidewall includes a plurality of retention windows extending radially therethrough such that said plurality of retention windows are spaced circumferentially around said pump holder sidewall; andsaid electric motor includes a plurality of retention tabs which are captured within said plurality of retention windows of said pump holder sidewall and retain said electric motor to said pump holder.

4. A fuel pump as in claim 3, wherein said pump holder sidewall includes a plurality of slots radially therethrough which extend from said first end toward said second end such that one or more of said plurality of slots are located between adjacent pairs of said plurality of retention windows.

5. A fuel pump as in claim 3, wherein said electric motor comprises: a motor frame having 1) a top section which is distal from said upper plate, 2) a base section which is annular in shape and which is proximal to said upper plate, and 3) a plurality of legs which are circumferentially spaced and connected to said top section and to said base section such that said plurality of legs space said top section apart from said base section;an armature which rotates within said motor frame when said an electric current is applied to said electric motor, said armature having a motor shaft extending therefrom such that one end of said motor shaft is radially supported by said top section and such that another end of said motor shaft is radially supported by said upper plate;wherein said base section includes said plurality of retention tabs.

6. A fuel pump as in claim 1, wherein said upper plate includes a vapor bleed passage which extends from said upper plate flow channel to an upper surface of said upper plate and which directs a flow of fuel to said electric motor.

7. A fuel pump as in claim 6, where said electric motor is not a sealed container, thereby allowing said flow of fuel from said vapor bleed passage to be depressurized.

8. A fuel pump as in claim 6, wherein said electric motor comprises: a motor frame having 1) a top section which is distal from said upper plate, 2) a base section which is annular in shape and which is proximal to said upper plate, and 3) a plurality of legs which are circumferentially spaced and connected to said top section and to said base section such that said plurality of legs space said top section apart from said base section;an armature which rotates within said motor frame when said an electric current is applied to said electric motor, said armature having a motor shaft extending therefrom such that one end of said motor shaft is radially supported by said top section and such that another end of said motor shaft is radially supported by said upper plate;wherein said base section includes said plurality of retention tabswherein said top section includes: a first brush holder within which a first carbon brush is located; anda second brush holder within which a second carbon brush is located;wherein said first carbon brush and said second carbon brush are in contact with a commutator portion of said armature and communicate electricity to said armature; andwherein said flow of fuel from said vapor bleed passage exits said electric motor through said first brush holder and through said second brush holder.

9. A fuel pump as in claim 1, wherein: one of said upper plate and said lower plate includes an inlet passage which extends radially inward from an outer periphery of said one of said upper plate and said lower plate such that said inlet passage connects to said upper plate flow channel if said one of said upper plate and said lower plate is said upper plate and connects to said lower plate flow channel if said one of said upper plate and said lower plate is said lower plate; andsaid pump holder sidewall includes pump holder inlet passage which extends radially therethrough such that said inlet passage of said one of said upper plate and said lower plate is aligned with said pump holder inlet passage and such that said pump holder inlet passage and said inlet passage of said one of said upper plate and said lower plate provides fluid communication from said fuel inlet of said pump holder to said upper plate flow channel if said one of said upper plate and said lower plate is said upper plate and to said lower plate flow channel if said one of said upper plate and said lower plate is said lower plate.

10. A fuel pump as in claim 1, wherein: said upper plate includes an upper plate inlet passage which extends radially inward from an outer periphery of said upper plate such that said upper plate inlet passage connects to said upper plate flow channel;said lower plate includes a lower plate inlet passage which extends radially inward from an outer periphery of said lower plate such that said lower plate inlet passage connects to said lower plate flow channel;said pump holder sidewall includes a pump holder inlet passage which extends radially therethrough; andsaid pump holder inlet passage is aligned with said upper plate inlet passage and with said lower plate inlet passage, thereby together providing fluid communication from said fuel inlet of said pump holder to said upper plate flow channel and to said lower plate flow channel.

11. A fuel pump as in claim 10, wherein: said lower surface of said upper plate extends over said upper plate inlet passage; andsaid upper surface of said upper plate extends over said lower plate inlet passage.

12. A fuel pump as in claim 1, further comprising: a pressure regulator holder having a pressure regulator holder sidewall extending along a second axis from a first end to a second end, said pressure regulator holder sidewall being annular in shape and surrounding said second axis such that said second end is closed off by a pressure regulator holder end wall which is transverse to said second axis;a pressure regulation passage which provides fluid communication from said outlet chamber to an interior of said pressure regulator holder; anda pressure regulator received within said pressure regulator holder which 1) opens when pressure within said outlet chamber exceeds a predetermined threshold, thereby reducing pressure within said outlet chamber and 2) closes when pressure within said outlet chamber is below said predetermined threshold.

13. A fuel pump as in claim 12, wherein a portion of said pump holder sidewall and a portion of said pump holder sidewall are common to both said pump holder and said pressure regulator holder.

14. A fuel pump as in claim 12, wherein said pressure regulation passage extends through said portion of said pump holder sidewall and said portion of said pump holder sidewall which is common to both said pump holder and said pressure regulator holder.

15. A fuel pump as in claim 12, wherein: said pump holder sidewall includes a plurality of retention windows extending radially therethrough such that said plurality of retention windows are spaced circumferentially around said pump holder sidewall; andsaid electric motor includes a plurality of retention tabs which are captured within said plurality of retention windows of said pump holder sidewall and retain said electric motor to said pump holder.

16. A fuel pump as in claim 15, wherein said pump holder sidewall includes a plurality of slots radially therethrough which extend from said first end toward said second end such that one or more of said plurality of slots are located between adjacent pairs of said plurality of retention windows.

17. A fuel pump as in claim 15, wherein said electric motor comprises: a motor frame having 1) a top section which is distal from said upper plate, 2) a base section which is annular in shape and which is proximal to said upper plate, and 3) a plurality of legs which are circumferentially spaced and connected to said top section and to said base section such that said plurality of legs space said top section apart from said base section;an armature which rotates within said motor frame when said an electric current is applied to said electric motor, said armature having a motor shaft extending therefrom such that one end of said motor shaft is radially supported by said top section and such that another end of said motor shaft is radially supported by said upper plate;wherein said base section includes said plurality of retention tabs.

18. A fuel pump as in claim 1, further comprising a check valve within said lower plate outlet passage which 1) allows flow of fuel from said lower plate flow channel to said outlet chamber and 2) prevents flow of fuel form said outlet chamber to said lower plate flow channel.