FUEL PUMP

Abstract

A vapor lock in a fuel pump can be prevented by reducing the formation of vapor within the fuel. A first group of concavities may be formed in an inner circumferential region of an intake side face of an impeller, and a second group of concavities may be formed concentrically in a region outside of the first group of concavities. A third group of concavities that communicates with the second group of concavities may be formed in a discharge side face of the impeller. The impeller is housed within a casing. A first groove that faces the first group of concavities and a second groove that faces the second group of concavities may be formed in the face of the casing that faces the intake side face of the impeller. A third groove that faces the third group of concavities may be formed in the face of the casing that faces the discharge side face of the impeller.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a vertical cross-sectional view of a fuel pump of the present embodiment.

FIG. 2 is a plan view of an impeller of the present embodiment seen from an intake side.

FIG. 3 is a plan view of the impeller of the present embodiment seen from a discharge side.

FIG. 4 is a plan view of a pump body of the present embodiment seen from the discharge side.

FIG. 5 is a plan view of a pump cover of the present embodiment seen from the intake side.

FIG. 6 is a cross-sectional view describing another configuration of a pump portion.

FIG. 7 is a plan view of a pump body of the pump portion shown in FIG. 6 seen from the discharge side.

FIG. 8 is a cross-sectional view along the line VIII-VIII of FIG. 7.

DETAILED DESCRIPTION OF THE INVENTION

First, important features of the art set forth in the embodiment will be listed below.

(Feature 1) An intake port and a discharge port are formed in a casing. The intake hole is connected with an upper flow end of a first groove, and the discharge hole is connected with a lower flow end of a third groove. Suction of the fuel into the casing is performed by a first group of concavities.

(Feature 2) The first groove is formed in the same plane as a second groove and a communicating groove. The grooves are thus formed in a spiral shape in an inner face of the casing facing an intake face of the impeller.

Embodiments

An embodiment according to the present teachings is described below with reference to figures. First, the mechanical configuration of a fuel pump will be described with reference to FIG. 1.

As shown in FIG. 1, the fuel pump 10 comprises a motor portion 70 and a pump portion 12.

The motor portion 70 comprises a housing 72, a motor cover 73, magnets 74, 75, and a rotor 76. The housing 72 is formed in a substantially cylindrical shape. The motor cover 73 is attached to the housing 72 by caulking the upper end 72a of the housing 72 (hereafter, the up-down direction of FIG. 1 will be considered the up-down direction of the fuel pump 10). A discharge port 73a is formed in the motor cover 73. The magnets 74, 75 are fixed to the inner walls of the housing 72. The rotor 76 has a main body 77, and a shaft 78 that vertically extends through the main body 77. An upper end 78a of the shaft 78 is rotatably mounted on the motor cover 73 via a bearing 81. A lower end 78b of the shaft 78 is rotatably mounted on a pump cover 14 of the pump portion 12 via a bearing 82. Since the motor portion 70 is the same as motor portions taught in Japanese Laid-open Patent Publications No. 60-113088 and No. 60-219495, a more detailed description thereof is omitted.

The pump portion 12 comprises a casing 18 and a substantially disc-shaped impeller 20. FIG. 2 is a plan view of the intake side of the impeller 20. FIG. 3 is a plan view of the discharge side of the impeller 20.

As shown in FIG. 2, a second group of concavities 20b that is formed continuously in the circumferential direction is disposed in a ring shape along an outer peripheral portion of the intake side face of the impeller 20 (not all concavities of the second group have been numbered in FIG. 2). The second group of concavities 20b is separated from the outer peripheral face 20e of the impeller 20 by the outer peripheral wall 20d of the impeller 20. A first group of concavities 20a that is formed continuously in the circumferential direction is disposed in a ring shape inwards from the second group of concavities 20b in the radial direction (not all concavities of the first group have been numbered in FIG. 2). Each concavity of the first group of concavities 20a are separated by a predetermined space from the second group of concavities 20b, and are disposed at a constant distance from a center of the impeller 20. An engaging hole 20c, that is substantially D-shaped in cross-section across a plane perpendicular to a rotational axis of the impeller 20, passes through a central portion of the impeller 20 in the direction of the thickness thereof. The shaft 78 engages with the engaging hole 20c. The shaft 78 rotates when current supplies to a coil of the main body 77, and the impeller 20 is rotated thereby.

As shown in FIG. 3, a third group of concavities 20f that is formed continuously in the circumferential direction is disposed in a ring shape along an outer peripheral portion of the discharge side face of the impeller 20 in a position corresponding to the second group of concavities 20b formed in the intake side face of the impeller 20 (not all concavities of the third group have been numbered in FIG. 3). Base portions of each of the second group of concavities 20b and the third group of concavities 20f communicate via a communicating hole (not shown).

The casing 18 comprises the pump cover 14 and a pump body 16. As shown in FIG. 1, a recess 14a is formed in the surface on the impeller side of the pump cover 14 (i.e., the lower surface). The diameter of the recess 14a is approximately the same as the diameter of the impeller 20. The recess 14a has approximately the same depth as the thickness of the impeller 20. The impeller 20 is rotatably inserted into the recess 14a.

An extremely small clearance is formed between the outer peripheral face 20e of the impeller 20 and a side face 14b of the recess 14a of the pump cover 14. This clearance is provided to allow the impeller 20 to rotate smoothly.

The casing 18 with the impeller 20 installed in the recess 14a of the pump cover 14 is fixed to the housing 72 by caulking the lower end 72b of the housing 72. The lower end 78b of the shaft 78 is press fit into the fitting hole 20c of the impeller 20, with that portion thereof being further downward from the portion supported by the bearing 82. A thrust bearing 33 that receives the thrust load of the rotor 76 is interposed between the lower end of the shaft 78 and the pump body 16.

FIG. 4 is a plan view of the pump body 16 viewed from the impeller 20 side (i.e. viewed from the upper side of FIG. 1). A first groove 30 is formed in an upper face 16a of the pump body 16 at the impeller 20 side (i.e. an upper face in FIG. 1). The first groove 30 extends in a circumferential direction in an area facing the first group of concavities 20a of the impeller 20. An intake hole 40 is formed at an upper flow end 30a of the first groove 30. A second groove 31 is formed in the upper face 16a of the pump body 16. The second groove 31 extends in a circumferential direction in an area facing the second group of concavities 20b. A lower flow end 30b of the first groove 30 and an upper flow end 31a of the second groove 31 communicate via a communicating groove 32. The cross-sectional area of the communicating groove 32 gradually contracts as it proceeds from the lower flow end 30b of the first groove 30 to the upper flow end 31a of the second groove 31. Furthermore, a vapor jet 32a that passes through the pump body 16 in the up-down direction (i.e., the up-down direction of FIG. 1) is formed with the communicating groove 32. The function of the vapor jet 32a is to remove vapor from fuel.

FIG. 5 is a plan view of the pump cover 14 viewed from the impeller 20 side (i.e. viewed from the lower side of FIG. 1). A third groove 33 is formed in a bottom face of the recess 14a of the pump cover 14 (may be referred to below as a lower face of the pump cover). The third groove 33 extends in a circumferential direction in an area facing the third group of concavities 20f of the impeller 20. An escape groove 33d is formed in the bottom face of the recess 14a of the pump cover. The escape groove 33d extends from a position 33c (hereafter referred to as the lower flow end 33c) that corresponds to the upper flow end 31a of the second groove 31 to a position 33a (hereafter referred to as the beginning end 33a) that corresponds to the lower flow end 30b of the first groove 30. The cross-sectional area of the escape groove 33d gradually expands as it proceeds from the beginning end 33a to the lower flow end 33c. A discharge hole 41 is formed at the lower flow end 33b of the third groove 33. The discharge hole 41 extends from the third groove 33 to an upper face of the pump cover 14 (i.e., the upper face in FIG. 1), and joins the third groove 33 with the exterior of the casing 18.

In the fuel pump 10, when a current flows to the rotor 76 and the impeller 20 rotates, fuel within the fuel tank (not shown) is drawn in through the intake hole 40 into the casing 18. The fuel that has been drawn into the casing 18 initially flows into the upper flow end 30a of the first groove 30. The first group of concavities 20a is formed only in the intake side of the impeller 20 (at the lower face in FIG. 1). As a result, fuel is not abruptly drawn into the casing 18, and it is possible to draw the fuel into the casing 18 without causing an abrupt change in the pressure of the fuel. The formation of vapor in the fuel can thus be reduced.

The pressure of the fuel that has flowed into the upper flow end 30a of the first groove 30 increases in conjunction with the rotation of the impeller 20 while this fuel flows from the upper flow end 30a to the lower flow end 30b of the first groove 30. The fuel that has flowed into the lower flow end 30b of the first groove 30 flows through the communicating groove 32 into the upper flow end 31a of the second groove 31. The cross-sectional area of the communicating groove 32 gradually contracts as it proceeds from the lower flow end 30b of the first groove 30 to the upper flow end 31a of the second groove 31. As a result, the fuel that has increased in pressure in the first groove 30 is prevented from flowing abruptly into the second groove 31. Pulsation of the fuel due to an abrupt change in pressure can consequently be decreased, and noise can consequently be reduced. Furthermore, the vapor that forms in the fuel, as the pressure is increased in the first groove 30, is discharged to the exterior of the fuel pump 10 via the vapor jet 32a while the fuel passes through the communicating groove 32. Fuel from which the vapor has been removed consequently flows into the second groove 31, and a vapor lock is thus prevented.

The fuel that has flowed into the second groove 31 increases in pressure as the impeller 20 rotates and as the fuel flows from the upper flow end 31a to the lower flow end 31b of the second groove 31. Simultaneously, the fuel that has flowed into the second groove 31 also flows from the second group of concavities 20b to the third group of concavities 20f and the third groove 33. The fuel that has flowed into the third groove 33 increases in pressure as the impeller 20 rotates and as the fuel flows toward the lower flow end 33b of the third groove 33. The fuel that has increased in pressure in the third groove 33 is discharged into the interior of the motor portion 70 from the discharge hole 41. The fuel that has been discharged into the motor portion 70 flows through the motor portion 70 and is discharged to the exterior of the fuel pump 10 from the discharge port 73a formed in the motor cover 73.

In the fuel pump 10, the fuel within the pump portion 12 increases in pressure due to the rotation of the impeller 20. As a result, the impeller 20 is pushed upward toward the discharge side (i.e., the upper side in FIG. 1) by the fuel in the first groove 30, the communicating groove 32, and the second groove 31 of the pump body 16. Furthermore, the impeller 20 is pushed downward toward the intake side (i.e., the lower side in FIG. 1) by the fuel within the third groove 33 and the escape groove 33d of the pump cover 14. The fuel within the pump portion 12 increases in pressure as it flows along the first groove 30, the communicating groove 32, the second groove 31, and the third groove 33. As a result, the fuel flowing along the third groove 33 has the highest pressure. In a conventional fuel pump, i.e. in a fuel pump that has only one groove in both the pump cover 14 and the pump body 16, there was an increase in the pressure pushing the impeller down toward the intake side. There was thus an increase in sliding resistance between the impeller and the pump body, and there was a decrease in pump efficiency. In the fuel pump 10 of the present embodiment, the impeller 20 is pushed upward toward the discharge side by the fuel in the first groove 30, the communicating groove 32, and the second groove 31, and consequently the balance between the pressures exerted upon the impeller 20 in the up-down direction is corrected. Sliding resistance between the impeller 20 and the pump body 16 can consequently be reduced compared to the conventional example.

Furthermore, the escape groove 33d is formed so as to correspond to the communicating groove 32 of the pump body 16. Fuel is also led into the escape groove 33d. As a result, there is a balance between the pressure of the fuel in the communicating groove 32 and the pressure of the fuel in the escape groove 33d, and consequently it is possible to correctly balance, across a plane face, the pressures exerted upon the impeller 20. Inclining of the impeller 20 is thus decreased, and the sliding resistance between the impeller 20 and the pump body 16 can consequently be reduced.

In the fuel pump described above, two groups of concavities are formed in the intake side face of the impeller, forming an upper flow side pump that draws in the fuel, and a lower flow side pump that pressurizes the fuel that has been drawn in by the upper flow side pump. In the present teachings, the impeller that forms the upper flow side pump and the impeller that forms the lower flow side pump can be formed separately. This type of fuel pump 140 will be described with reference to FIGS. 6 to 8.

The fuel pump 140 also comprises a motor portion 170 and a pump portion 100. The motor portion 170 of the fuel pump 140 can be configured identically to the motor portion 70 of the fuel pump 10 of the first embodiment. As a result, a description of the motor portion 170 of the fuel pump 140 is omitted.

A pump portion 100 comprises a casing 110, impellers 120 and 130. The impellers 120 and 130 are substantially disc shaped. The impeller 120 is smaller in diameter than the impeller 130, and is disposed at the upper flow side (a lower side in FIG. 6) of the impeller 130. Furthermore, the impeller 120 and the impeller 130 are disposed coaxially.

A group of concavities 120a that is formed continuously in the circumferential direction is disposed in a ring shape along an outer peripheral portion of an intake side face (i.e., a lower face in FIG. 6) of the impeller 120. A group of concavities is not formed in a discharge side face (i.e., an upper face in FIG. 6) of the impeller 120. An engaging hole 120b, that is substantially D-shaped in cross-section across a plane perpendicular to the rotational axis, passes through a central portion of the impeller 120 in the direction of the thickness thereof. The shaft 78 engages with the engaging hole 120b.

A group of concavities 130a that is formed continuously in the circumferential direction is disposed in a ring shape along an outer peripheral portion of the intake side face (i.e., a lower face in FIG. 6) of the impeller 130. A group of concavities 130b that is formed continuously in the circumferential direction is disposed in a ring shape along an outer peripheral portion of the discharge side face (i.e., an upper face in FIG. 6) of the impeller 130 in a position corresponding to the group of concavities 130a. Each concavity of the group of concavities 130a and each concavity of the group of concavities 130b communicates via a communicating hole (not shown). An engaging hole 130c, that is substantially D-shaped in cross-section across a plane perpendicular to the rotational axis, passes through a central portion of the impeller 130 in the direction of the thickness thereof. The shaft 78 engages with the engaging hole 130c.

The casing 110 comprises a pump cover 111 and a pump body 112. A recess 111a is formed in the pump cover 111. The recess 111a has approximately the same diameter and approximately the same depth as the thickness of the impeller 130. The impeller 130 is rotatably inserted into the recess 111a. An extremely small clearance is formed between the outer peripheral face 130d of the impeller 130 and the side face 111b of the recess 111a. This clearance is provided to allow the impeller 130 to rotate smoothly.

A recess 112a is formed in the pump body 112. The recess 112a has approximately the same diameter and approximately the same depth as the thickness of the impeller 120. The impeller 120 is rotatably inserted into the recess 112a. A recess 112d that has a smaller diameter than the recess 112a is formed in the central portion of the recess 112a. A thrust bearing 133 that receives the thrust load of the shaft 78 is disposed in a lower face of the recess 112d. An extremely small clearance is also formed between the outer peripheral face 120d of the impeller 120 and the side face 112b of the recess 112a. This clearance is provided to allow the impeller 120 to rotate smoothly.

The casing 110 (i.e., the pump cover 111 and the pump body 112), with the impeller 130 installed in the recess 111a of the pump cover 111 and the impeller 120 installed in the recess 112a of the pump body 112, is fixed to a housing 160.

FIG. 7 is a plan view seen from the discharge side of the pump body 112 viewed from the impeller 120 side (i.e. from the upper side in FIG. 7), and FIG. 8 is a cross-sectional view along the line VIII-VIII of FIG. 7. A groove 115 extending in a circumferential direction is formed in the bottom face of the recess 112a of the pump body 112 in an area facing the group of concavities 120a. A vapor jet 115c that passes through the pump body 112 in the up-down direction is formed within the groove 115. The function of the vapor jet 115c is to remove vapor. A groove 116 is formed in the face 112c of the pump body 112 that faces the impeller 120. The groove 116 extends in a circumferential direction in an area facing the group of concavities 130a. An intake hole 150 is formed at an upper flow end 115a of the groove 115. A lower flow end 115b of the groove 115 and an upper flow end 116a of the groove 116 communicate via a communicating passage 117 formed in the pump body 112.

A groove 118 is formed in a bottom face of the recess 111a of the pump cover 111. The groove 118 extends in a circumferential direction in an area facing the group of concavities 130b. An upper flow end of the groove 118 is located at a position corresponding to the upper flow end 116a of the groove 116. A discharge hole 151 is connected to a lower flow end of the groove 118. The discharge hole 151 joins the groove 118 with the exterior of the casing 110 (i.e., the interior of the motor portion).

In the fuel pump 140, when the shaft 178 of the motor portion 170 is driven causing it to rotate, the impellers 120 and 130 rotate. When the impeller 120 rotates, fuel within the fuel tank (not shown) is drawn in through the intake hole 150 into the upper flow end 115a of the groove 115. The fuel that has been drawn into the groove 115 flows from the upper flow end 115a toward the lower flow end 115b of the groove 115. The fuel that has increased in pressure in the groove 115 flows through the communicating passage 117 into the upper flow end 116a of the groove 116. The fuel that has flowed into the upper flow end 116a of the groove 116 is led to the groups of concavities 130a and 130b of the impeller 130 and to the groove 118. The fuel that has been led to the groups of concavities 130a and 130b of the impeller 130 and into the groove 116 and 118 increases in pressure in conjunction with the rotation of the impeller 130, and is discharged to the motor portion from the discharge hole 151.

In the fuel pump 50, as well, the upper flow side impeller 120 at the intake side is narrower in diameter than the lower flow side impeller 130. Furthermore, the impeller 120 only has a group of concavities 120a formed in the intake side face thereof. As a result, a case where a large amount of fuel is abruptly drawn into the casing 110 is prevented, and an abrupt change in the pressure of the fuel is prevented. The formation of vapor within the fuel can consequently be reduced.

Finally, although the preferred representative embodiments have been described in detail, the present embodiments are for illustrative purpose only and are not restrictive. It is to be understood that various changes and modifications may be made without departing from the spirit or scope of the appended claims. In addition, the additional features and aspects disclosed herein may also be utilized singularly or in combination with the above aspects and features.

Claims

1. A fuel pump comprising a casing and a substantially disc-shaped impeller rotating within the casing, wherein a first group of concavities and a second group of concavities are formed in a concentric pattern in an intake side face of the impeller, and the second group of concavities is located outside of the first group of concavities in a radial direction,a third group of concavities is formed in a discharge side face of the impeller, and the third group of concavities communicates with the second group of concavities,a first groove, a second groove and a communicating groove are formed in an inner face of the casing facing the intake side face of the impeller, the first groove extending continuously in a direction of rotation of the impeller from an upper flow end to a lower flow end in an area facing the first group of concavities, the second groove extending continuously in the direction of rotation of the impeller from an upper flow end to a lower flow end in an area facing the second group of concavities, and the communicating groove communicating with the lower flow end of the first groove and with the upper flow end of the second groove, anda third groove is formed in an inner face of the casing facing the discharge side face of the impeller, the third groove extending continuously in the direction of rotation of the impeller from an upper flow end to a lower flow end in an area facing the third group of concavities.

2. A fuel pump as set forth in claim 1, wherein an escape groove is formed in an inner face of the casing facing the discharge side face of the impeller, a first end of the escape groove facing the lower flow end of the first groove, a second end of the escape groove being connected to the upper flow end of the third groove, and the escape groove extending in a manner corresponding to the communicating groove.

3. A fuel pump as set forth in claim 2, wherein a cross-sectional area of the escape groove gradually expands as it proceeds from the first end to the second end.

4. A fuel pump as set forth in claim 3, wherein a cross-sectional area of the communicating groove gradually contracts as it proceeds from the lower flow end of the first groove to the upper flow end of the second groove.

5. A fuel pump as set forth in claim 1, wherein a vapor jet is formed in the casing, the vapor jet extending from the first groove and/or the communicating groove to the exterior of the casing.

6. A fuel pump comprising: a casing,a first impeller rotatably disposed within the casing, anda second impeller rotatably disposed within the casing, whereina first group of concavities is formed in only an intake side face of the first impeller, the first group of concavities is formed in an area located a first distance away from a rotational axis of the first impeller in a radial direction,a second group of concavities is formed in an intake side face of the second impeller, a third group of concavities is formed in a discharge side face of the second impeller, the second group of concavities communicates with the third group of concavities, and the second and third group of concavities are formed in an area located a second distance away from a rotational axis of the second impeller in a radial direction, the second distance being longer than the first distance,a first groove is formed in an inner face of the casing facing the intake side face of the impeller, the first groove extending continuously from an upper flow end to a lower flow end in an area facing the first group of concavities,a second groove is formed in an inner face of the casing facing the intake side face of the impeller, the second groove extending continuously from an upper flow end to a lower flow end in an area facing the second group of concavities,a third groove is formed in an inner face of the casing facing the discharge side face of the impeller, the third groove extending continuously from an upper flow end to a lower flow end in an area facing the third group of concavities, anda communicating passage is formed in the casing, the communicating passage communicating with the lower flow end of the first groove and with the upper flow end of the second groove.