1. Field of the Invention
The present invention relates to a fuel tank. In particular, it relates to a structure for installing in-tank component parts, for instance, such as valves to be installed to the inside of fuel tanks, to the fuel tanks.
2. Description of the Related Art
For example, as disclosed in Japanese Unexamined Patent Publication (KOKAI) NO.2001-41,124, an in-tank component part, such as a valve, is installed to the inner surface of a fuel tank by way of a connecting member, such as a bracket. However, the number of the fuel tank's component parts has increased by the number of the connecting members disposed.
Hence, National Publication of the Translated Version of PCT Application No. 2003-517,142 discloses a valve which is installed directly to a fuel tank by press-in fitting.
There is a fear, however, that radially-enlarging strain resides in the rib 105 after installing the valve 103 to the fuel tank 100 as disclosed in National Publication of the Translated Version of PCT Application No. 2003-517,142. As a result, the pressing force exerted by the pressing claw 106 to the outer peripheral surface of the projection 102 might degrade.
In other words, when installing the valve 103 to the fuel tank 100, the rib 105 deforms to radially enlarge as the projection 102 is fitted into the pressing claw 106 by press-in fitting. In this instance, a pressing force is applied to the projection 102 to radially contract the projection 102. The pressing force acts all around the projection 102 entirely. Accordingly, a first pressing force (e.g., a force F1 of
Moreover, when the fuel tank 100 disclosed in National Publication of the Translated Version of PCT Application No. 2003-517,142 is subjected to a radial swinging force (e.g., a force F3 of
The present invention has been developed and completed in view of such circumstances. It is therefore an object of the present invention to provide a fuel tank which can inhibit a fastening force acting between itself and in-tank components from degrading.
A fuel tank according to the present invention can solve the aforementioned problems, and comprises:
Specifically, in accordance with the present invention, the in-tank component part is installed to the present fuel tank by engaging the engaged portion disposed on the present fuel tank side with the engaging portion disposed on the in-tank component part side. In this instance, the in-tank component part comprises the accommodation, and the engaging portion is placed in the accommodation. Thus, the engaging portion engages with the engaged portion in the accommodation.
In accordance with the present invention, the engagement formed by the engaging portion and engaged portion is accommodated in the accommodation. That is, the accommodation reinforces the engagement. Accordingly, even when the present fuel tank is subjected to swinging forces to swing the in-tank component part, not only the engagement but also the accommodation can receive the swinging forces in a dispersed manner. Consequently, strain is less likely to reside in the engaging portion and engaged portion. Therefore, the present fuel tank can inhibit a fastening force acting between itself and the in-tank component part from degrading.
Moreover, when the in-tank component part or the accommodation is less likely to swell than the present fuel tank or the engaged portion is, the engaged portion swells in the accommodation after the in-tank component part is installed to the present fuel tank, specifically after the present fuel tank is filled up with a fuel. As a result, the engaged portion presses against the engaging portion placed in the accommodation. Thus, the present fuel tank can inhibit the fastening force from degrading in the installation of the in-tank component part, and can even raise the fastening force after the installation.
It is preferable to arrange the present fuel tank so that both of the engaged portion and the engaging portion can deform elastically to engage the engaging portion with the engaged portion; and the in-tank component part can be installed to the fuel tank with the engaged portion accommodated in the accommodation.
With such an arrangement, both of the engaged portion and the engaging portion deform in the installation of the in-tank component part to the present fuel tank. Accordingly, strain is much less likely to reside in the engaged portion and engaging portion after the installation. Consequently, it is possible to further inhibit the fastening force acting between the present fuel tank and the in-tank component part from degrading.
It is preferable to arrange the present fuel tank so that the engaged portion can comprise an engaged rib through which an engaged hole is bored; and the engaging portion can comprise an engaging claw engaging with the engaged hole. Note that the engaged rib has a simpler superficial construction than the engaging claw does. Accordingly, such an arrangement can make it more likely to integrally form the engaged rib with the present fuel tank by molding, for example.
It is preferable to arrange the present fuel tank so that the accommodation of the in-tank component part can comprise a thinned portion for making it easier to accommodate the engaged portion therein. Such an arrangement can expand the accommodation space in the accommodation by the space produced by the thinned portion. Accordingly, the engaged portion is more likely to come into the accommodation.
It is preferable to arrange the present fuel tank so as to further comprise an insertion tab fitted into the accommodation of the in-tank component part, wherein:
The term, “surplus allowance,” herein means a space for the insertion tab, that is, the “surplus allowance” is the difference between the accommodation allowance and a space for the engaged portion. Specifically, the “surplus allowance” is an excessive allowance being present in the accommodation allowance after the engaged portion is accommodated in the accommodation.
Specifically, with such an arrangement, the in-tank component part is installed to the present fuel tank stepwise. That is, the in-tank component part is installed temporarily to the present fuel tank, and is then fully installed to it.
In the first step, the insertion tab is fitted into the accommodation while securing an accommodation allowance for the engaging portion. That is, the insertion tab is fitted temporarily into the accommodation of the in-tank component part. In the second step, the engaging portion is engaged with the engaged portion using the accommodation allowance secured in the first step. Moreover, the engaged portion is accommodated in the accommodation. Note that, in the second step, it is possible to engage the engaging portion with the engaged portion with ease relatively, because the accommodation allowance has been secured in advance. The in-tank component part is installed temporarily to the present fuel tank by the engagement between the engaging portion and the engaged portion. In the third step, the insertion tab is further fitted into the accommodation until the surplus allowance disappears, surplus allowance which results from the accommodation allowance. In other words, the insertion tab is fitted fully into the accommodation. When the insertion tab is fully fitted into the accommodation, the surplus allowance disappears from the accommodation. To put it differently, the play for the engaged portion disappears from the accommodation. Accordingly, rattling diminishes between the engaging portion and the engaged portion. Moreover, the fastening force rises between the engaging portion and the engaged portion. Consequently, the in-tank component part is installed fully to the present fuel tank.
Thus, the arrangement makes it possible to temporarily install the in-tank component part to the present fuel tank and then to fully install it thereto. After the temporary installation (or the second step), the in-tank component part is installed temporarily to the present fuel tank by its own fastening force. Accordingly, even when the in-tank component part is suspended inside the present fuel tank, it is not necessary for an operator to support the in-tank component part after the temporary installation. Consequently, the arrangement can be applied appropriately to in-tank component parts with a relatively large volume or in-tank component parts to be suspended in fuel tanks, because it improve the operability.
In accordance with another aspect of the present invention, the aforementioned problems can be solved as well. A fuel tank comprises:
In the another aspect of the present invention, both of the engaged portion and the engaging portion deform in the installation of the in-tank component part to the present fuel tank. Accordingly, strain is much less likely to reside in the engaged portion and engaging portion after the installation. Consequently, such an arrangement according to the another aspect of the present invention makes it possible to further inhibit the fastening force between the present fuel tank and the in-tank component part from degrading in the installation.
Moreover, when the in-tank component part is less likely to swell than the present fuel tank is, the in-tank component part or the engaging portion is less likely to be swollen by fuels. On the other hand, the present fuel tank or the engaged portion is likely to be swollen by fuels. In view of these, in the present fuel tank according to the another aspect of the present invention, the engaged portion is disposed on an inner peripheral side, and the engaging portion is disposed on an outer peripheral side, respectively. Accordingly, in the present fuel tank after the installation of the in-tank component part, specifically after being filled up with a fuel, the engaging portion regulates the engaged portion, which expands radially outward from the inner peripheral side to the outer peripheral side, inward from the outer peripheral side to the inner peripheral side. As a result, the engaged portion presses against the engaging portion radially. Thus, the present fuel tank can inhibit the fastening force from degrading in the-installation of the in-tank component part, and can even raise the fastening force after the installation.
It is preferable to arrange the present fuel tank according to the another aspect of the present invention so that the engaged portion can comprise an engaged rib through which an engaged hole is bored; and the engaging portion can comprise an engaging claw engaging with the engaged hole. Note that the engaged rib has a simpler superficial construction than the engaging claw does. Accordingly, such an arrangement can make it more likely to integrally form the engaged rib with the present fuel tank by molding, for example.
All in all, the present fuel tank can inhibit the fastening force acting between the engaging portion and the engaged portion from degrading.
A more complete appreciation of the present invention and many of its advantages will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings and detailed specification, all of which forms a part of the disclosure.
Having generally described the present invention, a further understanding can be obtained by reference to the specific preferred embodiments which are provided herein for the purpose of illustration only and not intended to limit the scope of the appended claims.
A fuel tank according to Example No. 1 of the present invention comprises a fuel shut-off valve which is installed to the top wall.
First, the arrangement of a fuel tank according to Example No. 1 of the present invention will be hereinafter described in detail.
A fuel tank 9 is made of high-density polyethylene (hereinafter abbreviated to as “HDPE”), and comprises a top wall 90 from which engaged ribs 91a, 91b, 91c protrude. A fuel shut-off valve 1 is installed to the engaged ribs 91a, 91b, 91c. Note that the present in-tank component part includes the fuel shut-off valve 1. The fuel shut-off valve 1 comprises an upper case 2, a lower case 3, a bottom 4, and a float 5.
The upper case 2 is made of polyoxymethylene (hereinafter abbreviated to as “POM”), and is formed as a bottomed cylinder shape which opens downward. Accommodations 20a, 20b, 20c extend from the bottom end of the upper case 2 in a radially enlarging direction. The accommodation 20a is formed as a substantially “U”-shaped cross section which opens upward. An engaging claw 201a whose cross section is formed as a triangle shape protrudes from a top-end inner surface of an outer peripheral wall 200a of the accommodation 20a. Moreover, as shown in
As shown in
The lower case 3 is made of POM, and is formed as a bottomed cylinder shape which opens downward. As illustrated in
The bottom 4 is made of POM, and is formed as a bottomed cylinder shape which opens upward. As illustrated in
The float 5 is made of POM, and is formed as a cylinder shape in which a convexed valve element 50 protrudes from the top surface as illustrated in
Next, the operations of the fuel tank 9 according to Example No. 1 with the fuel shut-off valve 1 installed will be hereinafter described. In supplying a fuel, the fuel vapor is introduced into the canister from the inside of the fuel tank 9 by way of the tank communication holes 41, the float chamber 31, the inter-case communication hole 30, the inside of the upper case 2, the inside of the port 33 and the hose as can be seen from
Subsequently, how to install the fuel shut-off valve 1 to the fuel tank 9 according to Example No. 1 will be hereinafter described. First, the upper case 2 and the lower case 3 are welded together. Then, the lower-case engaging claws 40 are engaged with the lower periphery of the engaged recesses 34 to assemble the bottom 4 with the lower case 3. Thus, the fuel shut-off valve 1 is completed.
Thereafter, the positioning is carried out between the engaging claws 201a, 201b, 201c and the engaged ribs 91a, 91b, 91c. Then, the fuel shut-off valve 1 is brought closely to the top wall 90 of the fuel tank 9.
Finally, the advantages effected by the fuel tank 9 according to Example No. 1 will be hereinafter described. In the. fuel tank 9, the engagements formed by the engaging claws 201a, 201b, 201c and the engaged ribs 91a, 91b, 91c are accommodated in the accommodations 20a, 20b, 20c, respectively. That is, the accommodations 20a, 20b, 20c reinforce the engagements. Accordingly, even when the fuel tank 9 is subjected to swinging forces to swing the fuel shut-off valve 1, not only the engagements but also the accommodations 20a, 20b, 20c can receive the swinging forces in a dispersed manner. Consequently, strain is less likely to reside in the engaging claws 201a, 201b, 201c and engaged ribs 91a, 91b, 91c. Therefore, the fuel tank 9 can inhibit a fastening force acting between itself and the fuel shut-off valve 1 from degrading.
In the fuel tank 9 according to Example No. 1, both of the engaged ribs 91a, 91b, 91c and the engaging claws 201a, 201b, 201c deform simultaneously in the installation of the fuel shut-off valve 1 to the fuel tank 9. Accordingly, strain is much less likely to reside in the engaged ribs 91a, 91b, 91c and engaging claws 201a, 201b, 201c after the installation. Consequently, due to the arrangement as well, it is possible to further inhibit the fastening force acting between the fuel tank 9 and the fuel shut-off valve 1 from degrading.
In the fuel tank 9 according to Example No. 1, the engaged ribs 91a, 91b, 91c, the present engaged portion, protrude from the inner surface of the top wall 90 of the fuel tank 9. The engaged ribs 91a, 91b, 91c are formed as a rectangular plate shape, a simpler superficial construction. Accordingly, it is possible to mold the engaged ribs 91a, 91b, 91c integrally with the fuel tank 9.
In the fuel tank 9 according to Example No. 1, as shown in
In the fuel tank 9 according to Example No. 1, the thinned portions 203a, 203b, 203c are disposed in the accommodations 20a, 20b, 20c, respectively. Accordingly, the engagement claw 201a and outer peripheral wall 200a, the engagement claw 201b and outer peripheral wall 200b, and the engagement claw 201c and outer peripheral wall 200c curve elastically toward the outer peripheral side with ease comparatively when the fuel shut-off valve 1 is installed to the fuel tank 9. Moreover, the accommodation chambers 204a, 204b, 204c open greatly by the thinned portions 203a, 203b, 203c. Consequently, the engaged ribs 91a, 91b, 91c are likely to come into the accommodation chamber 204a, 204b, 204c, respectively. In addition, it is less likely to damage the engaged ribs 91a, 91b, 91c, which are made of HDPE and are soft relatively.
In the fuel tank 9 according to Example No. 1, the upper case 2 (more specifically the engaging claws 201a, 201b, 201c) is formed of POM. On the other hand, the fuel tank 9 (more specifically the engaged ribs 91a, 91b, 91c) is formed of HDPE. Accordingly, the upper case 2 is less likely to be swollen by fuels than the fuel tank 9 is. In view of these, in the fuel tank 9, the engaged ribs 91a, 91b, 91c are disposed on an inner peripheral side, and the engaging claws 201a, 201b, 201c are disposed on an outer peripheral side, respectively. Consequently, in the fuel tank 9 after the installation of the fuel shut-off valve 1, specifically after being filled up with a fuel, the engaging claws 201a, 201b, 201c regulate the engaged ribs 91a, 91b, 91c, which expand radially outward from the inner peripheral side to the outer peripheral side, inward from the outer peripheral side to the inner peripheral side, respectively. As a result, the engaged ribs 91a, 91b, 91c press against to the engaging claws 201a, 201b, 201c, radially. Thus, the fuel tank 9 can even raise the fastening force acting between itself and the fuel shut-off valve 1 after the installation, specifically after being filled up with a fuel.
In the fuel tank 9 according to Example No. 1, the engaged ribs 91a, 91b, 91c expand so as to bury the inside of the accommodation chambers 204a, 204b, 204c, respectively, after the fuel shut-off valve 1 is installed to the fuel tank 9, specifically after the fuel tank 9 is filled up with a fuel. Due to the operation, the fuel tank 9 can further raise the fastening force acting between itself and the fuel shut-off valve 1 after the installation.
In the fuel tank 9 according to Example No. 1, after the engaging claws 201a, 201b, 20c and engaged ribs 91a, 91b, 91c slide by a predetermined distance in the installation of the fuel shut-off valve 1 to the fuel tank 9, their restoring forces let the engaging claws 201a, 201b, 201c engage with the engaged holes 910a, 910b, 910c, respectively. The clicking feel in the instant of the engagement enables an operator to confirm that the installation is completed. As a result, the installation accuracy is enhanced.
In the fuel tank 9 according to Example No. 1, the paired rotation-stopper ribs 205a and 205a, 205b and 205b, 205c and 205c are disposed in the accommodations 20a, 20b, 20c, respectively. Hence, it is possible to inhibit the fuel shut-off valve 1 from rattling in the circumferential direction after it is installed to the fuel tank 9.
A fuel tank according to Example No. 2 of the present invention comprises a valve module which is installed to the top wall.
First, the arrangement of a fuel tank according to Example No. 2 of the present invention will be hereinafter described in detail. A valve module 7 is equipped with a plurality of valves (not shown). The term, “valve module,” herein means a separable component part, to be installed to an inner surface of a top wall of fuel tanks, in which independent valves, for example, those illustrated in
An insertion tab 6 is made of POM, and is formed as a “U” shape in cross section. The insertion tab 6 engages with the accommodation 20 in such a state that an inner wall 63 and a rotation-stopper rib 205, which will be described later, are fitted into the accommodation chamber 204 from down below. As shown in
Engaged ribs 91 protrude from the inner surface of the top wall (not shown) of the fuel tank which is made of HDPE. The engaged ribs 91 are formed as a rectangular plate shape. An engaged hole 910 is bored through the engaged ribs 91. The engaged ribs 91 are scattered at positions, which face the accommodations 20 in the up/down direction, in a quantity of eleven in total. The engaged rib 91 is accommodated in the accommodation chamber 204 of the accommodations 20. Specifically, the engaged rib 91 is accommodated between the inner wall 63 of the insertion tabs 6 and the outer peripheral wall 200 of the accommodations 20. The engaged hole 910 of the engaged ribs 91 engages with the engaging claw 201 of the accommodations 20 facing the engaged ribs 91. The engagement installs the valve module 7 to the top wall of the fuel tank.
Subsequently, how to install the valve module 7 to the fuel tank according to Example No. 2 will be hereinafter described. In a first step, the insertion tab 6 is fitted temporarily into the accommodation 20 from down below as shown with the blank arrow of
In a second step, the accommodation 20 engaged temporarily with the insertion tab 6 is brought closer to the engaged rib 91 from down below. Then, the engaged rib 91 is accommodated in the accommodation chamber 204. In this instance, the engaging claw 201 contacts with the engaged rib 91. As shown in
In a third step, the insertion tab 6 is pushed up further upward. That is, the insertion tab 6 is fitted fully into the accommodation chamber 204. The fully-fitted insertion tab 6 buries a surplus allowance 208 between the tapered surface 64 and the engaged rib 91b in the accommodation chamber 204 as illustrated in
Finally, the advantages effected by the fuel tank according to Example No. 2 will be hereinafter described. The fuel tank produces the advantages in the same manner as the fuel tank 9 according to Example No. 1. In the second step, the engaged ribs 91 are guided into the accommodation chambers 204 utilizing the accommodation allowances 207 which have been secured in the first step. Accordingly, the engagement claws 201 can be engaged with the engaged holes 910 with ease comparatively. In the third step, the fully-fitted insertion tabs 9 make the surplus allowances 208 disappear from the accommodation chambers 204. That is, the play for the engaged ribs 91 disappear from the accommodation chambers 204. Consequently, rattling diminishes between the engaging claws 201 and the engaged holes 910. In other words, the valve module 7 is less likely to rattle in the fuel tank. Moreover, the fastening force rises between the engaging claws 201 and the engaged holes 910.
Note that the outer wall 60 of the insertion tabs 6 reinforces the outer peripheral wall 200 and engaging claw 201 of the accommodations 20. Accordingly, it is possible to further inhibit the fastening force between the accommodations 20 and the engaged ribs 91 from degrading. Moreover, the tapered surface 64 is formed on the top end of the inner wall 63 of the insertion tabs 6. Consequently, it is more likely to guide the engaged ribs 91 into the accommodation chambers 204.
Note that, after the temporary installation (or the second step), the valve module is installed temporarily to the fuel tank by its own fastening force. Accordingly, it is not necessary for an operator to support the valve module 7 after the temporary installation. Consequently, the fuel tank according to Example No. 2 improves the operability in the installation of the valve module 7.
Heretofore, a few of the embodiment modes of the present fuel tank are described. However, the embodiment modes are not limited to the above-described embodiment modes particularly. It is possible to perform the present fuel tank in various modified embodiment modes or improved embodiment modes which one of ordinary skill in the art can carry out.
For example, the engaging claws 201a, 201b, 201c or 201 and the engaged holes 910a, 910b, 910c or 910 can be disposed inversely to the disposition described in Example Nos. 1 and 2. Namely, the engaging claws can be disposed in fuel tanks, and the engaged holes can be disposed in in-tank component parts. Moreover, in Example Nos. 1 and 2, the fuel tank 9 is made of HDPE, and the fuel shut-off valve 1 and the valve module 7 (i.e., the in-tank component part) are made of POM. However, the materials for making the component parts are not limited in particular. In addition, the shapes of the engaging portion and engaged portion are not necessarily limited to the above-described shapes.
Having now fully described the present invention, it will be apparent to one of ordinary skill in the art that many changes and modifications can be made thereto without departing from the spirit or scope of the present invention as set forth herein including the appended claims.
Number | Date | Country | Kind |
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2003-315628 | Sep 2003 | JP | national |