This invention relates generally to an integrated fuel delivery system for a combustion engine, and more particularly to a versatile fuel pump module of the system having a universal structural pod for supporting a fuel pump, motor, and reversible filter cartridge.
Automotive fuel pump modules commonly having a fuel pump, pump motor, filters, and a pressure regulator are known to be located inside a fuel tank. The modules are typically inserted through an access hole of the tank and supported therein by a flange which also sealably covers the access hole. Depending upon the fuel delivery system application, known modules differ widely from one another. For instance, a majority of modules are known to be inserted through the top of the tank thus being attached to a top flange, and a limited few are inserted through the tank bottom thus being attached to a bottom flange and typically known in motorcycle fuel tank applications such as that disclosed in U.S. patent application Ser. No. 10/634,258, filed Aug. 5, 2003, assigned to Walbro Engine Management, LLC, and incorporated herein by reference.
Unfortunately, in such differing applications, the module and especially the supporting structure of the module differ. For instance, the supporting structure design differs widely depending on whether the flange is mounted to the top or bottom of the tank. Yet further, differences in the support structure can lead to design differences in the outlet filter and the pressure regulator which are known to be separate from one-another and thus individually supported by the module structure. The multitude of differing module components required for differing system applications is costly in design, manufacturing and generally complicates maintenance and repair tasks. Furthermore, the separate placement of each module component requires excessive tubes and fittings to flow the fuel, and increases the overall size of the module which is undesirable in small fuel tanks or where size of the access hole must be minimized for structural integrity of the tank and to minimize fuel vapor permeation through the tank.
A fuel delivery system for a combustion engine has a fuel tank which has a covered access hole preferably communicating through either the top wall or the bottom wall of the tank. A versatile fuel pump module has a universal structural pod in the fuel tank which preferably extends substantially vertically between the top and bottom walls in a consistent upright position and is used in differing fuel tank applications regardless of whether the access hole communicates through the top wall or bottom wall. The pod houses a fuel pump in a first bore and a reversible filter cartridge, preferably having a fuel filter element and an integrated pressure regulator, in a second bore. Fuel enters the fuel pump through a bottom port of the pod and pressurized fuel exits the pump and flows through a fuel passage of the pod into the second bore where it flows through the reversible cartridge filter and a pressure regulator before the fuel is expelled from the module as supply and bypass fuel through respective ports generally of the second bore. Both the fuel pump and the reversible cartridge are utilized in conjunction with the universal pod regardless of the access hole location in the fuel tank.
For applications or aspects where the access hole is located in the top wall of the fuel tank, the fuel pump module utilizes a top flange for covering the hole. The, top flange has a fuel supply channel for flowing pressurized fuel out of the tank from the upper port of the second bore preferably via a flexible tube coupled between the pod and the top flange. The cartridge is preferably retained in the second bore by a bottom cover which fastens to the pod and generally defines the lower port. Excess or bypass fuel controlled or produced by the pressure regulator flows through the lower port and back into the fuel tank chamber. For applications or aspects where the access hole is located in the bottom wall of the fuel tank, the fuel pump module utilizes a bottom flange, preferably identical to the top flange, for covering the bottom access hole and for flowing pressurized fuel through the supply channel and out of the tank.
In applications where the cartridge preferably has an integrated pressure regulator, the orientation of the cartridge is reversed or flipped over when compared to the top flange application, thus flowing supply fuel generally downward through the lower port and fuel channel, and flowing bypass fuel generally upward through the upper port and back into the fuel tank chamber. For the bottom flange application, the bottom cover is preferably not utilized and instead, the bottom flange fastens to the pod in preferably the same manner as the bottom cover does for the top flange application.
Objects, features and advantages of this invention is a fuel pump module which is more robust, flexible in application, cost effective, reduces the number of parts required for varying applications and is capable of utilizing low cost pressure regulators. Moreover, the module is capable of being disassembled for easy maintenance, is rugged, compact, durable, of relatively simple design, economical manufacture, and in service has a long useful life.
These and other objects, features and advantages of this invention will be apparent from the following detailed description of the preferred embodiments and best mode, appended claims and accompanying drawings in which:
Referring in more detail to the drawings,
As best illustrated in
The pod 40 carries an inner cylindrical first surface 54 defining a first bore 56 having a central axis 58 extending substantially vertically, and an inner cylindrical second surface 60 defining a second bore 62 spaced radially outward from the first bore 56 and having a central axis 64 disposed substantially parallel to the central axis 58 of the first bore 56. The pump and motor 44, 46 are assembled in the first bore 56 and the filter cartridge 48 is assembled in the second bore 62.
During manufacture, components of the fuel pump 44 are preferably assembled into the first bore 56 through an open top end 66 and are generally nested against a continuous bottom shoulder 68 projecting radially and unitarily inward from the first cylindrical surface 54. After the fuel pump 44 is assembled, the pump motor 46 which has a stator encircling an armature with a drive shaft 57 journaled for rotation by a pair of bearings is inserted into the first bore 56 from above and coupled mechanically to the pump 44. The open end 66 is then sealed-off by a cap 70 which preferably carries one of the bearings. At least one electrical lead 53 extends through the end cap 70. When operating, fuel enters the pump 44 through a bottom port 72 generally defined by the shoulder 68 of the pod 40 and pressurized fuel exits the pump 44 and flows into the second bore 62 via a fuel passage 74 defined by the pod 40 and communicating through the first and second surfaces 54, 60.
As best illustrated in
The primary end retainer 76 has an inverted bowl-like base portion 88 which carries a cylindrical inward face 90 that defines in-part a fuel cavity 92 held at system operating pressure by the pressure regulator 52, and a collar portion 94 which projects upward from the base portion 88 and defines a supply fuel outlet channel 96 that communicates axially with the cavity 92. The collar portion 94 projects into a counter bore 98 defined by a cylindrical third surface 100 carried by the pod 40. An outer cylindrical face 102 of the base portion 88 has a circumferentially continuous groove 104 which seats a resilient seal or O-ring 106 that seals to the second surface 60 of the second bore 62. An outer cylindrical face 108 of the collar portion 94 also has a circumferentially continuous groove 110 which seats an O-ring 112 that seals to the third surface 100 of the counter bore 98, and likewise, an outer cylindrical face 114 of a base segment 116 of the secondary end retainer 80 has a circumferentially continuous groove 118 which seats an O-ring 120 that seals to the second surface 60 of the second bore 62. All three O-rings 106, 112, 120 and the seating arrangement of the filter element 50 to the retainers 76, 80 assure that all of the fuel flowing from the fuel passage 74 is filtered before entering the pressurized fuel cavity 92.
After filtration, fuel which enters the cavity 92 flows to the engine through the fuel outlet channel 96 of the collar portion 94, through an upward projecting barbed nipple or filter 122 of the pod 40 and into a flexible tube 124 press fitted to the nipple 122 and extending upward to couple to a similar nipple 126 projecting downward from the top flange 34 (as best shown in
As best illustrated in
When fuel system pressure is exceeded, the spring 142 compresses as the valve head 138 moves downward and axially away from the seat 148. Bypass fuel 82 flows through the aperture 150 and downward through the valve chamber 136 and exits the second bore 62 through the hole 152 of the base 116 and through a slightly larger hole 154 of the cover 42.
During manufacture, at least one and preferably three upward projecting flex arms 156 of the cover 42 snap fit to the pod 40 to hold the cartridge 48 within the second bore 62 (as best shown in
Referring to
As previously described, the filter cartridge 48 is turned up-side-down so that the collar portion 94 and respective O-ring 112 are inserted into a counter bore 98′ of the bottom flange 34′ which communicates axially with, and is located generally concentrically to, the fuel outlet channel 128′ of the bottom flange 34′. The supply fuel 78′ exits out of the bottom of the second bore 62 and the bypass fuel 82′ exits through the top of the second bore and through the counter bore 98 and nipple 122. A deflector 166 preferably snap fits into the nipple 122 to prevent fuel spray from exiting the tank if the tank fill cap happens to be removed, and to prevent disturbance of fuel flow into the fuel pump inlet filter (not shown).
Referring to
While the forms of the invention herein disclosed constitute presently preferred embodiments, many others are possible. It is not intended herein to mention all the possibly equivalent forms or ramifications of the invention and it is understood that the terms used herein are merely descriptive rather than limiting and that various changes may be made without departing from the spirit or scope of the invention.
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