Patent Application
20070056567
This invention relates generally to fuel delivery systems for vehicles and, more particularly to a fuel delivery assembly disposed in a fuel tank of a vehicle fuel delivery system.
Typical automotive fuel systems have a fuel delivery assembly mounted within and received through an opening in an upper wall of a fuel tank of a vehicle. A typical fuel delivery assembly may include a mounting flange for mounting to the upper wall of the fuel tank, multiple spaced-apart posts fixed to the mounting flange, and a reservoir housing connected to the mounting flange by the posts. The typical fuel delivery assembly may also include various conduits and wires extending through the mounting flange and terminating in connections to various components of the assembly, a fuel level sender mounted to the reservoir housing to measure the level of fuel in the fuel tank, and a fuel pump carried by the reservoir housing and having an inlet relatively adjacent a lower wall of the fuel tank to draw fuel from the fuel tank and deliver the fuel under pressure to an engine of the vehicle.
Currently, many fuel pump assemblies must be specifically designed to suitably match the height of the fuel tanks in which the assemblies are mounted. This is because every vehicle type requires a fuel tank of unique height, wherein the distance between the lower and upper walls of the fuel tank may be significantly different from one tank design to another or from one tank chamber to another in the case of saddle-type fuel tanks with dual chambers. But custom designing many different fuel pump assemblies may not be the most cost effective approach.
A modular fuel delivery assembly for a fuel tank of a vehicle includes a mounting flange that is preferably configured for mounting within an opening of the fuel tank. The assembly further includes a common support member adjustably engaged with the mounting flange, and a plurality of accessories attached to the common support member.
At least some of the objects, features and advantages that may be achieved by at least certain embodiments of the invention include providing a modular fuel delivery assembly, that includes a common support member of selectable length and to which various modular accessories may be mounted; modular accessories that may be standardized and used in a variety of fuel delivery assemblies for different fuel tanks and vehicles; standardized attachment between the modular accessories and the common support member; is adaptable for use with fuel tanks of different heights or fuel tank chambers of different heights; adjustable attachment between the common support member and a mounting flange of the assembly to ensure location of an accessory against a bottom of the fuel tank; is of relatively simple design and economical manufacture and assembly, rugged, durable, reliable and in service has a long useful life.
Of course, other objects, features and advantages will be apparent in view of this disclosure to those skilled in the art. Various other fuel delivery assemblies embodying the invention may achieve more or less than the noted objects, features or advantages.
These and other objects, features and advantages of the present invention will be apparent from the following detailed description of the preferred embodiment(s) and best mode, appended claims, and accompanying drawings in which:
Referring in more detail to the drawings,
The mast 100 preferably extends in a generally vertical direction, but it is contemplated that the mast 100 could extend in any suitable direction including a non-vertical direction. The mast 100 is preferably composed of a plastic or metal material, and is preferably formed in a generally tubular shape of hollow cross section, non-circular in revolution, and substantially constant over its length. For example, the mast 100 may be of polygonal cross section, such as hexagonal cross section as shown. The polygonal, or at least non-circular cross-sectional shape of the support mast 100 is preferred to provide angular fixation of the various accessories 210-280 carried by the mast 100 and, thus, accurate positioning of the various accessories 210-280 and prevention of relative rotation between the mast 100 and the various accessories 210-280.
The mast 100 preferably includes a plurality of longitudinally elongate slots 102 adjacent its upper end. Such slots 102 can be provided on one or more of the faces of the mast 100. The slots 102 are configured to receive lateral projections 214 formed on a pillar or post 212 attached to the lower face of the mounting flange 210.
The mounting flange 210 is intended to be attached to a fuel tank (not shown), and preferably to an upper wall (not shown) of the fuel tank. The general structure of a mounting flange is well known to those of ordinary skill in the art. It can be seen that the mounting flange 210 preferably carries, on its upper surface, an electrical connector 216 to make connections with electrical accessories, such as an electric pump 266 and a fuel level sensor (not shown), as well as at least one tube 218 to convey to the engine (not shown) fuel delivered by the electric fuel pump 266.
The post 212 of the mounting flange 210 is engaged to the mast 100, preferably inserted within the mast 100. Consequently, it preferably has an external profile that is non-circular and complementary to the internal profile of the mast 100, such as hexagonal, to prevent relative rotation therebetween but permit axial adjustment therebetween. Those of ordinary skill in the art will understand that the assembly of the projections 214 into the slots 102 allows relative sliding or adjustment between the mounting flange 210 and the mast 100 in a direction that is substantially parallel the axis of the mast 100. Accordingly, this axial adjustment enables a lower end of the mast 100, or an accessory mounted thereto, to be located and yieldably biased, such as by a spring, against a bottom wall of the fuel tank (not shown), in order to provide reliable measurement of fuel in relation to the bottom and to assure that a fuel pump intake is located adjacent the fuel tank bottom for suitable fuel pumping.
Those of ordinary skill in the art will recognize that the connection between the mounting flange 210 and the mast 100 is not limited to the above-mentioned arrangements. For example, in another configuration the post 212 of the mounting flange 210 could instead be engaged on the outside of the mast 100 and not inside latter. In other words, the mast 100 could instead be fit within the post 212. According to yet another modification, one could provide longitudinal slots in the post 212 fixed to the mounting flange 210 and projections on the mast 100.
In any case, those of ordinary skill in the art will recognize that the mast 100 and post 212 arrangement makes the modular fuel delivery assembly 200 adjustable and amenable for use with fuel tanks wherein the distance between the lower and upper walls of the fuel tanks may be significantly different from one tank design to another or from one tank chamber to another in the case of saddle-type fuel tanks with dual chambers. In other words, when designing a modular fuel delivery assembly for use with multiple fuel tanks of different heights, one chooses masts 100 of different lengths and/or flanges 210 which include posts 212 of different lengths wherein the lengths of the masts 100 and/or posts 212 correspond to the height of the particular fuel tank or fuel tank chambers.
The various other accessories 220, 230, 240, 250, 260, 270, 280 are preferably commonly attached to the sides or faces of the mast 100 by any appropriate means, such as by welding, gluing, clipping, sockets, sliding connections, snap fasteners and the like. As can be seen with the pressure-regulating assembly 220, the distributor 230, the filter 240, and the electric fuel pump assembly 260, at least some of these accessories are secured to the mast 100 using attachment means which may include one or more brackets 222, 232, 242, 262 suitable for being placed alongside and attached to the mast 100. More specifically, some of the accessories may be attached to a support yoke defined by two of such brackets 222, 232, 242, 262 suitable for being secured respectively to different faces of the mast 100, and typically to two diametrically opposite faces of the mast 100.
The pressure-regulating assembly 220 functions to limit the pressure of the fuel conveyed from the fuel tank to the engine (not shown). The pressure-regulating assembly 220 can be of any suitable type known to those of ordinary skill in the art. For example, the pressure regulating assembly 220 may be formed from a diaphragm type or unit that includes a membrane compressed elastically by a spring against an output orifice. Accordingly, when the pressure of the fuel is less than a threshold predetermined by the spring force imposed on the membrane, the membrane remains in contact with the output orifice to close it off. On the contrary, when the pressure of the fuel is greater than this predetermined threshold, the membrane is forced back from the output orifice to allow a return of excess fuel to the reserve tank 280 or the fuel tank for example.
The distributor 230 functions to provide fluid communication between some or all of the accessories, such as between the output of the electric fuel pump assembly 260, the regulator 220, the filter 240, and the venturi jet pump 250.
The filter 240 functions to filter the fuel before it is conveyed to the engine, and may be positioned upstream or downstream of the pump.
The venturi jet pump assembly 250 transfers fuel from a first location, such as the general volume of the fuel tank, to a second location, such as the reserve tank 280. Those of ordinary skill in the art are familiar with venturi jet pump assemblies. The assembly 250 operates using a flow, such as a return flow of fuel from the engine coming from a take-off point at the output of the filter or from an output stage of the fuel pump, which is injected through a nozzle that discharges into a throat which results in the creation of a vacuum capable of drawing fuel from the first location. The assembly 250 may be attached to the mast 100 such as by a ferrule 252 attached to the assembly 250 and suitable to be engaged axially in the lower end of the mast 100.
The electric fuel pump assembly 260 pumps fuel for transfer from the reservoir to the engine. It can be formed from any suitable configuration known to those of ordinary skill in the art, but may include a support 264 carrying the aforementioned brackets 262, and an electric pump 266 fitted at the input to a filter 267 such as an upstream or suction-side filter.
In order to simplify the drawing figures, the fuel level sensor that may be carried by the support 270 has not been shown. The fuel level sensor can be formed from any structures known to those of ordinary skill in the art that is capable of measuring the level of fuel present in the fuel tank, and of sending the information for use by a vehicle occupant.
The reserve tank 280 holds a predetermined quantity of fuel at the inlet to the pump 266, irrespective of acceleration or incline of the vehicle, in order to avoid any fuel starvation or cavitation of the pump. The structure of reserve tanks is well known to those of ordinary skill in the art. It can be seen that the reserve tank 280 is preferably equipped with a check valve 282 in the inlet to the reserve tank. The reserve tank 280 may be secured to the mast 100 by any suitable means, such as suitable structure to be engaged in the lower end of the mast 100 or the ferrule 252. It is possible to attach several accessories to the mast 100 by telescopically slotting a variety of accessory supports into each other. The reserve tank 280 may also be attached to the mast 100 by means of brackets inside the reserve tank 280, similar to those described earlier.
The modular fuel delivery assembly 300 of
Those of ordinary skill in the art will recognize that some accessories or components, as well as their method of attachment, may be symmetrical in relation to the mast 100. Such accessories can, therefore, be fixed in a reverse direction or position in order to allow different configurations.
Referring now to
Those of ordinary skill in the art will understand that the mast 100 may serve as a reference for the assembly process of the complete modular fuel delivery assembly 200, whether assembled manually, automatically or by robotic systems. The mast 100 and the various accessories 210 to 280 can be made from any appropriate material, such as those based on a plastic material or a metal. Preferably, the mast 100 and at least the part of the accessories 220 to 280, intended to be brought into contact with this mast 100, are made from a plastic material. This arrangement allows attachment of the accessories by welding. Preferably however, it is preferable to ensure that the post 212 of the mounting flange 210 and the mast 100 are not made simultaneously from a plastic material. In this context, it is possible, for example, to create the post 212 in metal and the mast 100 in a plastic material, or inversely to create the post 212 in a plastic material and the mast 100 in metal.
As used in this specification and claims, the terms “for example,” “for instance,” and “such as,” and the verbs “comprising,” “having,” “including,” and their other verb forms, when used in conjunction with a listing of one or more components or other items, are each to be construed as open-ended, meaning that that the listing is not to be considered as excluding other, additional components, elements, or items. Moreover, directional words such as top, bottom, upper, lower, radial, circumferential, axial, lateral, longitudinal, vertical, horizontal, and the like are employed by way of description and not limitation. Other terms are to be construed using their broadest reasonable meaning unless they are used in a context that requires a different interpretation. When introducing elements of the present invention or the embodiments thereof, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements.
It is to be understood that the invention is not limited to the particular exemplary embodiments disclosed herein, but rather is defined by the claims below. In other words, the statements contained in the foregoing description relate to particular exemplary embodiments and are not to be construed as limitations on the scope of the invention as claimed below or on the definition of terms used in the claims, except where a term or phrase is expressly defined above.
Although the present invention has been disclosed in conjunction with a limited number of presently preferred exemplary embodiments, many others are possible and it is not intended herein to mention all of the possible equivalent forms and ramifications of the present invention. Other modifications, variations, forms, ramifications, substitutions, and/or equivalents will become apparent or readily suggest themselves to persons of ordinary skill in the art in view of the foregoing description. In other words, the teachings of the present invention encompass many reasonable substitutions or equivalents of limitations recited in the following claims. As just one example, the disclosed structure, materials, sizes, shapes, and the like could be readily modified or substituted with other similar structure, materials, sizes, shapes, and the like. In another example, the invention has been disclosed in conjunction with a saddle-type fuel tank having dual chambers. However, additional applications are contemplated wherein the present invention can be applied to any type of fuel, diesel or gasoline, and to any type of vehicle application, whether equipped with one or more single or multiple chamber fuel tank(s), and whether or not it has one or more of the specific accessories discussed herein, and can be provided without departing from the disclosure. Indeed, the present invention is intended to embrace all such forms, ramifications, modifications, variations, substitutions, and/or equivalents as fall within the spirit and broad scope of the following claims.
