Abstract:
A fuel tank assembly comprising a fuel tank having a plurality of walls spaced apart by a floor, a flange having a top portion and a bottom portion, and extending downward from one of the plurality of walls, is provided. The fuel tank assembly further includes a housing, a crimp ring and a lip, wherein the crimp ring is fitted over the lip for engaging the flange and the housing. A fuel pump is housed within the housing, wherein the housing is arranged to fixedly position at least one inlet connected to the fuel pump at or in close proximity to the floor of the fuel tank. A fuel reservoir extends away from the floor having at least one passage formed therein, the fuel reservoir being positioned within the fuel tank so as to create an accumulated area of the fuel tank surrounding the at least one inlet, wherein fuel enters the accumulated area through the at least one passage for receipt by the at least one inlet.

Description:
FIELD OF THE INVENTION 
     The present invention relates to fuel tank assemblies and more particularly to a composite fuel pump with an integrated flange and housing within a fuel tank assembly for a vehicle. 
     BACKGROUND OF THE INVENTION 
     In automotive vehicles, a fuel pump is typically disposed within a fuel tank assembly. The fuel pump draws fuel from the fuel tank through the fuel lines for supply to the engine. Known fuel tanks utilize mounted fuel pumps having an inlet arranged to receive fuel from a separately constructed reservoir tank arranged within the fuel tank, i.e. a tank within a tank. Such arrangements use supplemental pumps that are arranged to transfer fuel from the fuel tank to the reservoir tank, thus requiring additional mechanical energy. Consequently, such fuel tank assemblies utilizing fuel pumps tend to be more costly to assemble and difficult to access for service. 
     BRIEF SUMMARY OF THE INVENTION 
     A fuel pump draws fuel from the fuel tank, usually located in the rear of a vehicle, through fuel lines that run the length of the vehicle to the engine&#39;s injection system. The fuel pump disclosed herein is an electric fuel pump that is located inside the fuel tank. The fuel pump contains a direct current (DC) motor with an impeller mounted on the end of the motor shaft. A cover is mounted over the impeller, having inlet and discharge ports. When the armature rotates, thus rotating the impeller, fuel is moved from the fuel tank and into the inlet port of the fuel pump. The impeller grooves force the fuel out of the fuel pump, through the discharge port. 
     A fuel pump is located within the fuel tank to aid in keeping the fuel pump cool during operation, and aid in ensuring the fuel line is pressurized to prevent premature fuel evaporation. The pump is housed within a housing and enclosed by a fuel filter. The housing is engaged to a flange that fits within a cavity of the fuel tank located within a side wall or the top of the fuel tank. The top portion is located outside the fuel tank, and the bottom portion extends within the fuel tank. 
     Accordingly, one aspect of the present invention is to provide a fuel tank assembly comprising a fuel tank having a plurality of walls spaced apart by a floor. A flange extends downward from one of the plurality of walls. The flange may extend at an angle toward the floor, or extend from the top of the fuel tank toward the floor. A fuel pump extends from the flange; and the fuel pump and flange are arranged to fixedly position at least one inlet connected to the fuel pump at or in close proximity to the floor of the fuel tank. A filter surrounds the fuel pump for filtering the fuel, and a housing encompasses both the pump and filter. The fuel pump includes at least one inlet for drawing fuel into the housing, and the inlet is engaged to a suction filter for filtering the gas prior to entering the inlet. The flange is engaged to the housing by way of a crimp ring that is fitted over a lip, forming an engaged arrangement. 
     A fuel reservoir located within the fuel tank extends away from the floor and has at least one passage formed therein. The fuel reservoir is positioned within the fuel tank so as to create an accumulated area surrounding the at least one inlet. Fuel enters the accumulated area through the at least one passage and is received by the at least one inlet by way of the suction filter. Optionally, a channel is formed within the fuel reservoir for receiving at least one inlet from the fuel pump. 
     According to an exemplary embodiment of the present invention, a fuel pump assembly comprises a flange having a top portion and a bottom portion, and extending downward from one of the plurality of walls. The fuel pump assembly includes a housing, a crimp ring and a lip, wherein the crimp ring is fitted over the lip for engaging the flange and the housing. A fuel pump is housed within the housing, wherein the housing is arranged to fixedly position at least one inlet at or in close proximity to the floor of the fuel tank. 
     According to another embodiment of the present invention, the fuel tank assembly includes a fuel pump having at least one inlet for receiving fuel, the at least one inlet being in fluid communication with the pump. 
     According to yet another embodiment of the present invention, the fuel tank assembly includes a suction filter having an internal frame for shaping the suction filter into a predetermined form, wherein the suction filter is positioned to be at or in close proximity to the floor of the fuel tank, the suction filter being in fluid communication with the at least one inlet of the housing. 
     According to yet another embodiment of the present invention, the fuel tank assembly includes a housing enclosing a fuel filter disposed around the fuel pump, wherein the fuel filter forms the inner wall of the fuel filter. 
     According to yet another embodiment of the present invention, the fuel tank assembly includes an o-ring engaged to the flange for providing a secure fit between the flange and housing. 
     According to yet another embodiment of the present invention, the fuel tank assembly includes a pressure regulator mounted to the housing for regulating the pressure within the fuel filter. 
     According to yet another embodiment of the present invention, the fuel tank assembly includes a fuel reservoir extending away from the floor having at least one passage formed therein, the fuel reservoir positioned within the fuel tank so as to create an accumulated area of the fuel tank surrounding the at least one inlet, wherein fuel enters the accumulated area through the at least one passage for receipt by the at least one inlet of the housing. 
     According to yet another embodiment of the present invention, a fuel tank assembly includes a fuel tank having a plurality of walls spaced apart by a floor, a flange having a top portion and a bottom portion, and extending downward from one of the plurality of walls. The fuel tank assembly includes a housing, a crimp ring and a lip, wherein the crimp ring is fitted over the lip for engaging the flange and the housing. A fuel pump is housed within the housing, wherein the housing is arranged to fixedly position at least one inlet at or in close proximity to the floor of the fuel tank, and a fuel reservoir extends away from the floor having at least one passage formed therein, the fuel reservoir positioned within the fuel tank so as to create an accumulated area of the fuel tank surrounding the at least one inlet, wherein fuel enters the accumulated area through the at least one passage for receipt by the at least one inlet. 
     According to yet another embodiment of the present invention, the fuel tank assembly includes the fuel reservoir having a predetermined height relative to the floor that decreases along a path of the fuel reservoir defining the enclosed area, wherein the predetermined height becoming negligible prior to the fuel reservoir reaching one of the plurality of walls. 
     According to yet another embodiment of the present invention, the fuel tank includes the accumulated area and comprises a corner between two of the plurality of walls with the fuel reservoir extending between the two walls. 
     According to yet another embodiment of the present invention, the fuel tank assembly includes a channel positioned in the fuel reservoir. 
     According to yet another embodiment of the present invention, the fuel tank assembly includes a fuel tank having a plurality of walls spaced apart by a floor, and a flange having a top portion and a bottom portion, and extending downward from one of the plurality of walls. The fuel tank assembly further includes a housing a crimp ring and a lip, wherein crimp ring is fitted over the lip for engaging the flange and the housing, and a fuel pump housed within the housing, wherein the housing is arranged to fixedly position at least one inlet at or in close proximity to the floor of the fuel tank. At least one suction filter is positioned on the at least one inlet for filtering the fuel before introduction into the fuel pump, and a fuel reservoir extends away from the floor having at least one passage formed therein. The fuel reservoir is positioned within the fuel tank so as to create an accumulated area of the fuel tank surrounding the at least one suction filter inlet, wherein fuel enters the accumulated area through the at least one passage for receipt by the at least one suction filter. 
     According to yet another embodiment, a fuel tank assembly includes the fuel pump extending from a top wall of the fuel tank. 
     According to yet another embodiment of the present invention, a fuel tank assembly includes the fuel pump extending at an angle downward from one of the plurality of walls. 
     According to yet another embodiment of the present invention, the crimp ring is located on the flange and the lip is located on the housing. 
     According to yet another embodiment of the present invention, the crimp ring is located on the housing and the lip is located on the flange. 
     Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
       The present invention is illustrated and described herein with reference to the various drawings, in which like reference numbers denote like method steps and/or system components, respectively, and in which: 
         FIG. 1  shows a perspective view of a composite fuel tank assembly according to the present invention. 
         FIG. 2  shows an alternative placement of a fuel pump cartridge assembly according to the present invention. 
         FIG. 3  shows an exploded view of one embodiment of a fuel tank assembly according to the present invention. 
         FIG. 4  shows a side view of one embodiment of a composite fuel pump assembly according to the present invention. 
         FIG. 5  shows another side view of one embodiment of a composite fuel pump assembly according to the present invention. 
         FIG. 6  shows another side view of one embodiment of the composite fuel pump assembly according to the present invention. 
         FIG. 7  shows another side view of one embodiment of the composite fuel pump assembly according to the present invention. 
         FIG. 8  shows a cross-sectional view of an exemplary embodiment of a composite fuel pump assembly according to the present invention. 
         FIG. 9  shows a perspective view of a fuel tank assembly having a fuel reservoir according to the present invention. 
         FIG. 10  shows a perspective view of a fuel tank assembly having a fuel reservoir according to the present invention. 
         FIG. 11  shows a perspective view of another embodiment of the fuel tank assembly having a fuel reservoir according to the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to  FIG. 1 , a fuel tank assembly  10  according to an exemplary embodiment is shown, including a fuel pump assembly. The fuel pump assembly includes a flange  12 , a housing  14 , a fuel pressure regulator  16 , and a suction filter  18 . The flange  12  has a top portion and a bottom portion, and is further positioned on a wall of a fuel tank  20 . The flange  12  can be positioned on a side wall of fuel tank  20  within a wall cavity  22  that is arranged to be adjacent to a vehicle exterior member (not shown) when the fuel tank assembly  10  is installed in a vehicle chassis (not shown). This arrangement enables the fuel tank assembly  10  to be accessed simply by removing, for example, a rear quarter panel (not shown) of a vehicle. 
     In another arrangement, as shown in  FIG. 2 , the flange  12  can be positioned on the top wall of the fuel tank  20 . This arrangement enables the fuel tank assembly  10  to be accessed simply be removing, for example, an access panel (not shown) of a vehicle located under a rear seat bottom. 
     As illustrated in  FIG. 3 , the fuel tank assembly  10  comprises the flange  12  that fits within the wall cavity  22  of the fuel tank  20  (as illustrated in  FIGS. 1 and 2 ), an optional electrical connected  24  that may be engaged to the flange  12 , a housing  14 , a fuel pump  26 , a fuel filter  28 , a grommet  30  to seal the pump to the housing  14 , a pressure regulator  16 , and suction filter  18 . The electrical connector  24  may be engaged with the flange  12  for providing the requisite electricity to power the fuel pump  26 . In one embodiment, neither the electrical connector  24  nor flange  12  is pressurized. Alternatively, an end of the fuel pump  26  may extend from within the flange  12  to receive power from an external source for operation, whereby the fuel pump  26  is sealed to the flange  12  with o-rings (not shown). Alternatively, the electrical connector  24  and the flange  12  may be pressurized. 
     The fuel filter  28  surrounds the fuel pump  26  for filtering the fuel, wherein the outer housing of the fuel pump  26  performs a secondary function as the inner wall of the fuel filter  28 . This arrangement allows the elimination of an inner filter wall of the fuel filter  28 . The housing  14  houses the fuel pump  26  and filter  28 . A grommet  30  is used to securely retain the fuel pump  26  within the housing  14 . The grommet  30  fits within a recess in the housing  14  having a diameter slightly larger than the diameter of the grommet  30 . The grommet  30  has a diameter slightly larger than the diameter of the fuel pump  26 , allowing the fuel pump  26  to be positioned within the grommet  30 . The grommet  30  fits within the recess, and the fuel pump  26  fits within the grommet  30 , thus preventing the fuel pump  26  from moving within the housing  14 . 
     In one exemplary embodiment, the flange  12  includes a crimp ring  36  located on the periphery of the bottom portion of the flange  12 . The crimp ring  36  may entirely cover the entire periphery of the bottom portion of the flange  12 . Alternatively, the crimp ring  36  may be arranged in sections (not shown) upon the periphery of the bottom portion of the flange  12 . Specifically, the crimp ring  36  may be composed of multiple spaced apart crimp rings  36  located around the periphery of the bottom portion of the flange  12  (not shown). The purpose of the crimp ring  36  is to engage the flange  12  with the housing  14 . 
     The housing  14  includes a lip  38  located on the upper portion of the housing  14 . The crimp ring  36  is designed to be fitted over the lip  38  of the housing, creating an engaged arrangement between the flange  12  and housing  14 . The crimp ring  36  is fitted over the entire area of the lip  38  or a portion of the lip  38 , forming a single, solitary arrangement. This arrangement is designed to form a solid, substantially leak prevention seal that prevents the intrusion of the gas within the assembly  10 . The flange  12 , housing  14 , crimp ring  36 , and lip  38  may be composed of stainless steel, or other metal, wherein the crimp ring  36  and lip  38  may be laser welded together to form an engaged arrangement. 
     Alternatively, this exemplary embodiment also allows dissimilar materials to be joined together to form the flange  12  and housing  14  arrangement. For example, the flange  12  may be composed of stainless steel, or other type of suitable steel, while the housing  14  is composed of plastic. The stainless steel crimp ring  36  may be formed over the plastic lip  38  of the housing  14 , forming a single, solitary arrangement of the flange  12  and housing  14  that are composed of dissimilar materials. In another exemplary embodiment, any type of metal or composite material may compose the flange  12  and crimp ring  36 , which is engaged to the housing  14  and lip  38  composed of plastic or a composite material. In still yet another exemplary embodiment, the housing  14  may be made of plastic or a composite material, and the lip  38  may be composed of another material, such as a metal, while the housing  14  is composed of a separate material, such as plastic. In still yet another exemplary embodiment, the crimp ring  36  may be plastic, and the lip  38  composed of steel or similar metal. In still yet another exemplary embodiment, the crimp ring  36  may be plastic and the lip  38  composed of plastic. 
     Another exemplary embodiment of the present invention is illustrated in  FIG. 4 . In this embodiment, the flange  112  comprises a lip  138 , for receiving a crimp ring  136  located on the top portion of the housing  114 . The housing  114  includes a crimp ring  136  located on the upper portion of the housing  114 . The crimp ring  136  is designed to be fitted over the lip  138  of the flange  112 , creating an engaged arrangement between the flange  112  and housing  114 . The crimp ring  136  is fitted over the entire area of the lip  138  or a portion of the lip  138 , forming a single, solitary arrangement. This arrangement is designed to form a solid, substantially leak preventing seal that prevents the intrusion of the gas within the housing  114 . In addition, an o-ring  144  may be engaged to the flange  112  for providing a secure fit between the flange  112  and housing  114 , as illustrated in  FIG. 5 . 
     An exemplary embodiment of the present invention is illustrated in  FIG. 6  and is a derivation of  FIGS. 4 and 5 . This particular embodiment includes a second lip  252  located upon the upper portion of the housing  214 . The flange  212  is engaged to the housing by way of a crimp ring  236 . The crimp ring  236  is fitted over the lip  238  of the flange  212  and the lip  252  of the housing  214 . An o-ring  244  is optionally engaged to the flange for providing a secure fit between the housing  214  and flange  212 . 
     An exemplary embodiment of the present invention is shown in  FIG. 7 . This embodiment includes a flange  312  comprising a lip  338 , for receiving a crimp ring  336 . The crimp ring  336  is designed to engage the flange  312 . The crimp ring  336  is designed to be fitted over the lip  338  of the flange  312 , creating an engaged arrangement between the flange  312 . The crimp ring  336  is fitted over the entire area of the lip  338  or a portion of the lip  338 , forming a single, solitary arrangement. Alternatively, the flange  312  may include a crimp ring for being fitted over a lip located on the housing. 
     In this embodiment as illustrated in  FIG. 7 , the flange  312  may consist of an upper portion  346  and a lower portion  348 . The upper portion  346  comprises a second lip  352 , for receiving a second crimp ring  354  located on the lower portion  348 . The lower portion  348  includes a second crimp ring  354  for engaging the flange  312  to the housing  314 . The second crimp ring  354  is designed to be fitted over the second lip  352  of the flange  312 , creating an engaged arrangement between the flange  312  and housing  314 . The second crimp ring  354  may be welded or roll-crimped to the second lip  352 . An o-ring (not shown) may be engaged to the flange  312 , for providing a secure fit between the flange  312  and housing  314 . 
     As illustrated in  FIG. 8 , the pressure regulator  16  regulates the system pressure within the fuel pump  26 . The suction filter  18  may be connected to the inlet  32  of the fuel pump  26  and draws fuel from the fuel tank  20  and into the housing  14 . The suction filter  18  filters the fuel as it is drawn into the housing  14  from the fuel tank  20  for protecting the fuel injectors, as illustrated in  FIGS. 1 and 2 . The suction filter  18  includes an internal frame member, allowing the suction filter  18  to be formed into a particular shape beneficial for the intake of fuel. 
     As shown in  FIGS. 1 ,  2 , and  3 , the internal frame member can be formed in a number of different arrangements based upon a desired function. In  FIG. 1 , the suction filter  18  may be formed to include an arch extending away from the housing  14  and a flat portion for positioning on the floor of the fuel tank  20  or in close proximity to the floor of the fuel tank  20 . The positioning of the suction filter  18  on the floor of the fuel tank  20 , allows the suction filter  18  to perform a wicking function for drawing fuel into the suction filter  18  during the intake of fuel. In addition, the design of the suction filter  18 , allows the flange  12  and housing  14  to be suspended above the floor of the fuel tank  20 . Alternatively, the suction filter  18  includes an arch that is similar to an “A-shape,” wherein the highest point on the suction filter  18  is attached to the inlet  32  and the two opposite ends of the suction filter  18  are disposed on the gas tank  20  floor, or in close proximity to the floor. 
     As shown in  FIG. 8 , the fuel pump  26  contains an inlet  32  for receiving, fuel that has previously been filtered by the suction filter  18 . The suction filter  18  provides a first filtering of the fuel from the tank  20  for protecting the fuel pump  26 . The fuel is drawn through the suction filter  18 , through the inlet  32 , and deposited within the housing  14 . The fuel is then drawn through the fuel filter  28 , thus filtering the fuel, before the fuel is pumped to the fuel injectors. 
     The flange  12  and housing  14  substantially fit within the fuel tank  20 , and are suspended above the floor of the fuel tank  20 . The suction filter  18  may touch the floor of the fuel tank  20 , while the housing  14  and pressure regulator  32  are suspended above the floor. Alternatively, the suction filter  18  is in close proximity to the floor of the fuel tank  20 , while the housing  14  and pressure regulator  32  are suspended above the floor. 
     Referring to  FIGS. 9 ,  10 , and  11 , the fuel tank assembly  10  is shown according to an exemplary embodiment to include a fuel reservoir  40  positioned on the floor of the fuel tank  20 . According to an aspect of the present invention, the fuel reservoir  40  can be an integrally molded or formed cavity or partition extending upward from the floor of the fuel tank  10 , and following a path that generally encircles the fuel pump assembly  10 . The fuel reservoir  40  may extend from a side wall of the fuel tank  20  and encloses the fuel pump assembly  10  against the side wall. According to a another exemplary embodiment, the fuel reservoir  40  extends from one side wall to another side wall of the fuel tank  20  and encloses the fuel pump assembly  10  in a corner of the fuel tank  20 . In accordance with another aspect of the present invention, the fuel reservoir  40  also includes at least one channel  42  for receiving at least one remote inlet of the pump (not shown). 
     The fuel reservoir  40  depicted in  FIGS. 9 ,  10 , and  11  is vital in preventing damage to the fuel pump  26 , and vital engine components. For example, when a vehicle is low on fuel and travels around a curve, the small amount of fuel within the fuel tank  20  will be forced to the side of the fuel tank  20  away from the curve. In many instances, this removes gas from the suction filter  18  or pump inlet  32 , thus preventing gas from entering the fuel pump  26 . When gas does not enter the fuel pump  26 , the fuel pump  26  still operates, but without the fuel that serves a secondary purpose as a type of lubricant to reduce wear on a pump&#39;s internal compartments, providing a liquid surface boundary. As the fuel pump  26  has no fuel to pump throughout the system, the engine has no fuel to use in the combustion process, resulting in no fuel or a less than adequate amount of fuel to be expelled into the combustion chamber, possibly resulting in a misfire. 
     The fuel reservoir  40  prevents all of the gas from freely flowing within the fuel tank  20 . The fuel reservoir  40  keeps an adequate amount of fuel within the reservoir  40 , allowing the fuel pump  26  to pump fuel through the fuel pump  26  and into the engine. Because of the fuel reservoir  40 , fuel is in close proximity to the suction filter  18  or inlet  32 , even when a car makes a sharp turn, or other maneuver that would affect the gas within the fuel tank  20 . 
     According to either exemplary embodiment, the floor of the fuel tank  10  may be sloped downward in the direction of the fuel pump assembly  10 . In addition, the fuel reservoir  40  includes a passage allowing fuel to enter an accumulated or “pooled” area. According to an aspect of the present invention, the passage can be formed by the height of the fuel reservoir  40  generally decreasing along the path and becoming negligible as the path approaches the side wall of the fuel tank  20 . As a result, fuel will flow around the fuel reservoir  40  and into an area enclosed by the fuel reservoir  40 . Furthermore, the fuel reservoir  40  is arranged to retain a quantity of fuel within an area defined by the path. This arrangement is relevant when small quantities of fuel remain in the fuel tank  20  as the floor and the fuel reservoir  40  ensure that fuel remains available to suction filter  18 , without the use of a reservoir within the tank. 
     The description of the invention is merely exemplary in nature, and thus variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.