Steel fuel flange with plastic strut mounts

A method of coupling a metal strut 14 to a metal flange 10 of a fuel supply unit is provided. The method provides a metal flange 10 having a plurality of tabs 46 coupled to and extending from a bottom surface of the flange 10. A plastic strut holder structure 36 holds at least one metal strut 14. The plastic strut structure is engaged with the tabs 46 thereby securing the strut with respect to the flange.

FIELD OF THE INVENTION

The invention relates to fuel supply units for automobile vehicles and more particularly, to a plastic strut mount for connecting metal struts to a flange of the fuel supply unit.

BACKGROUND OF THE INVENTION

A typical fuel supply unit for a vehicle includes a steel fuel flange configured to be sealed to a wall of a fuel tank. The flange is interconnected with a fuel pump assembly by a pair of metal struts. Typically, metal mounts, cups or brackets are used to secure the struts in place with respect to the flange. The struts are typically secured to the brackets or mounts using a welding process that increases costs of assembly. In addition, the flange supplier must deal with the struts extending from the flange, which increases the complexity of shipping the flange, and increases the number of parts required at the flange supplier. Furthermore, the reliability of the strut-flange connections needs to be improved.

Accordingly, there is a need provide a plastic strut mount structure for a fuel supply unit so that assembly of the unit can be made more easily.

SUMMARY OF THE INVENTION

An object of the invention is to fulfill the need referred to above. In accordance with the principles of the present invention, this objective is obtained by providing a method of coupling a metal strut to a metal flange of a fuel supply unit. The method provides a metal flange having a plurality of tabs coupled to and extending from a bottom surface of the flange. A plastic strut holder structure holds at least one metal strut. The tabs are engaged with the plastic strut holder structure thereby securing the strut with respect to the flange.

In accordance with another aspect of the invention, a flange assembly of a fuel supply unit includes a metal flange having a bottom surface; a plurality of tabs coupled to the bottom surface; at least one metal strut; and a plastic strut holder structure holding an end of the at least one metal strut. The plastic strut holder structure is secured to the flange by engagement with the tabs thereby securing the plastic strut holder structure and the at least one metal strut with respect to the flange.

In accordance with yet another aspect of the invention, a connection between a metal flange of a fuel supply unit and at least one metal strut is provided. The flange includes a plurality of tabs coupled to an underside thereof. The connection includes a plastic strut holder structure constructed and arranged to hold an end of the at least one metal strut. The plastic strut holder structure is constructed and arranged to be engaged with the tabs, thereby securing the plastic strut holder structure and the at least one metal strut with respect to the flange.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENT

With reference toFIG. 1, a flange10is interconnected with a fuel pump assembly12by a pair of metal struts14, in accordance with the principles of the present invention. A first embodiment of a connection of the struts14with the bottom of the flange10is shown inFIG. 2. A plurality of metal tabs15is joined to or integral with a metal or steel insert16. The insert16is welded or otherwise connected to the flange and can be considered to be part of the bottom or underside of the flange10. In accordance with the embodiment ofFIG. 2, a one-piece plastic strut holder, generally indicated at18, includes a pair of strut-receiving bosses20, each having an opening for receiving and holding and end of a metal strut14in preferably a press-fit arrangement. The end of the strut14can include a barb that bites into the plastic for secure coupling with the strut holder18. The bosses20are molded integrally with a body22of the strut holder18. The body22is of generally semi-circular configuration and has a central portion including an opening24there through. Tabs15extend through the opening24and are bent to secure the central portion of the strut holder18to the flange10. Tabs15are also at ends of the body22to secure the ends of the body to the flange10.

In accordance with a second embodiment of the invention,FIG. 3shows a pair of metal tabs, generally indicated at30, secured, by welding or the like, to the bottom of the flange10, which are associated with securing a strut14with respect to the flange10. Thus, two pairs of metals tabs30are provided on the bottom of the flange10. The metal tabs30are generally L-shaped having a first portion32secured to the flange10and a second portion34extending generally upwardly from the first portion32. A plastic strut holder, in accordance with the second embodiment of the invention is shown generally indicated at36inFIG. 4. One strut holder36is provided for each strut14. The strut holder36has a boss38having an opening for receiving and holding an end of the metal strut14in preferably a press-fit arrangement. The boss38extends from a body40. The portions34of the tabs30are bent to secure the strut holder36to the flange10.

In accordance with a third embodiment of the invention,FIG. 5shows a single metal tab bracket, generally indicated at42, secured, by welding or the like, to the bottom of the flange10which is associated with securing a strut14with respect to the flange10. Thus, two tab brackets42are provided on the bottom of the flange10. Each tab bracket42has a base44secured to the flange10and tabs46extending generally upwardly from ends of the base44. The base44also includes a mounting boss48that can receive an end of the metal strut so as to ground the strut. A plastic strut holder36, of the same configuration as the second embodiment, is shown ready to be coupled to the tab bracket42inFIG. 6. One strut holder36is provided for each strut14. The strut holder36has a boss38having an opening for receiving and holding an end of the metal strut14. The end of the strut14can be received in the opening of boss48if grounding is desired. The strut holder36includes crush ribs50on body40to prevent the plastic from breaking during bending of the tabs46(or tabs30ofFIG. 4). As shown inFIGS. 5–7, the strut holder36is located over the tab bracket42and the tabs46are bent to secure the strut holder36to the flange10.

In accordance with a fourth embodiment of the invention as shown inFIGS. 8 and 9, the metal tab bracket42′ fixed to the bottom of the flange10is similar to that shown inFIG. 5, but each tab46includes at least one barb47extending from an edge thereof. A pair of barbs extends from each tab46in the illustrated embodiment. The plastic strut holder36′ includes tab receiving members37each having a channel39therethrough. A tab46is received in an associated channel39of a tab-receiving member37with the barbs47engaging the surfaces defining the channels37(FIG. 9) to secure the tabs46with respect to the tab-receiving member37. Part of a tab-receiving member37is shown in section to clearly show the engagement with the tab46.

A method of coupling a metal strut to a metal flange of a fuel supply unit in accordance with the invention provides a metal flange10having a plurality of tabs30coupled to and extending from a bottom surface of the flange. A plastic strut holder structure36holding at least one metal strut14. The plastic strut holder structure is engaged with the tabs thereby securing the plastic strut holder structure and strut with respect to the flange.

Advantages of using the plastic strut holders of the invention are:

Reliability: The steel struts14hold better in plastic than in steel.

Cost: At the flange manufacturer, there is less welding and manufacturing time due to the use of the plastic strut holder. The flange supplier does not have to deal with the long struts attached to the flange, since the struts can be attached later. This will improve quality from the flange supplier: ease of shipment, lower part numbers if only difference in application is strut length, more accurate location of the struts for further assembly in-house.