# Patent

## Title
Methods and apparatus to provide a protective barrier to fuel tank coupling apparatus

## Abstract

Methods and apparatus to provide a protective barrier to fuel tank coupling apparatus are described. An example method includes coupling a barrier to an outer surface of the fuel tank, where the barrier includes a support surface and a wall protruding from the support surface to define a cavity; providing a weld pad within the cavity such that a first side of the weld pad engages the support surface; disposing a valve within the cavity of the barrier after the barrier is coupled to the outer surface such that a flange portion of the valve engages the weld pad and at least a portion of the valve is positioned in the fuel tank; and heating the weld pad and the flange portion of the valve to a temperature greater than a melting temperature of a material of the flange portion and the weld pad.

## Background
CROSS REFERENCE TO RELATED APPLICATION
This patent arises from a divisional of U.S. application Ser. No. 13/242,904, (Now U.S. Pat. No. 9,114,701) filed on Sep. 23, 2011, which claims the benefit of U.S. Provisional Patent Application Ser. No. 61/386,253, filed on Sep. 24, 2010, both of which are incorporated herein by reference in their entireties.


FIELD OF THE DISCLOSURE
The present disclosure relates generally to fuel delivery systems and, more particularly, to methods and apparatus to provide a protective barrier to fuel tank coupling apparatus.
BACKGROUND
Fuel delivery systems of marine vehicles typically include a fuel tank having a plurality of coupling apparatus or components that are coupled to a surface of the fuel tank. For example, the fuel tank coupling apparatus may include, but are not limited to, grade valves, vent valves, fill line inlet valves, anti-siphon valves, and/or any other component or coupling to be coupled to the fuel tank. These coupling apparatus fluidly couple various components or systems (e.g., a venting system) of the fuel delivery system to the fuel tank.
In some instances, portions of the coupling apparatus (e.g., a barb fitting of a grade valve) may become damaged during shipment of the fuel tank (having the coupling apparatus attached to a surface of the fuel tank) and/or shipment of the coupling apparatus. Additionally or alternatively, a coupling apparatus is typically composed of a thermoplastic material, which provides relatively low resistance to temperatures and, thus, may not be in compliance with certain government standards or regulations (e.g., SCG Fire safety standards per CFR 33).



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is schematic representation of an example fuel delivery system having a fuel tank coupling apparatus implemented with an example protective barrier described herein.
FIG. 2A is an enlarged view of the example fuel tank coupling apparatus of FIG. 1.
FIG. 2B illustrates an exploded view of the example fuel tank coupling apparatus of FIGS. 1 and 2A.
FIG. 3 illustrates a plan view the example fuel tank coupling apparatus of FIGS. 1, 2A and 2B.
FIG. 4A illustrates a cross sectional view of the example fuel tank coupling apparatus taken along line A-A of FIG. 3.
FIG. 4B illustrates an enlarged view of a portion of the example fuel tank coupling apparatus of FIG. 4A.



DETAILED DESCRIPTION
In general, an example fuel delivery system described herein may be used with marine crafts or vehicles. The example fuel delivery system described herein includes enhanced or improved fuel tank coupling apparatus or fittings (e.g., a grade valve) that are implemented with an example protective barrier described herein. An example protective barrier apparatus described herein protects the fuel tank coupling apparatus from damage during, for example, shipment (or handling) of the fuel tank and/or during shipment of the coupling apparatus. Additionally or alternatively, an example protective barrier apparatus described herein provides compliance with certain government standards (e.g., SCG Fire safety standards per CFR 33). More specifically, the example protective barrier apparatus provides local protection to a fuel tank coupling apparatus such that, in the event of a fire, the protective barrier apparatus is destroyed first (e.g., provides a sacrificial wall), thereby providing a duration of time (e.g., greater than two and a half minutes) before the flames reach the fuel tank coupling apparatus.
As used herein, a “fluid” includes, but is not limited to, a liquid such as fuel (e.g., gasoline), a vapor such as fuel vapor (e.g., gasoline vapor), a gas (e.g., air) and/or any combination or mixture thereof.
FIG. 1 illustrates an example marine fuel delivery system 100 described herein. The fuel delivery system 100 includes a fuel tank 102 for storing fuel 104 (e.g., gasoline, diesel fuel, etc.) and has a plurality of fuel tank coupling apparatus or fittings mounted or coupled to an outer, upper surface 108 of the fuel tank 102. The fuel tank coupling apparatus 110-116 fluidly couple various systems or components of the fuel delivery system 100 to the fuel tank 102. For example, the fuel tank coupling apparatus 110-116 may include, but are not limited to, grade valves, vent valves, fill line inlet valves, anti-siphon valves, fuel demand valves, or any other component or coupling apparatus to be mounted or coupled to a surface (e.g., the surface 108, a side surface, etc.) of the fuel tank 102. In this example, a coupling apparatus of the fuel tank 102 include a grade valve assembly 110, a vent valve 112, a fuel demand valve 114, and an inlet valve 116. For example, the grade valve assembly 110 and the vent valve 112 fluidly couple a venting system 118 to the fuel tank 102, the fuel demand valve 114 fluidly couples a fuel line 120 to the fuel tank 102, and the inlet valve 116 fluidly couples a filler tube apparatus 122 to the fuel tank 102.
The venting system 118 equalizes the pressure in the fuel tank 102 to accommodate volumetric changes (e.g., expansion) in the fuel tank 102. In this example, tubing 124 fluidly couples the vent valve 112 and the grade valve assembly 110, and the vent valve 112 is fluidly coupled to a vent 126 that vents to, for example, the atmosphere. To help reduce venting emissions and/or pollutants to the environment, the venting system 118 may include a vapor collection apparatus 128, which is disposed between the vent 126 and the vent valve 112 such that an inlet 130 of the vapor collection apparatus 128 is fluidly coupled to the vent valve 112 via tubing 132 and an outlet 134 of the vapor collection apparatus 128 is fluidly coupled to the vent 126 via tubing 136. The vapor collection apparatus 128 includes an emission(s)-capturing or filter material (e.g., an adsorbent material) such as, for example, activated carbon, charcoal, etc., that collects and stores evaporative emissions such as, for example, hydrocarbons to reduce pollution to the environment. The emissions captured and stored by the vapor collection apparatus 128 are returned or carried to the fuel tank 102 as air is drawn from the atmosphere to the fuel tank 102 and flows through the vapor collection apparatus 128 between the outlet 134 and the inlet 130 via the venting system 118.
FIG. 2A is an enlarged view of the example grade valve assembly 110 shown in FIG. 1. FIG. 2B illustrates an exploded view of the example grade valve assembly 110 of FIGS. 1 and 2A. Referring to FIGS. 2A and 2B, the example grade valve assembly 110 includes valve 202 and a protective barrier or flange 204. The valve 202 includes a fitting 206 (e.g., a barb fitting) that is coupled to a valve body 208 (FIG. 2B). The fitting 206 receives, for example, the tubing 124 of FIG. 1 to fluidly couple the fuel tank 102 to the venting system 118 (FIG. 1). The fitting 206 and/or the valve body 208 may be composed of a plastic material (e.g., a thermoplastic material), a metallic material (e.g., stainless steel), etc. The fitting 206 and/or the valve body 208 may be manufactured via, for example, injection molding as separate pieces and may be coupled together via snap-fit connection, welding (e.g., plastic welding), fasteners (e.g., mechanical fasteners, chemical fasteners, etc.) or any other suitable fastening mechanism(s). In some examples, the fitting 206 and the valve body 208 are integrally formed as a unitary piece or structure (e.g., via injection molding).
In this example, the protective barrier 204 substantially surrounds or encircles (e.g., a peripheral or outer edge of) the valve 202 when the valve 202 is coupled to the protective barrier 204. The protective barrier 204 is shown as a cylindrically-shaped body having a cavity 210 to define a support surface 212 and an annular wall 214. In other examples, the protective barrier 204 may be square, oval or may have any other shape(s). The support surface 212 may include a recessed surface 216 (e.g., an annular recessed surface) to define a stepped or elevated rim or weld pad 218 adjacent an opening 220 (e.g., a central opening) of the support surface 212. In this example, the opening 220 is substantially axially aligned with an axis 222 of the valve body 208 when the valve 202 is coupled to the protective barrier 204. As shown in this example, the wall 214 protrudes away from the support surface 212 about a peripheral edge 224 of the recessed surface 216. The opening 220 of the support surface 212 has a diameter that is larger than an outer diameter of the valve body 208 so that the protective barrier 204 slidably receives at least a portion of the valve body 208.
The support surface 212 may also include a plurality of apertures 226 for receiving fasteners (e.g., bolts) to couple the grade valve assembly 110 to the surface 108 of the fuel tank 102. For example, the fuel tank 102 may include fasteners (e.g., nuts) that are molded (e.g., insert molded) with the surface 108 of the fuel tank 102 to receive the fasteners of the grade valve assembly 110 when coupling the grade valve assembly 110 to the fuel tank 102. Thus, the example grade valve assembly 110 is coupled to the fuel tank 102 via a clamp and compression gasket.
In this example, at least the weld pad 218 and the protective barrier 204 are composed of a thermoplastic material such as, for example, high density Polyethelyne, a polyvinyl chloride material, a nylon material, a Polyurethane Prepolymer material and/or any other thermoplastic material(s).
The valve 202 includes a flange 228 disposed between the fitting 206 and the valve body 208. The flange 228 has an outer diameter that is larger than the outer diameter of the valve body 208 and the diameter of the opening 220 so that the flange 228 engages the support surface 212 when the valve 202 is coupled to the protective barrier 204. In particular, as described in greater detail below, at least a portion of the flange 228 engages at least a portion of the weld pad 218. The wall 214 includes an access opening or port 230 to enable the tubing 124 to be coupled to the fitting 206 when the valve 202 is coupled to the protective barrier 204. The access port 230 also includes a bearing or load surface 232 to provide support to, for example, the tubing 124 when the tubing 124 is coupled to the fitting 206 to substantially reduce stress or loads that may be imparted to the fitting 206 by the tubing 124 when the tubing 124 is coupled to the fitting 206.
The grade valve assembly 110 may include a washer 236 (e.g., a metal washer) that is to be disposed within the cavity 210 and engage the recessed surface 216. The washer 236 includes an opening 238 that is coaxially aligned with the opening 220 of the support surface 212 and has a diameter that is larger than an outer diameter of the flange 228 of the valve 202 and the diameter of the weld pad 218. The washer 236 includes a plurality of apertures 240 that align with the plurality of apertures 226 of the recessed surface 216 when the washer 236 is disposed within the cavity 210. Further, in this example, the washer 236 includes an opening 242 that is to align with the access port 230 of the wall 214 when the washer 236 is disposed within the cavity 210. In this manner, the opening 242 provides clearance relative to the fitting 206 during assembly of the grade valve assembly 110 and, in some instances, depending on the thickness of the washer 236, the washer 236 will not interfere with the tubing 124 when the tubing 124 is coupled to the fitting 206. The washer 236 takes or absorbs the load provided by the fasteners when the fasteners couple the grade valve assembly 110 to the surface 108 of the fuel tank 102.
The grade valve assembly 110 may also include a seal or gasket 244 (e.g., a rubber gasket) to provide a seal between the grade valve assembly 110 and the fuel tank 102 when the grade valve assembly 110 is coupled to the fuel tank 102. As shown in FIG. 2B, the gasket 244 includes an opening 246 to receive a portion of the valve body 208 when the valve 202 is coupled to the protective barrier 204. The gasket 244 also includes a plurality of apertures 248 that align with the plurality of apertures 226 and 240 of the recessed surface 216 and the washer 236, respectively.
FIG. 3 is a plan view of the example grade valve assembly 110 of FIGS. 2A and 2B. FIG. 4A is a cross-sectional view of the example grade valve assembly 110 taken along line A-A of FIG. 3. FIG. 4B is an enlarged view of a portion of the example grade valve assembly 110 of FIG. 4A. Referring to FIGS. 4A and 4B, the fitting 206 includes an opening 402 and the valve body 208 includes an opening 404 that define a passageway 406 to allow fuel vapors and/or air to flow through the grade valve assembly 110 between the fuel tank 102 and the atmosphere via the venting system 118 (FIG. 1).
To assemble the valve 202 and the protective barrier 204, the valve 202 is disposed within the cavity 210 of the protective barrier 204. In particular, the valve body 208 is at least partially disposed within the opening 220 of the protective barrier 204 until at least a portion 408 of the flange 228 engages at least a portion 410 of the weld pad 218. In this example, the valve 202 is permanently or integrally coupled to the protective barrier 204. As noted above, both the valve 202 and the protective barrier 204 are composed of thermoplastic materials such as, for example, High Density Polyethelyne. In some examples, only the portion 408 of the flange 228 and only the portion 410 of the weld pad 218 are composed of a thermoplastic material (e.g., HDPE). Because the flange 228 and the weld pad 218 are composed of a thermoplastic material, the valve 202 can be permanently fixed or attached to the protective barrier 204 via, for example, plastic welding (e.g., hot plate welding). In particular, in this example, the portion 408 of the flange 228 and the portion 410 of the weld pad 218 of the protective barrier 204 are heated to a temperature above the melting temperature of the materials of the portions 408 and 410 of the flange 228 and the weld pad 218. When the materials of the portions 408 and 410 of the flange 228 and the weld pad 218 cool, the materials of the portions 408 and 410 integrally mesh and solidify or harden as schematically illustrated with reference numeral 412 of FIG. 4B, thereby permanently attaching the valve 202 to the protective barrier 204. In other examples, any portion of the valve 202 and/or the protective barrier 204 may be heated to permanently attach or fix the protective barrier 204 and the valve 202. Although not shown, in other examples, the protective barrier 204 may be integrally formed with the valve body 208 and/or the valve 202 as a unitary piece or structure via, for example, injection molding. For example, the protective barrier 204 may be integrally formed with the flange 228.
As shown in FIG. 4A, when the valve 202 is coupled to the protective barrier 204, the fitting 206 is positioned adjacent the access port 230 of the wall 214 and the valve 202 is at least partially recessed within the cavity 210 of the protective barrier 204 so that an upper surface 414 of the valve 202 is above an upper edge 416 of the protective barrier 204. In some examples, the valve 202 is fully recessed within the cavity 210 so that the upper surface 414 of the valve 202 is below the upper edge 416 of the wall 214. Thus, the wall 214 may be sized to extend above an upper surface (e.g., the upper surface 414) of a valve (e.g., the valve 202). The washer 236 is then disposed within the cavity 210 and adjacent the valve 202 so that the apertures 240 are substantially, coaxially aligned with the apertures 226 of the recessed surface 216 and the opening 238 is coaxially aligned with the axis 222. Further, the opening 242 of the washer 236 is substantially aligned with the access port 230 of the protective barrier 204 as most clearly shown in FIG. 3. The gasket 244 may be coupled to an under surface 418 of the protective barrier 204 such that the opening 246 of the gasket 244 receives the valve body 208 and the apertures 248 are coaxially aligned with the apertures 226 of the recessed surface 216 and the apertures 240 of the washer 236. The grade valve assembly 110 is then fastened to the surface of the fuel tank 102 via, for example, fasteners.
As noted above, the grade valve assembly 110 is coupled to the surface 108 of the fuel tank 102 via a clamp and gasket compression. Alternatively, in other examples, a surface (e.g., the surface 108 of FIG. 1) of a fuel tank (e.g., the fuel tank 102 of FIG. 1) may be implemented with a plurality of insert materials to enable a plurality of coupling apparatus or components (e.g., the grade valve assembly 110) to be coupled to the surface of the fuel tank via, for example, welding (e.g., plastic welding). Such an example insert material is described in U.S. patent application Ser. No. 12/793,005, which is incorporated herein by reference in its entirety. In yet other examples, a portion of the protective barrier 204 and/or a portion of the valve 202 may be composed of a first material or a thermoplastic material and the other portions of the valve 202 and/or the protective barrier may be composed of a second material or a thermoset material. For example, the weld pad 218 and/or the flange 228 may be composed of a thermoplastic material (e.g., HDPE) and the wall 214 and the recessed surface 216 of the protective barrier and/or the valve body 208 and the fitting 206 may be composed of a thermoset material (e.g., Ethylene Vinyl Alcohol or EVOH).
As noted above, when the grade valve assembly 100 is coupled to the fuel tank 102, the protective barrier 204 protects the valve 202 (e.g., the fitting 206) from becoming damaged during shipment (or handling) of the fuel tank 102.
Additionally or alternatively, the protective barrier 204 provides local protection to the valve 202 in compliance with certain government standards or regulations (e.g., SCG Fire safety standards per CFR 33). For example, many fuel tank coupling apparatus or components are composed of thermoplastic materials that have relatively low temperature resistance and, thus, may not be in compliance with certain government standards because such components composed of low temperature thermoplastic materials often lack sufficient protection from heat during a fire. For example, government regulations require a fuel tank coupling to withstand heat from a fire for a specific duration of time (e.g., for at least two and a half minutes).
The grade valve assembly 110 described herein provides adequate protection from fire for a duration of, for example, at least two and half minutes. For example, if flames propagate around sides of the fuel tank 102, the protective barrier 204 blocks the flames from reaching the valve 202 for a duration of time (e.g., for at least two and a half minutes). Further, the wall 214 of the protective barrier 204 provides a sacrificial structure because the wall 214 substantially surrounds the valve 202 and, thus, will be destroyed by the flames of a fire before the flames reach the valve 202.
Although not shown, in other examples, any one of the plurality of coupling apparatus or components of a fuel tank such as, for example, a vent valve, a fill line inlet valve, an anti-siphon valve, a fuel demand valve, or any other fuel tank coupling apparatus or fittings may be implemented with the example protective barrier 204 described herein. For example, the fuel demand valve 112 and/or the inlet valve 114 of the fuel tank 102 of FIG. 1 may be implemented with the example protective barrier 204 described herein.
Although certain apparatus, methods, and articles of manufacture have been described herein, the scope of coverage of this patent is not limited thereto. To the contrary, this patent covers all apparatus, methods, and articles of manufacture fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents.

## Claims

1. A method of attaching a coupling apparatus to a fuel tank, the method comprising:
coupling a barrier to an outer surface of a fuel tank, wherein the barrier includes a support surface and a wall protruding from the support surface to define a cavity;
positioning a valve in the cavity from above an upper surface of the wall of the barrier such that the valve is at least partially recessed in the cavity and relative to the upper surface of the wall, and the wall of the barrier substantially surrounds a dimensional footprint of the valve; and
plastically welding the support surface and a portion of the valve in contact with the support surface to permanently attach the valve to the support surface of the barrier.

2. The method of claim 1, further comprising coupling the barrier to the outer surface of the fuel tank prior to positioning the valve in the cavity of the barrier.

3. The method of claim 1, further comprising coupling tubing to a fitting of the valve through an access port of the wall.

4. The method of claim 1, wherein plastically welding the support surface and the portion of the valve comprises positioning a weld pad between the support surface of the barrier and the valve and heating the weld pad and the portion of the valve to a temperature that is greater than a melting temperature of a material of the weld pad and the portion of the valve.

5. The method of claim 4, further comprising cooling the weld pad and the portion of the valve to room temperature to enable the weld pad and the portion of the valve to mesh and solidify to permanently attach the valve to the barrier.

6. The method of claim 1, wherein coupling the barrier to the fuel tank comprises fastening the barrier to the outer surface of the fuel tank via fasteners that pass through respective openings of the support surface.

7. The method of claim 6, wherein coupling the barrier to the fuel tank comprises clamping the barrier to the outer surface of the fuel tank via a clamp and gasket compression.

8. A method of attaching a coupling apparatus to a fuel tank, the method comprising:
attaching a barrier to a fuel tank;
positioning a valve in a cavity of the barrier from above an upper surface of a wall of the barrier after the barrier is attached to the fuel tank such that the valve is at least partially recessed relative to the upper surface of the wall; and
plastically welding the valve and the barrier to couple the valve to the fuel tank.

9. The method of claim 8, further including positioning a weld pad in the cavity of the barrier prior to positioning the valve in the cavity such that a first side of the weld pad engages a support surface of the barrier.

10. The method of claim 9, wherein positioning the valve in the cavity of the barrier further includes positioning the valve such that a flange of the valve engages a second side of the weld pad opposite the first side.

11. The method of claim 10, further comprising heating the flange and the weld pad to plastically weld the valve and the barrier.

12. The method of claim 11, further comprising cooling the weld pad and the flange to enable the weld pad and the flange to solidify as a unitary structure to permanently attach the valve to the barrier.

13. The method of claim 9, wherein coupling the barrier to the fuel tank comprises fastening the barrier to an outer surface of the fuel tank via fasteners that pass through respective openings of the support surface.

14. A method of attaching a coupling apparatus to a fuel tank, the method comprising:
coupling a barrier to an outer surface of the fuel tank, the barrier having a support surface and a wall protruding from the support surface to define a cavity;
positioning a valve within the cavity of the barrier after the barrier is coupled to the outer surface; and
heating the support surface and a flange portion of the valve to a temperature greater than a melting temperature of a material of the flange portion to plastically weld the valve and the barrier.

15. The method of claim 14, further comprising coupling the barrier to the outer surface of the fuel tank prior to coupling the valve and the barrier.

16. The method of claim 14, further comprising providing a weld pad within the cavity prior to disposing the valve within the cavity of the barrier such that a first side of the weld pad engages the support surface of the barrier, and a second side of the weld pad opposite the first side engages the flange of the valve.

17. The method of claim 16, wherein positioning of the valve in the cavity of the barrier includes positioning the flange portion of the valve to engage the weld pad, wherein at least a portion of the valve extending from the flange of the valve is positioned in the fuel tank.

18. The method of claim 16, further comprising cooling the weld pad, the valve, and the barrier to enable the weld pad, the valve, and the barrier to solidify to permanently attach the valve to the barrier.

19. The method of claim 16, further comprising permanently attaching the weld pad to the support surface.

20. The method of claim 14, further comprising coupling tubing to a fitting of the valve via an access port formed in the wall.

21. The method of claim 14, wherein coupling the barrier to the fuel tank comprises clamping the barrier to the outer surface of the fuel tank via a clamp and gasket compression.

22. The method of claim 4, wherein the portion of the valve comprises a flange of the valve.