A fuel tank/heat shield assembly

Abstract: A heat shield retainer is provided for mounting a heat shield (60) onto a polymeric fuel tank (40). The heat shield retainer (10) comprises a nut and bolt combination (50) and a retainer body (12). The retainer body (12) has bulbous pegs (21) located on a first side thereof for engaging within corresponding sockets (43) located within a fuel tank (40) to secure the retainer body (12) to the fuel tank (40). The retainer body (12) further includes a releasable channel (22) located on a second side thereof for releasably connecting the nut (52) and bolt (54) thereto. One or more retainers of the present invention may be employed to mount a heat shield (60) onto a polymeric fuel tank (40).

Description: The present invention relates to a fuel tank/heat shield assembly and a method of forming such assembly. It is known in the prior art to use fuel tanks made from polymeric materials, such as polyethylene, in motor vehicles. Such fuel tanks are advantageous because they resist corrosion and can be easily formed having various shapes and sizes, thus permitting flexibility in their design. Further, since polymeric fuel tanks are light weight, they make the vehicles in which they are employed more fuel efficient and economical to operate. Polymeric fuel tanks, while having many advantages, are susceptible to damage caused from heat emitted by the exhaust system on a motor vehicle. In order to prevent such damage, heat shields have been used in combination with polymeric fuel tanks. The heat shields serve to reflect a harmful portion of the heat emitted from the exhaust system away from the fuel tanks. The heat shields are normally mounted to the fuel tanks a spaced distance therefrom by heat shield retainers. Air contained within the spaced distance between the heat shield and the fuel tank acts as an insulator for the fuel tank. Heat shield retainers for mounting a heat shield to a polymeric fuel tank have, in the past, been welded onto the polymeric fuel tanks in order to be connected thereto. Welding heat shield retainers onto fuel tanks, however, has been found to be inefficient and tedious. This is because, in order to connect a heat shield retainer to a polymeric fuel tank, an operator must proceed through a time consuming welding process. Accordingly, a need exists for an improved heat shield retainer whereby a simplified method may be employed for connecting the same to a plastic fuel tank. According to the present invention there is provided a fuel tank/heat shield assembly comprising, a fuel tank of a polymeric material, a heat shield for shielding said fuel tank, and retainer means for mounting said heat shield to said fuel tank, characterised in that said retainer means includes retainer body having a first side and a second side, peg fastening means located on said first side of said retainer body for securing said retainer body to said fuel tank and attachment means located on said second side of said retainer body for attaching said heat shield to said retainer body, said fuel tank including integrally moulded socket means for receiving and lockingly engaging said peg fastening means therein to secure said retainer body to said fuel tank. One or more retainers may be employed to mount a heat shield onto a polymeric fuel tank. After a polymeric tank has been formed, and before it has cooled, the respective pegs of each heat shield retainer are inserted into corresponding sockets formed in the outer surface of the fuel tank. As the tank cools, the polymeric material defining the sockets contracts about the pegs. As a result, after the tank cools, the pegs are locked within the sockets, and hence to the fuel tank. The retainer body and the peg fastening means may be integrally formed as a single unit from a polymeric material. The peg fastening means on the retainer body may comprise one or more bulbous pegs received by the socket means. The retainer body preferably includes a releasable channel means on the second side thereof for releasably connecting the attachment means to the retainer body. The attachment means may comprises a bolt and nut combination which is releasably connected to the second side of the retainer body by engagement with the channel means. The bolt comprises a main body section having a head thereon and the releasable channel means receives the head and a portion of the main body section of the bolt. The releasable channel means includes a recess defined by a wall in the retainer body. A portion of the wall has an arcuate shape defining a substantially semicircular opening of substantially the same diameter as the main body section of the bolt. The wall further has rounded surfaces spaced apart a distance slightly narrower than the main body section of the bolt to form a constriction at the entrance of the semicircular opening to releasably capture the main body section of the bolt. The heat shield protects the fuel tank from a harmful amount of heat generated by a motor vehicle by reflecting heat which would otherwise be applied to the tank. The heat shield is mounted to the fuel tank a spaced distance therefrom. The distance is defined by the retainer means and permits air contained therein to act as an insulator for the fuel tank. The heat shield is preferably made from a metallic material. The bolt comprises a main body section having a head thereon and the releasable channel means receives the head and a portion of the main body section of the bolt. The releasable channel means includes a recess defined by a wall in the retainer body. A portion of the wall has an arcuate shape defining a substantially semicircular opening of substantially the same diameter as the main body section of the bolt. The wall further has rounded surfaces spaced apart a distance slightly narrower than the main body section of the bolt to form a constriction at the entrance of the semicircular opening to releasably capture the main body section of the bolt. The fastener means may comprise one or more bulbous pegs capable of fitting into the same number of sockets in the fuel tank. In accordance with another aspect of the present invention, there is provided a method for forming a fuel tank assembly comprising the steps of, forming a fuel tank having at least one integrally moulded socket therein from heated polymeric material, providing a heat shield, providing retainer means for connecting said heat shield to said fuel tank, said retainer means including a retainer body having peg fastening means on a first side thereon for connecting said retainer body to said fuel tank, connecting said retainer body to said fuel tank by inserting said peg fastening means into said at least one socket in said fuel tank after said tank has been formed and before said tank has cooled in order to permit said socket means to contract about said peg fastening means as said tank cools, and attaching said heat shield to said retainer body. The step of attaching the heat shield to the retainer body preferably comprises the steps of: snap-fitting the bolt in a channel located in the retainer body, placing the heat shield on the retainer body and fastening the heat shield onto the retainer body by threadedly engaging and tightening the nut on the bolt. The invention will now be described further, by way of example, with reference to the accompanying drawings, in which : Fig. 1 is a schematic perspective view of a fuel tank having a heat shield mounted thereto in accordance with the method and apparatus of the present invention; Fig. 2 is a frontal view of a heat shield retainer of the present invention; Fig. 3 is a cross-sectional view of the heat shield retainer of Fig. 2 taken along section line 3-3; Fig. 4 is a side view of the nut and bolt combination of the heat shield retainer of Fig. 2; and Fig. 5 is a perspective view of the retainer body of the heat shield retainer of Fig. 2. Referring to Fig. 1, the retainer 10 of the present invention is schematically shown at three locations about a fuel tank 40 for mounting a heat shield 60 to the fuel tank 40. The fuel tank 40 is preferably made from a polymeric material, such as polyethylene. The heat shield 60 is employed to protect the polymeric fuel tank 40 from harmful amounts of heat generated by an exhaust system on a motor vehicle (not shown). The heat shield 60 is preferably made from a metallic material, such as aluminised steel, so that it may reflect a harmful portion of the heat emitted from the exhaust system away from the fuel tank 40. The heat shield 60 is mounted a spaced distance defined by the retainers 10 from the fuel tank 40. The air contained within the spaced distance between the heat shield 60 and the fuel tank 40 acts as an insulator for the fuel tank 40. The retainer 10, as best shown in Figs. 2 and 3, comprises attachment means 50 and a retainer body 12 which releasably receives the attachment means 50. The attachment means comprises a bolt 52 in combination with a nut 54. The bolt 52 includes a main body section 56 integrally formed with a substantially square-shaped base or head 58. The main body section 56 is externally threaded in order that the nut 54 may be threadedly engaged thereon. The retainer body 12 is preferably formed from a polymeric material, such as polyethylene. The retainer body 12, as best shown in Fig. 5, has a generally rectangular shape having a lower first side 14, an upper second side 16, a front face 18 and a rear face 20. Bishops or bulbous pegs 21 are located on the first side 14 thereof for connecting the retainer body 12 onto the fuel tank 40. The bulbous pegs 21 are received within corresponding sockets 43 formed into the outer surface of the fuel tank 40, as shown in Fig. 2. The retainer body 12 further includes a releasable channel 22 generally located on the second side 16 thereof. A lower open portion 24 of the channel 22 extends through the retainer body 12, between the front face 18 and the rear face 20. The head 58 of the bolt 52 is received within the lower open portion 24 of the channel 22. The channel 22 further includes an upper recess 26, as best shown in Fig. 5, which is defined by a wall 28 of the retainer body 12. A portion of the wall 28 has an arcuate shape defining a substantially semicircular opening 30 of the recess 26. The opening 30 has substantially the same diameter as the main body section 56 of the bolt 52. A further portion of the wall 28 defines an entrance 32 of the recess 26 which extends from the front face 18 and opens into the semicircular opening 30. The wall 28 further includes rounded surfaces 34 located between the portions of the wall 28 defining the entrance 32 and the semicircular opening 30. The rounded surfaces 34 are spaced apart a distance slightly narrower than the main body section 56 of the bolt 52 to form a constriction at the entrance of the semicircular opening 30. The constriction serves to capture the main body section 56 of the bolt 52, thereby releasably retaining the bolt 52 within the channel 22. A method for mounting the heat shield 60 onto the polymeric fuel tank 40 by employing at least one heat shield retainer 10 will now be described. It is first noted, that it is within the skill of one working in the art to make a determination of the required number of heat shield retainers needed to mount a given heat shield having a certain shape and weight. The retainer body 12 of each required heat shield retainer 10 is secured onto the polymeric fuel tank 40 just after the tank has been formed and before it has cooled. Each retainer body 12 is secured onto the fuel tank 40 by inserting its respective bulbous pegs 21 into corresponding sockets 43 formed within the fuel tank 40. As the tank 40 cools, the polymeric material of the fuel tank 40 defining the sockets 43 will contract around the pegs 12. As a result, after the tank cools, the pegs 21 are locked within the sockets 43, and hence to the fuel tank 40. After the heat shield retainer bodies 12 have been mounted onto the fuel tank 40, bolts 52 are snap-fitted into the channels 22 of the retainer bodies 12. The heat shield 60 is subsequently placed on the retainer bodies 12. As the heat shield 60 is placed on the retainer bodies 12, the main body section 56 of each bolt 52 extends through a corresponding opening in the heat shield 60. Thereafter, nuts 54 are threadedly engaged and tightened onto the bolts 52, thereby securing the heat shield 60 into the heat shield retainers 10, and hence the fuel tank 40.

Claims: A fuel tank/heat shield assembly comprising, a fuel tank (40) of a polymeric material, a heat shield (60) for shielding said fuel tank (40), and retainer means (10) for mounting said heat shield (60) to said fuel tank (40), characterised in that said retainer means includes retainer body (12) having a first side (14) and a second side (16), peg fastening means (21) located on said first side of said retainer body (12) for securing said retainer body to said fuel tank and attachment means (50) located on said second side of said retainer body for attaching said heat shield to said retainer body, said fuel tank (40) including integrally moulded socket means (43) for receiving and lockingly engaging said peg fastening means (21) therein to secure said retainer body (12) to said fuel tank (40). A fuel tank/heat shield assembly as claimed in claim 1, wherein said peg fastening means comprises at least one bulbous peg (21) received by said socket means (43). A fuel tank/heat shield assembly as claimed in claim 2, wherein said peg fastening means comprises two bulbous pegs (21) received by said socket means (43). A fuel tank/heat shield assembly as claimed in claim 1, wherein said attachment means (50) comprises a bolt (52) and nut (54) combination. A fuel tank/heat shield assembly as claimed in claim 1, wherein said retainer body includes releasable channel means (22) on said second side (16) thereof for releasably connecting said attachment means (50) to said retainer body (12). A fuel tank/heat shield assembly as claimed in claim 5, wherein said attachment means (50) comprises a bolt (52) and nut (54) combination, said bolt and nut combination being releasably connected to said second side (16) of said retainer body (12) by engagement with said channel means (22). A fuel tank/heat shield assembly as claimed in claim 6, wherein said bolt (52) comprises a main body section (56) having a head (58) thereon and said releasable channel (22) means receives said head (58) and a portion of said main body section of said bolt, said releasable channel means (22) including a recess defined by a wall (28) in said retainer body (12), a portion of said wall (28) having an arcuate shape defining a substantially semicircular opening (30) of substantially the same diameter as the main body section (50) of said bolt (52), said wall further having rounded surfaces (34) spaced apart a distance slightly narrower than the main body section (56) of said bolt (52) to form a constriction at the entrance of said semicircular opening (30) to releasably capture said main body section (56) of said bolt. A fuel tank/heat shield assembly as claimed in claim 1, wherein said heat shield (60) serves to protect said fuel tank (40) from a harmful amount of heat generated by a motor vehicle by reflecting heat which would otherwise be applied to said tank, and wherein said heat shield (60) is mounted to said fuel tank (40) a spaced distance therefrom, said distance being defined by said retainer means (10) and permitting air contained therein to act as an insulator for said fuel tank (40). A method for forming a fuel tank assembly comprising the steps of, forming a fuel tank (40) having at least one integrally moulded socket (43) therein from heated polymeric material, providing a heat shield (60), providing retainer means (10) for connecting said heat shield (60) to said fuel tank (40), said retainer means (10) including a retainer body (12) having peg fastening means (21) on a first side (14) thereon for connecting said retainer body (12) to said fuel tank (40), connecting said retainer body (12) to said fuel tank (40) by inserting said peg fastening means (21) into said at least one socket (43) in said fuel tank after said tank has been formed and before said tank has cooled in order to permit said socket means (43) to contract about said peg fastening means (21) as said tank cools, and attaching said heat shield (60) to said retainer body (12). A method for forming a fuel tank assembly as claimed in claim 9, wherein said retainer means (10) further includes a channel (22) located on said retainer body )12) and a bolt (52) and nut (54) combination, and wherein said step of attaching said heat shield (60) to said retainer body (12) comprises the steps of, snap-fitting said bolt (52) in said channel (22) located in said retainer body (12), placing said heat shield (60) on said retainer body (12) , and fastening said heat shield (60) onto said retainer body (12) by threadedly engaging and tightening said nut (54) on said bolt (52).

Inventors: BRYANS THOMAS J, HYDE JAMES P, BRYANS, THOMAS J., HYDE, JAMES P.
Applicants: FORD FRANCE, FORD MOTOR CO, FORD WERKE AG, FORD FRANCE S. A., FORD MOTOR COMPANY LIMITED, FORD-WERKE AKTIENGESELLSCHAFT
Application year: 1991
Main classification: B60K15
IPC codes: B60K15, B29C49