Automotive fuel pump housing

Abstract: An automotive fuel pump housing for a fuel pump encases a rotary pumping element (34). The housing has two portions, a cover (40) and a bottom (38). The cover has an inlet port (32) which defines a directional control surface (52) having an inclined frustoconical portion (52a) and an inclined planar portion (52b) conjoined therewith and laterally extending therefrom such that fuel flowing over the inclined frustoconical portion accelerates primarily radially and combines with fuel flowing primarily axially over the inclined planar portion, whereby the combined flow is smoothly directed to an annular cover channel (54). The bottom (38) has an annular bottom channel (56) which, when the cover and bottom are assembled, the annular cover channel (54) and annular bottom channel (56) co-operate to form the inlet channel. A transition section (62) is located at the beginning of the inlet channel and extends along a portion of the arc of the inlet channel. The transition section (62) decreases in depth from a maximum depth at the beginning thereof to the depth of the remaining portion of the inlet channel. The annular cover channel (54) has a two-step transition section depth whereas the annular bottom channel (56) has a single-step transition section depth. In addition, the radius of the base circle of the inlet channel outside of the transition section is not less than the radius of the rotary pumping element near the vane grooves.

Description: This invention relates to automotive fuel pumps, and, in particular, to a fuel pump housing having an inlet port and inlet channel configured for smooth directional control of the pumped fluid during high temperature fluid operation. Conventional tank-mounted automotive fuel pumps typically have a rotary pumping element encased within a pump housing. Fuel flows into a pumping chamber within the pump housing and the rotary pumping action of the vanes and the vane grooves of the rotary pumping element cause the fuel to exit the housing at a higher pressure. Regenerative turbine fuel pumps are commonly used to pump fuel to automotive engines because they have a higher and more constant discharge pressure than, for example, positive displacement pumps. In addition, regenerative turbine pumps typically cost less and generate less audible noise during operation. A problem may develop, however, when the pump pumps high temperature fuel at a high flow rate. When high temperature fuel (60°C - 71°C (140° F - 160° F)) is pumped at high velocity (which is required at high engine demand), cavitation may occur, which, in turn, causes pump flow to drop by as much as 40%. Thus, a single stage pump may be unable to meet high engine demand by preventing cavitation. Prior art devices overcome this problem by utilising an expensive two-stage pump. The present invention, on the other hand, overcomes this problem utilising a low cost, single-stage pump having a unique inlet port and channel configuration that improves the net positive suction head (NPSH) and hot fuel handling capability by reducing inlet flow losses and cavitation, both of which would otherwise cause fuel vaporisation and audible noise. US-A-5 364 238 discloses a fuel pump as set forth in the preamble of Claim 1 as appended hereto. According to the present invention, there is provided a fuel pump for supplying fuel from a fuel tank to an automotive engine, comprising: a pump casing; a motor mounted within said casing and having a shaft extending therefrom; a rotary pumping element slidingly engaged onto said shaft and having a plurality of vanes around an inner circumference, said inner circumference defining a rotary pumping element inner radius; and a pump housing mounted within said pump casing and encasing said rotary pumping element therein, said pump housing comprising: a cover having an inlet port with an axis and an annular cover channel in fluid communication with said inlet port, and a bottom having an annular bottom channel in fluid communication with said annular cover channel and a fuel outlet port in fluid communication with said annular bottom channel; characterised by said inlet port comprising a directional control surface defined by an inclined frustoconical portion and an inclined planar portion conjoined therewith and laterally extending therefrom such that fuel flowing over said inclined frustoconical portion accelerates primarily radially and combines with fuel flowing primarily axially over said inclined planar portion, whereby the combined flow is smoothly directed to said annular cover channel. Also, according to the present invention, there is provided a pump housing for an automotive fuel pump comprising: a cover having an inlet port and an annular cover channel in fluid communication with said inlet port; and a bottom having an annular bottom channel in fluid communication with said annular cover channel, when assembled therewith, and a fuel outlet port in fluid communication with said annular bottom channel; characterised by said inlet port comprising a directional control surface defined by an inclined frustoconical portion and an inclined planar portion conjoined therewith and laterally extending therefrom such that fuel flowing over said inclined frustoconical portion accelerates primarily radially and combines with fuel flowing primarily axially over said inclined planar portion, whereby the combined flow is smoothly directed to said annular cover channel. Accordingly, an advantage of the present invention is that hot fuel handling is improved by reducing inlet flow losses and cavitation. Another advantage of the present invention is that a low cost, single stage pump can be used to pump high temperature fuel at high velocity. Still another advantage of the present invention is that fuel vaporisation and audible noise are reduced. The invention will now be described, by way of example, with reference to the accompanying drawings, in which: Figure 1 is a cross-sectional view of a fuel pump according to the present invention; Figure 2 is a plan view of the outside of a fuel pump cover showing the inlet port of the present invention; Figure 3 is an enlarged view of the inlet port encircled by line 3 of Figure 2; Figure 4 is a cross-sectional view taken along line 4-4 of Figure 3 showing an inclined frustoconical portion of a directional control surface of the inlet port; Figure 5 is a cross-sectional view taken along line 5-5 of Figure 3 showing an inclined planar portion of the directional control surface of the inlet port; Figure 6 is a cross-sectional view taken along line 6-6 of Figure 3 showing the directional control surface of the inlet port; Figure 7 is a perspective sectional view of Figure 6 showing the directional control surface of the inlet port; Figure 8 is an enlarged view of a portion of the fuel pump encircled by line 8 of Figure 1; Figure 9 is a plan view of the inside of the fuel pump cover showing the inlet port and the cover channel of the present invention; Figure 10 is a cross-sectional view taken along line 10-10 of Figure 9 showing the profile of the cover channel of the present invention; Figure 11 is a plan view of the inside of the fuel pump bottom showing the bottom channel of the present invention; and, Figure 12 is a cross-sectional view taken along line 11-11 of Figure 12 showing the profile of the bottom channel of the present invention. Referring now to Figure 1, fuel pump 20 has casing 22 for containing motor 24, preferably an electric motor, which is mounted within motor space 26. Motor 24 has shaft 28 extending therefrom in a direction from fuel pump outlet 30 to fuel inlet 32. Rotary pumping element 34, preferably an impeller, or, alternatively, a regenerative turbine, is slidingly engaged onto shaft 28 and encased within pump housing 36, which is composed of pump bottom 38 and pump cover 40 according to the present invention. Rotary pumping element 34 has a central axis which is coincident with the axis of shaft 28. Shaft 28 passes through shaft opening 42 of rotary pumping element 34 and into cover recess 44 of pump cover 40. As seen in Figure 1, shaft 28 is journalled within bearing 46. Pump bottom 38 has fuel outlet 48 (shown in Fig. 11) leading from pumping chamber 50 formed along the periphery of rotary pumping element 34. In operation, fuel is drawn from a fuel tank (not shown), in which pump 20 may be mounted, through fuel inlet 32 in pump cover 40, and into pumping chambers 50 by the rotary pumping action of rotary pumping element 34. Pressurised fuel is discharged through fuel outlet 48 to motor space 26 and cools motor 24 while passing over it to fuel pump outlet 30. As shown in Figs. 2 and 3, fuel inlet 32 is formed in pump cover 40 such that directional control surface 52 directs fuel from fuel inlet 32 into annular cover channel 54 (See Fig. 9). Fig. 3 shows directional control surface 52 having an inclined frustoconical portion 52a on the left relative to the beginning of annular cover channel 54, with its apex located on a line parallel to, but spaced from, axis 33 of fuel inlet 32 (shown at point "X" in Fig. 3) such that fuel entering fuel inlet 32 is directed toward the right and into the plane of the page, shown as flow arrows "F 1 ". Fig. 3 further shows directional control surface 52 having an inclined planar portion 52b on the right relative to the beginning of annular cover channel 54, conjoined with and laterally extending from frustoconical portion 52a, such that fuel entering inlet 32 is directed upward and into the plane of the page, shown as flow arrows "F 2 ". The result is that the fuel exits inlet 32 at a resultant angle toward annular cover channel 54 shown as flow arrow "F". For the sake of the example shown in Fig. 3, frustoconical portion 52a is shown to the left of inclined planar 52b; however, the location and inclination of portions 52a and 52b are relative to the beginning of annular cover channel 54. That is, if annular cover channel 54 is shown counter-clockwise with rotary pumping element 34 rotating counter-clockwise, then inclined frustoconical portion 52a would be on the right of inclined planar portion 54b. Similarly, if annular cover channel 54 is positioned closer to the central axis of rotary pumping element 34, when assembled, frustoconical portion 52a and inclined planar portion 52b may be inclined downward. It should be noted that a completely planar inlet (no frustoconical portion) causes significant losses as the fuel turns to enter the inlet channel. On the other hand, a completely frustoconical inlet (no planar portion) is too restrictive because the fuel is directed toward the apex of the frustoconical portion and the fuel flow rate is reduced. According to the present invention having both a frustoconical portion and a planar portion, fuel flowing over frustoconical portion 52a accelerates primarily radially and combines with fuel flowing primarily axially over planar portion 52b, whereby the combined flow is smoothly directed to annular cover channel 54 at an acceptable fuel flow rate with minimal losses. Figs. 4 - 7 best show inclined frustoconical portion 52a and inclined planar portion 52b. Fig. 4 is a cross-sectional view of Fig. 3 taken along line 4-4 which shows inclined frustoconical portion 52a of directional control surface 52. Fig. 5 is a cross-sectional view of Fig. 3 taken along line 5-5 which shows inclined planar portion 52b of directional control surface 52. Fig. 6 is a cross-sectional view of Fig. 3 taken along line 6-6 showing both portions (52a and 52b) of directional control surface 52 in communication with annual cover channel 54. As best shown in perspective view by flow arrow "F" in Fig. 7, as fuel enters fuel inlet 32, directional control surface 52 smoothly directs the fuel toward annular cover channel 54. As is well known in the art, annular cover channel 54 and annular bottom channel 56 (see Fig. 11), when assembled, cooperate with vane grooves 58 (see Fig. 8) of rotary pumping element 34 to form pumping chamber 50. Rotary pumping action of vanes 60 on rotary pumping element 34 propels primary vortices circumferentially around annular pumping chamber 50. Vanes 60 then carry the fuel to fuel outlet 48 (see Fig. 11) at the end of annular bottom channel 56 of pump bottom 38 where the fuel exits at high pressure. According to the present invention, directional control surface 52 smoothly guides fuel into annular cover channel 54 and annular bottom channel 56 to improve the net positive suction head (NPSH) and hot fuel handling capability of fuel pump 20 by reducing the inlet flow losses and cavitation, both of which would otherwise cause fuel vaporisation and audible noise. Referring to Fig. 8, a part of planar portion 52b is shown so that angle of inclination ψ of planar portion 52b can be seen. Angle of inclination ψ is shown relative to surface 41 of cover 40. Here, angle of inclination ψ is shown non-tangential to rotary pumping element inlet angle ρ. That is, angle of inclination ψ is less than rotary pumping element inlet angle ρ by about 10° to about 45°. In a preferred embodiment, angle of inclination ψ is about 33° and rotary pumping element inlet angle ρ is about 75°. Angle of inclination ψ can also be seen in Figs. 4 and 5. This smaller angle of inclination ψ with respect to inlet angle ρ reduces the inlet velocity of the fuel at directional control surface 52, which unifies the fuel distribution throughout inlet port 32. Thus, cross-flow (fuel flow from inlet port 32 into annular bottom channel 56) capability is improved. Annular cover channel 54 and annular bottom channel 56 are both configured to form an inlet channel when assembled. The radius of the base circle of the inlet channel is preferably the same radius as inner radius 35 of rotary pumping element 34 defined by the bottom of the vane groove, at least for a portion of the inlet channel. That is, as seen in Figs. 9 and 11, annular cover channel 56 and annular bottom channel 56 have a base circle radius of 12.5 mm as indicated by "R 1 " and "R 2 " in Figs. 9 and 11, respectively, and inner radius 35 also has a radius of 12.5 mm. The purpose of this is to create a smooth transition for fuel flowing between vane grooves 58 and channels 54 and 56 (i.e. fuel flowing in pumping chamber 50). However, according to the present invention, transition section 62 (see Fig. 11) is provided in annular bottom channel 56 such that the radius previously described is slightly less than the radius of rotary pumping element 34 near the bottom of the vane groove as shown in Fig. 8. In transition section 62 of annular bottom channel 56, the base circle radius is about 12.3 mm, shown in Figs. 8 and 11 as "R 3 ", near the beginning of annular bottom channel 56. Further, according to the present invention, transition section 62 extends along an arc beginning at inlet axis 33 and having an angle  of approximately 30° - 60°, as shown in Figs. 9 and 11, in which the depth of channels 54 and 56, as measured from surfaces 41 and 39, respectively, is greater than in the remaining portion of the channels. That is, with respect to cover 40, as shown in Figs. 9 and 10, the depth of annular cover channel 54 is deeper at point "B" than at point "D", which demarcates the end of transition section 62. With respect to bottom 38, as shown in Figs. 11 and 12, the depth of annular bottom channel 56 is deeper at point "F" than at point "E", which also demarcates the end of transition section 62. Annular cover channel 54 has a two-step transition section 62 as best shown in Fig. 10 such that the depth of channel 54, as measured from surface 41, decreases from a maximum at point "B" to point "D" in two discrete steps. The first-step occurs between point "B" and point "C" in which the depth of annular cover channel 54 decreases linearly at an angle α between about 10° and 30°, preferably about 20°. Point "C" is located at an angle  which is approximately 30° as measured along the arc of transition section 62 as shown in Fig. 9. The second-step is located between point "C" and point "D" in which the depth of annular cover channel 54 decreases linearly at an angle β of about 7°. As previously indicated, point "D" demarcates the end of transition section 62. Transition section 62 of annular bottom channel 56 also decreases in depth as measured from surface 39 from a maximum at point "E" to point "F". However, this transition occurs in a single-step. As shown in Fig. 12, the depth of annular bottom channel 56 decreases linearly at an angle δ of about 4.2° from point "E" at the beginning of transition section 62 to point "F" at the end of transition section 62. This convergence of the inlet channel (as defined by annular cover channel 54 and annular bottom channel 56 when assembled) provides a smooth path for the fuel vortices to migrate toward fuel outlet 48 thereby reducing losses. In addition, the two-step transition in annular cover channel 54 improves NPSH capability. If a single step transition is used, the energy gain from rotary pumping element 34 will be delayed, which will result in undesirable cavitation. In addition, according to the present invention, pump housing 36 may be formed of a plastic material, such as moulded from phenolic, acetyl or other plastic which may or may not be glass-filled or of a non-plastic material known to those skilled in the art and suggested by this disclosure such as die cast in aluminium or steel.

Claims: A fuel pump for supplying fuel from a fuel tank to an automotive engine, comprising: a pump casing (22); a motor (24) mounted within said casing (22) and having a shaft (28) extending therefrom; a rotary pumping element (34) slidingly engaged onto said shaft (28) and having a plurality of vanes (60) around an inner circumference, said inner circumference defining a rotary pumping element inner radius (35); and a pump housing mounted within said pump casing (22) and encasing said rotary pumping element (34) therein, said pump housing comprising: a cover (40) having an inlet port (32) with an axis and an annular cover channel (54) in fluid communication with said inlet port, and a bottom (38) having an annular bottom channel (56) in fluid communication with said annular cover channel (54) and a fuel outlet port (48) in fluid communication with said annular bottom channel (56); characterised by said inlet port comprising a directional control surface (52) defined by an inclined frustoconical portion (52a) and an inclined planar portion (52b) conjoined therewith and laterally extending therefrom such that fuel flowing over said inclined frustoconical portion accelerates primarily radially and combines with fuel flowing primarily axially over said inclined planar portion, whereby the combined flow is smoothly directed to said annular cover channel (54). A fuel pump according to claim 1, wherein said inclined frustoconical portion (52a) has an apex located on a line parallel to, but space from, said axis of said inlet port (32). A fuel pump as claimed in claim 1 or 2, wherein said inclined planar portion (52b) is inclined at an angle of inclination relative to a surface (41) of said cover (40) that is less than an inlet angle of said rotary pumping element (34) relative to surface (41) of said cover (40). A fuel pump as claimed in any of claims 1,2 and 3, wherein said annular cover channel (54) has a base radius not less than said rotary pumping element inner radius (35). A fuel pump as claimed in any preceding claim, wherein at least a portion of said annular bottom channel (56) has a base radius not less than said rotary pumping element inner radius (35). A fuel pump as claimed in any preceding claim, wherein said annular cover channel (54) comprises a two-step transition section (62) extending along an arc having an angle of about 30° to about 60° from said inlet port axis and defining a transition section depth, as measured from a surface (41) of said cover (40), that is greater than an annular cover channel depth outside said transition section, the first-step in said transition section extends along an arc having an angle of about 30° from said inlet port axis and defines a depth greater than a depth in the second-step of said transition section (62). A fuel pump according to claim 6, wherein the depth of said annular cover channel (54) in said first-step as measured from a surface (41) of said cover (40) decreases linearly from a maximum depth to a depth beginning at the second-step at a first-step angle of about 10° to about 30°. A fuel pump as claimed in any preceding claim, wherein said annular bottom channel (56) comprises a transition section (62) extending along an arc having an angle of about 30° to about 60° from said inlet port axis, when assembled with said cover (40), and defining a transition section depth that is greater than an annular bottom channel depth outside said transition section (62). A pump housing for an automotive fuel pump comprising: a cover (40) having an inlet port (32) and an annular cover channel (54) in fluid communication with said inlet port (32); and a bottom (38) having an annular bottom channel (56) in fluid communication with said annular cover channel (54), when assembled therewith, and a fuel outlet port (32) in fluid communication with said annular bottom channel(56); characterised by said inlet port (32) comprising a directional control surface (52) defined by an inclined frustoconical portion (52a) and an inclined planar portion (52b) conjoined therewith and laterally extending therefrom such that fuel flowing over said inclined frustoconical portion (52a) accelerates primarily radially and combines with fuel flowing primarily axially over said inclined planar portion (52b), whereby the combined flow is smoothly directed to said annular cover channel(54). A pump housing according to claim 9, wherein said inlet port (32) has an axis and said inclined frustoconical portion (52a) has an apex located on a line parallel to, but space from, said axis of said inlet port (32) and said inclined planar portion (52b) is inclined at an angle of about 33° relative to a surface (41) of said cover (40), and wherein said annular cover channel (54) and at least a portion of said annular bottom channel (56) each have a base radius of about 12.5 mm; said annular cover channel (54) comprising a two-step annular cover channel transition section (62) extending along an arc having an angle of about 60° from said inlet port axis and defining an annular cover channel transition section depth, as measured from said surface (41) of said cover (40), that is greater than an annular cover channel depth outside said annular cover channel transition section (62), the first-step in said annular cover channel transition section (62) extends along an arc having an angle of about 30° from said inlet port axis and defines a depth greater than a depth in the second-step of said annular cover channel transition section (62), the depth in said first-step decreases linearly from a maximum depth to a depth beginning at the second-step at a first-step angle of about 20°, the depth in said second-step decreases linearly from said first-step depth to said annular cover channel depth at a second-step angle of about 7°; and, said annular bottom channel (56) comprises a single-step annular bottom channel transition section (62) extending along an arc having an angle of about 60° from said inlet port axis, when assembled with said cover (40), and defining a single-step annular bottom channel transition section depth, as measured from a surface (39) of said bottom (38), that is greater than an annular bottom channel depth outside said single-step annular bottom channel transition section (62), the depth of said single-step annular bottom channel transition section decreases linearly from a maximum depth to said annular bottom channel depth at an angle of about 4.2°.

Inventors: CASTLE HAROLD L, YU DEQUAN, CASTLE, HAROLD L., YU, DEQUAN
Applicants: FORD MOTOR CO, FORD MOTOR COMPANY
Application year: 1996
Main classification: F04D5
IPC codes: F04D29, F04D5