Abstract:
Provided is a fuel pump module used for a car, and more particularly, to a fuel pump module with a driver equipped inside a fuel tank capable of solving a problem of space limitation due to the installation of the driver by disposing the driver for controlling a BLDC fuel pump between a flange and a reservoir and mounting it in the fuel tank, minimizing the degradation in performance of the BLDC fuel pump caused by voltage drop and efficiency degradation due to a wire by reducing a length of a wire for electrically connecting the driver with the BLDC fuel pump, and achieving a sufficient heat radiation effect by directly transferring the heat energy generated from electrical devices such as FET, MCU, or the like, mounted in the driver to the fuel in the fuel tank through the case cover.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority under 35 U.S.C. §119 to Korean Patent Application No. 10-2010-0014938, filed on Feb. 19, 2010, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference in its entirety. 
     TECHNICAL FIELD 
     The present invention relates to a fuel pump module used for a car, and more particularly, to a fuel pump module with a driver equipped inside a fuel tank capable of solving a problem of space limitation due to the installation of the driver by disposing the driver for controlling a brushless direct current (BLDC) fuel pump between a flange and a reservoir and mounting it in the fuel tank, minimizing degradation in performance of the BLDC fuel pump caused by a voltage drop and efficiency degradation due to a wire by reducing a length of a wire for electrically connecting the driver with the BLDC fuel pump, and achieving a sufficient heat radiation effect by directly transferring the heat energy generated from electrical devices such as FET, MCU, or the like, mounted in the driver to the fuel in the fuel tank through the case cover. 
     BACKGROUND 
       FIG. 1  shows an exploded perspective view of a driver  10  according to the related art, a BLDC fuel pump module  20 , and a connector  30  for electrically connecting the driver  10  and the BLDC fuel pump module  20 . 
     In order to drive a BLDC pump operated by a BLDC motor, there is a need for a control device referred to as the driver  10  for controlling a conducting sequence of current applied to each of the phases U, V, and W and Rpm. 
     The BLDC fuel pump module  20  is fastened to the fuel tank (not shown) in a state where the top surface of the flange  21  is exposed to the outside of the fuel tank (not shown) and the remaining components are installed to be disposed in the fuel tank (not shown). 
     In the related art, the BLDC fuel pump module  20  supplying necessary pressure and flux to an engine separates from the driver  10 , thereby causing problems in limitation in an installation position and a distance due to a length of a power supplying wire  30  for electrically connecting between the driver  10  and the BLDC fuel pump module  20  and efficiency degradation due to the voltage drop of the wire  30 , when the driver is applied to a vehicle. 
     In addition, in the related art, the driver  10  is mounted on the outside of the vehicle, such that it is exposed to vibrations of a vehicle or foreign materials (moisture, dust, etc.). Therefore, the related art increases costs for handling the above-mentioned problems and needs countermeasures against EMC. 
     SUMMARY 
     An object of the present invention is to provide a fuel pump module with a driver equipped inside a fuel tank capable of solving a problem of space limitation due to the installation of the driver by disposing the driver between a flange and a reservoir and mounting it in the fuel tank, minimizing degradation in performance of the BLDC fuel pump caused by a voltage drop and efficiency degradation due to a wire by reducing a length of a wire for electrically connecting the driver with the BLDC fuel pump, and achieving a sufficient heat radiation effect by directly transferring the heat energy generated from electrical devices such as FET, MCU, or the like, mounted in the driver to the fuel in the fuel tank through the case cover. 
     According to an exemplary embodiment of the present invention, there is provided a BLDC fuel pump module including a flange having the top surface exposed to the outside and fastened to a fuel tank, a support bar having the top end connected to the bottom end of the flange and extended downward, and a reservoir connected to the bottom end of the support bar and including a BLDC fuel pump embedded therein, the BLDC fuel pump module including: driver cases disposed between the flange and the reservoir and mounted in the fuel tank; a driver embedded in the driver cases to control the BLDC fuel pump; a first connector housing provided in the driver cases and seated with a first connector supplying power applied through the flange to the driver; and a second connector housing provided in the driver cases and seated with a second connector electrically connecting the driver with the BLDC fuel pump. 
     The driver cases may include a case main body having an opened bottom surface so that the driver can be installed into the case main body so as to be assembled and a case cover disposed at the bottom portion of the driver and fastened to the bottom surface of the case main body, and epoxy is filled between the top surface of the driver and the inner top surface of the case main body through an epoxy injection hole formed in the driver in order to prevent the injection of fuel. 
     The BLDC fuel pump module may further include: a fastening protrusion formed on the bottom circumferential surface of the case main body; and an elastic fastening plate protruded upward from the edge of the case cover, provided with a fastening groove fastened to the fastening protrusion, and made of an elastic material to apply an elastic force in the bottom circumferential direction of the case main body. 
     The case cover may be fastened to the case main body by heat-caulking the cover fastening part formed to be protruded on the bottom end of the case main body. 
     The bottom end of the case main body may be provided with a ring insertion groove, and the ring insertion groove is provided with an elastic ring of an elastic material mounted so that the case main body is closely fastened to the case cover. 
     The case cover may be made of an aluminum material or a stainless steel (SUS) material in order to efficiently discharge heat generated from electrical devices mounted in the driver to the outside. 
     The first connector housing and the second connector housing may be each formed on the top surface or the side of the driver case. 
     The BLDC fuel pump module may further include: a top support bar guide pipe formed in the driver cases in order to guide the support bar while being inserted with the support bar; an intank filter formed with a bottom support bar guide pipe to guide the support bar passing through the top support bar guide pipe while being inserted with the support bar and mounted with the BLDC fuel pump; a top support bar spring inserted into the support bar and having the top end elastically contacting the flange and the bottom end elastically contacting the top end of the top support bar guide pipe; and a bottom support bar spring inserted into the support bar and having the top end elastically contacting the bottom end of the top support bar guide pipe and the bottom end elastically contacting the top end of the bottom support bar guide pipe. 
     The BLDC fuel pump module may further include: a sub-support bar insertion pipe formed in the driver cases and having the closed top end and the opened bottom end; a sub-support bar guide pipe formed in the intank filter and having the opened top and bottom ends; a sub-support bar guided while being inserted into the sub-support bar guide pipe and having the top end inserted into the sub-support bar insertion pipe; and a sub-support bar spring inserted into the sub-support bar and having the top end elastically contacting the bottom end of the sub-support bar insertion pipe and the bottom end elastically contacting the top end of the sub-support bar guide pipe. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an exploded perspective view of a driver of the related art, a BLDC fuel pump module, and a connector for electrically connecting the driver with the BLDC fuel pump module; 
         FIG. 2  is a perspective view of an exemplary embodiment of the present invention; 
         FIG. 3  is an exploded perspective view of the exemplary embodiment of the present invention. 
         FIGS. 4 to 7  are rear perspective views of main components of the exemplary embodiment of the present invention; 
         FIGS. 8 and 9  are rear perspective views of main components of another exemplary embodiment of the present invention; and 
         FIGS. 10A to 10C  are assembling process diagrams of main components of the exemplary embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     Hereinafter, an exemplary embodiment of the present invention will be described in detail with reference to the accompanying drawings. 
       FIG. 2  is a perspective view of an exemplary embodiment of the present invention,  FIG. 3  is an exploded perspective view of the exemplary embodiment of the present invention,  FIGS. 4 to 7  are rear perspective views of main components of the exemplary embodiment of the present invention,  FIGS. 8 and 9  are rear perspective views of main components of another exemplary embodiment of the present invention, and  FIGS. 10A to 10C  are assembling process diagrams of main components of the exemplary embodiment of the present invention. 
     Referring to  FIGS. 2 and 3 , the exemplary embodiment of the present invention may be configured to include a flange  110 , driver cases  130  and  140 , a reservoir  210 , an intank filter  310 , and a BLDC fuel pump  410 . 
     Although not shown in  FIGS. 2 and 3 , the flange  110  is fastened to a fuel tank (not shown) so that the top surface thereof is exposed to the outside of the fuel tank (not shown) and the bottom surface thereof is disposed in the fuel tank (not shown). 
     Referring to  FIG. 2 , the driver cases  130  and  140  are disposed between the flange  110  and the reservoir  210  and are mounted in the fuel tank (not shown). 
     Referring to  FIG. 3 , the driver cases  130  and  140  include a case main body  130  and a case cover  140 . 
     Referring to  FIGS. 4 and 5 , in order to enter the driver  120  into the case main body  130  to be assembled, the bottom surface of the case main body  130  is opened. The driver  120  is a control device controlling the BLDC fuel pump  410 . The driver  120  may be a PCB in which predetermined electrical devices for controlling the BLDC fuel pump  410  are mounted. Meanwhile, the driver  120  is provided with an epoxy injection hole  120 - h.  The epoxy injection hole  120 - h  may be formed at an edge of the driver  120 . Epoxy is filled between the top surface of the driver  120  and the inner top surface of the case main body  130  through the epoxy injection hole  120 - h . Due to the filling of epoxy, it is possible to prevent the fuel in the fuel tank (not shown) from permeating between the top surface of the driver  120  and the inner top surface of the case main body  130 . In addition, the epoxy is filled in the case main body  130  and as described below, a top support bar spring  151  and a bottom support bar spring  152  are inserted into a support bar  150  and a sub-support bar spring  152 ′ is inserted into a sub-support bar  150 ′, such that the driver is not almost affected by the vibrations of a vehicle. The epoxy may be filled to cover the bottom surface of the driver  120 . Meanwhile, according to the exemplary embodiment of the present invention, the driver  120  is mounted in the fuel tank (not shown) without being mounted on the outside of the vehicle, such that it has sufficient stability against EMC. 
     Referring to  FIGS. 3 and 6 , the case cover  140  is disposed at the bottom portion of the driver  120  and is fastened to the bottom surface of the case main body  130 . That is, the case cover  140  is fastened to the bottom end of the driver  120  after the epoxy is filled between the top surface of the driver  120  and the inner top surface of the case main body  130 . The case cover  140  is fastened to the bottom end of the driver  120 , such that the driver  120  is sealed from the outside to be protected. 
     Referring to  FIG. 6 , the bottom circumferential surface of the case main body  130  is provided with fastening protrusions  134 . 
     Referring to  FIG. 6 , the case cover  140  is provided with an elastic fastening plate  144  to be protruded upward along an edge thereof. The elastic fastening plate  144  is provided with a fastening groove  144 - h  fastened to the fastening protrusion  134 . The elastic fastening plate  144  is made of an elastic material to apply an elastic force to the bottom circumferential surface of the case main body  130 . That is, the elastic fastening plate  144  is closely attached to the bottom circumferential surface of the case main body  130  by elastic force in the state where it is fastened to the fastening protrusion  134 , such that the fastening force between the case main body  130  and the case cover  140  is maintained. 
     Meanwhile, the case cover  140  is made of a material having large thermal conductivity to radiate heat, preferably, an aluminum material or an SUS material. As the case cover  140  is made of the aluminum material or the SUS material, the heat radiation of the case cover  140  is improved, such that the heat generated due to electrical devices such as FET, MCU, etc., mounted in the driver  120  is effectively discharged to the outside. 
     Referring to  FIG. 7 , the bottom end of the case main body  130  may be provided with a ring insertion groove  130 - h . The ring insertion groove  130 - h  is inserted with an elastic ring 
     R of an elastic material. The case main body  130  is more closely attached to the case cover  140  by inserting the elastic ring R into the ring insertion groove  130 - h , such that the possibility of fuel permeating into the fuel tank (not shown) is further reduced. The elastic ring R may be made of a rubber material. 
     Referring to  FIG. 3 , the top surface of the case main body  130  is provided with a first connector housing  131  and a second connector housing  132 . Differently from  FIG. 3 , any one or both of the first connector housing  131  and the second connector housing  132  may be provided on the side of the case main body  130 . 
     The first connector housing  131  is seated with the first connector (not shown) . The first connector (not shown) is a connector for supplying power applied through the flange  110  to the driver  120 . That is, referring to  FIG. 3 , one side of the first connector module  421  is connected with the flange  110  and the other side thereof is inserted into the first connector housing  131 , such that the power applied through the flange  110  is supplied to the driver  120 . 
     The second connector housing  132  is seated with the second connector (not shown) . The second connector (not shown) is a connector for electrically connecting the driver  120  with the BLDC fuel pump  410 . That is, referring to  FIG. 3 , one side of the second connector module  422  is connected to the second connector housing  132  and the other side thereof is connected to the BLDC fuel pump  410 , such that the driver  120  is electrically connected with the BLDC fuel pump  410 . 
     Referring to  FIG. 3 , the intank filter  310  is mounted in the reservoir  210  and the receiving groove (not shown) formed at the central portion of the intank filter  310  is mounted with the BLDC fuel pump  410 . The BLDC fuel pump  410  is a BLDC pump driven by a BLDC driver. 
     Referring to  FIG. 3 , the bottom surface of the reservoir  210  is mounted with a check valve  220 . In addition, a regulator  230  is mounted from the outside of the reservoir  210 , such that the end of the regulator  230  is disposed in the reservoir  210 . The end of the regulator  230  is connected to the intank filter  310  and some of the fuel supplied to the engine from the intank filter  310  may be returned to the reservoir  210  through the regulator  230 . In addition, when some of the fuel supplied to the engine from the intank filter  310  is returned to the reservoir  210  through the regulator  230 , the end of the regulator  230  may communicate with the fuel tank (not shown) through a connection pipe (not shown) so that the fuel in the fuel tank (not shown) may be injected into the reservoir by an orifice effect. 
     Referring to  FIG. 3 , the bottom end of the BLDC fuel pump  410  is mounted with a primary filter  430 . The primary filter  430  filters the fuel in the reservoir  210  and then, injects it into the BLDC fuel pump  410 . That is, the fuel passing through the primary filter  430  is absorbed through the BLDC fuel pump  410 , filtered through the intank filter  310 , and then, supplied to the engine. 
     Reference numeral  500  indicates a fuel gage module, which is connected to the reservoir  210  to be seated into the fuel tank (not shown). 
     Referring to  FIGS. 3 and 10A  to  10 C, the bottom surface of the flange  110  is connected with the top end of the support bar  150 . 
     Referring to  FIGS. 2 ,  3 , and  10 A to  10 C, the driver cases  130  and  140  are mounted with a top support part guide pipe  130 - 1  to guide the support bar  150  while being inserted with the support bar  150 . The top support bar guide pipe  130 - 1  may be formed on the outer circumferential surface of the case main body  130  and is formed to open the top and bottom ends thereof . 
     Referring to  FIGS. 3 and 10C , the intank filter  310  is provided with a bottom support bar guide pipe  310 - 1  mounted with the BLDC fuel pump  410 . The bottom support bar guide pipe  310 - 1  may be formed on the outer circumferential surface of the intank filter  310  and is formed to open the top and bottom ends thereof . The bottom support bar guide pipe  310 - 1  is to guide the support bar  150  passing through the top support bar guide pipe  130 - 1  while being inserted with the support bar  150 . 
     Referring to  FIGS. 2 ,  3 , and  10 A to  10 C, the top portion of the support bar  150  is inserted with a top support bar spring  151 . The top end of the top support bar spring  151  is mounted to elastically contact the flange  110  and the bottom end thereof is mounted to elastically contact the top end of the top support bar guide pipe  130 - 1 . 
     Referring to  FIGS. 2 ,  3 , and  10 A to  10 C, the bottom portion of the support bar  150  is inserted with the bottom support bar spring  152 . The top end of the bottom support bar spring  152  elastically contacts the bottom end of the top support bar guide pipe  130 - 1  and the bottom end thereof elastically contacts the top end of the bottom support bar guide pipe  130 - 1 . 
     Referring to  FIGS. 2 ,  3 , and  10 A to  10 C, the driver cases  130  and  140  are mounted with a sub-support bar insertion pipe  130 - 2  of which the top end is closed and the bottom end is opened. 
     The sub-support bar insertion pipe  130 - 2  may be formed at the outer circumferential surface of the case main body  130 . 
     Referring to  FIGS. 3 and 10C , the intank filter  310  is provided with a sub-support bar guide pipe  310 - 2 . The sub-support bar guide pipe  310 - 2  may be formed on the outer circumferential surface of the intank filter  310  and is formed to open the top and bottom ends thereof. 
     Referring to  FIGS. 3 and 10B  to  10 C, the sub-support bar guide pipe  310 - 2  guides a sub-support bar  150 ′ while being inserted with the sub-support bar  150 ′ . Meanwhile, the top end of the sub-support bar  150 ′ may be inserted into the sub-support bar inserting pipe  130 - 2 . 
     Referring to  FIGS. 2 ,  3 , and  10 B to  10 C, the sub-support bar spring  152 ′ is inserted into the sub-support bar  150 ′ . The top end of the sub-support bar spring  152 ′ elastically contacts the bottom end of the sub-support bar insertion pipe  130 - 2  and the bottom end thereof elastically contacts the top end of the sub-support bar guide pipe  310 - 2 . 
     Meanwhile, each of the bottom ends of the support bar  150  and the sub-support bar  150 ′ are fixedly mounted to the reservoir  210 . That is, the reservoir body assembly (not shown) including the reservoir  210 , the intank filter  310 , the BLDC fuel pump  410 , etc., is fastened to the flange  110  through the support bar  150  to be fixedly mounted in the fuel tank. 
       FIGS. 2 ,  3 , and  10 A to  10 C show that each of the support bar  150  and the sub-support bar  150 ′ is two of each, but the number thereof is not limited thereto. For example, each of the support bar  150  and the sub-support bar  150 ′ may be three of each. 
     Referring to  FIG. 10C , the above-mentioned exemplary embodiment relieves vibrations by the top support bar spring  151  inserted into the support bar  150  and the sub-support bar spring  152 ′ inserted into the bottom support bar spring  152  and the sub-support bar  150 ′ when the vehicle is vibrating, such that the driver  120  mounted in the driver cases  130  and  140  is not almost affected by the vibrations of the vehicle. 
     Meanwhile, referring to  FIGS. 8 and 9 , another exemplary embodiment of the present invention may protrudedly form a cover fastening part  136  on the bottom end of the case main body  130  in order to fasten the case main body  130  to the case cover  140 . The case main body  130  is mutually fastened to the case cover  140  by heat-caulking the cover fastening part  136  on the bottom surface of the case cover  140  in the state where the case cover  140  is closely attached to the bottom end of the case main body  130 . 
     Hereinafter, the operation of the exemplary embodiment will be described. 
     The exemplary embodiment solves the problem of space limitation due to the installation of the driver  120  in the vehicle since the driver  120  is mounted in the fuel tank (not shown). 
     In addition, the exemplary embodiment reduces the length of the wire for electrically connecting the driver  120  with the BLDC fuel pump  410  since the driver  120  is disposed between the flange  110  and the reservoir  210  and is mounted in the fuel tank (not shown) . Therefore, the exemplary embodiment can minimize the degradation in performance of the BLDC fuel pump  410  caused by the voltage drop and the efficiency degradation due to the wire for electrically connecting the driver  120  with the BLDC fuel pump  410 . 
     In addition, according to the exemplary embodiment, the driver  120  can have the sufficient stability against the EMC and is not almost affected by the vibrations of the vehicle since the driver  120  is disposed between the flange  110  and the reservoir  210  and is mounted in the fuel tank (not shown) , the epoxy is filled in the driver cases  130  and  140 , the top support bar spring  151  and the bottom support bar spring  152  are inserted into the support bar  150 , and the sub-support bar spring  152 ′ is inserted into the sub-support bar  150 ′. 
     Moreover, the exemplary embodiment can prevent the fuel in the fuel tank (not shown) from permeating into the driver  120  since the epoxy having oil resistance is filled in the driver cases  130  and  140 . 
     Further, according to the exemplary embodiment, the case cover  140  is made of the aluminum material or the SUS material to directly transfer the heat energy generated from the electrical devices such as FET, MCU, or the like, mounted in the driver  120  to the fuel in the fuel tank (not shown) through the case cover  140 , thereby making it possible to achieve the sufficient heat radiation effect. 
     The present invention can solve the problem of space limitation due to the installation of the driver when being mounted in the vehicle by mounting the driver in the fuel tank. 
     The present invention can reduce the length of the wire for electrically connecting the driver with the BLDC fuel pump by mounting the driver between the flange and the reservoir and mounting it in the fuel tank. Therefore, the present invention can minimize degradation in performance of the BLDC fuel pump caused by the voltage drop and efficiency degradation due to the wire for electrically connecting the driver with the BLDC fuel pump. 
     The present invention can provide sufficient stability against the EMC by disposing the driver between the flange and the reservoir and mounting it in the fuel tank and allow the driver not to be affected by the vibrations of the vehicle by filling the epoxy in the driver cases, inserting the top support bar spring and the bottom support bar spring into the support bar, and inserting the sub-support bar spring into the sub-support bar. 
     The present invention can prevent the fuel in the fuel tank from being permeated into the driver by filling epoxy having oil resistance into the driver cases. 
     The present invention includes the case cover of the aluminum material or the SUS material to directly transfer the heat energy generated from the electrical devices such as FET, 
     MCU, or the like, mounted in the driver to the fuel in the fuel tank (not shown) through the case cover, thereby making it possible to achieve a sufficient heat radiation effect. 
     The present invention is not limited to the embodiment described herein and it should be understood that the present invention may be modified and changed in various ways without departing from the spirit and the scope of the present invention. Therefore, it should be appreciated that the modifications and changes are included in the claims of the present invention.