Abstract:
A fuel module mountable on the fuel tank of a vehicle has a bottom cover extending below the fuel tank. The bottom cover can be quickly removed from the module to allow easy access to the fuel filter in the module.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates generally to fuel modules, and more particularly to fuel modules for motor vehicles. 
       BACKGROUND OF THE INVENTION 
       [0002]    Fuel modules have been provided in which much of a vehicle&#39;s fuel system is enclosed in a single housing. Thus, a fuel module may include a fuel pump, a fuel strainer, a pressure regulator, and a fuel filter, and typically is mounted on or in the fuel tank of the vehicle. 
         [0003]    As recognized herein, it is sometimes necessary to replace the filter in the module, but this requires removing the entire module from the fuel tank and disassembling it. As further recognized herein, it would be desirable to provide a means to quickly and easily access the filter for replacement without having to remove the entire module from the tank. 
       SUMMARY OF THE INVENTION 
       [0004]    A fuel module for a vehicle has a housing with an open bottom end, a fuel pump supported by the housing, and a fuel filter in the housing and having a lower end juxtaposed with the open bottom end of the housing. The fuel filter is sized to pass through the open bottom end. A bottom cover is releasably engaged with the housing by a quick disconnect mechanism to selectively cover the open bottom end. With this structure, the bottom cover is removable by hand from the housing by means of the quick disconnect mechanism. If desired, a fuel pressure regulator can be in the housing in communication with the fuel pump. 
         [0005]    In some implementations the quick disconnect mechanism may include one more hollow brackets on the cover or the housing and one or more protrusions on the other of the housing or the cover and snappingly engageable with the bracket. In particular non-limiting implementations the quick disconnect mechanism includes first and second brackets on the cover and first and second protrusions on the housing. 
         [0006]    In alternate implementations the quick disconnect mechanism includes a threaded part on the cover engaging a threaded part on the housing. In still other implementations the quick disconnect mechanism includes a bayonet channel on the cover or housing and a detent on the other of the housing or cover slidably engaging the bayonet channel. In yet other implementations the quick disconnect mechanism includes a cam-lock mechanism. 
         [0007]    In another aspect, a fuel module for a vehicle includes a housing disposable in a fuel tank of the vehicle for supporting a fuel pump in the tank and a fuel filter in the housing and having a lower end juxtaposed with an open bottom end of the housing. The fuel filter is sized to pass through the open bottom end. A bottom cover is engageable with and removable from the housing by means of a quick disconnect mechanism to provide access to the fuel filter without removing the module from the tank. 
         [0008]    In still another aspect, in a fuel module having a housing configured for placement in a fuel tank to support a fuel pump and a fuel filter, with the housing being formed with an access through which the fuel filter can be replaced, a cover is configured for blocking the access. Quick disconnect means are provided for releasably holding the cover onto the housing. 
         [0009]    The details of the present invention, both as to its structure and operation, can best be understood in reference to the accompanying drawings, in which like reference numerals refer to like parts, and in which: 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is a perspective view of the fuel module with bottom cover engaged with the housing, with portions of the fuel tank cut away for clarity and with the fuel pump shown in phantom; 
           [0011]      FIG. 2  is an exploded perspective view of the fuel module with bottom cover disengaged with the housing and with the fuel filter shown part way out of the housing, with portions of the fuel tank cut away for clarity and with the fuel pump shown in phantom; 
           [0012]      FIG. 3  is a schematic side view of the fuel module showing the internal components and fuel flow; 
           [0013]      FIG. 4  is a perspective view of an alternate embodiment in which the quick disconnect mechanism is established by threads; and 
           [0014]      FIG. 5  is a perspective view of an alternate embodiment in which the quick disconnect mechanism is established by a bayonet-style coupling between the cover and housing. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0015]    The present invention is intended for application in automotive vehicle systems and will be described in that context. It is to be understood, however, that the present invention could also be successfully applied in many other applications including non-vehicle applications. 
         [0016]    Referring initially to  FIGS. 1 and 2 , a fuel module is shown, generally designated  10 , that includes a fuel module housing  12  disposed mainly within a fuel tank  14  of a vehicle  16 , and more specifically in the non-limiting embodiment shown the housing  12  rests on the bottom of the tank  14 . A bottom cover  18  is releasably engaged with the housing  12  at the bottom of the tank  14  and outside the tank to cover an open bottom  20  ( FIG. 2 ) of the housing, such that a fuel filter  22  may be advanced into or removed from the housing  12  through the open bottom  20 . The cover  18  may be formed with a fuel supply tube  24  as shown to which a fuel line can be connected to convey fuel to the engine. 
         [0017]    Both the housing  12  and cover  18  may be respective unitary pieces of material such as plastic or metal. 
         [0018]    In the non-limiting embodiment shown in  FIGS. 1 and 2 , the cover  18  is easily and quickly engageable with and disengageable from the housing  18  by hand by means of the quick disconnect mechanism that includes first and second brackets  26  on opposite upper portions of the cover  18  from each other and first and second protrusions  28  on opposite lower portions of the housing from each other. In some implementations the brackets can be on the housing and the protrusions on the cover. In any case, to engage the cover  18  with the housing in the embodiment shown, the cover is advanced upwardly past the housing with the brackets  26  riding against the protrusions  28 , causing the brackets to deform slightly outwardly. When the protrusions  28  are juxtaposed with the openings in the brackets  26 , the brackets snap back against the lower part of the housing  12  as shown in  FIG. 1  to hold the cover  18  onto the housing  12  at the bottom of the fuel tank, closing the open bottom  20  of the housing  12 . In some implementations the brackets  26  may be deformed outwardly by hand to fit them over the protrusions  28 . The protrusions  28  are formed complementarily to the openings of the brackets  26  as shown. 
         [0019]    To remove the cover  18  from the housing  12 , a person need only deform the brackets  26  outwardly either by pulling them apart gently by hand or simply by pulling the cover  18  down away from the housing  12 , causing the protrusions  28  to clear the openings of the brackets  26 . With the cover  18  disengaged from the housing  12 , the fuel filter  22  may be removed from the housing  12  through the open bottom end  20  and replaced with another filter. A seal such as an o-ring or gasket may be provided between the cover  18  and housing  12 . 
         [0020]      FIG. 3  shows additional details of the non-limiting fuel module shown in  FIGS. 1 and 2 . As shown, a fuel pump  30  can be supported inside the fuel tank in a pump receptacle  32  of the housing  12 . Arrows in  FIG. 3  show that the fuel path starts by entering an intake  33  of the fuel pump from the tank near a pump electrical connector  34 , also supported on the housing  12  as shown. The fuel is pumped through a delivery tube  36  to the intake  38  of a filter portion  40  of the housing  12  which closely surrounds the fuel filter  22 . Some of the fuel passes down through the fuel filter  22  and out of the fuel supply tube  24  to the engine, while some of the fuel is recirculated up through a pressure regulator  42 , which regulates fuel pressure. From the pressure regulator  42 , the fuel can pass through a strainer  44  and back into the pump intake  33 . 
         [0021]    Other connection mechanisms between the cover and fuel module housing may be used. For example,  FIG. 4  shows that a fuel module  200  may include a module housing  202  and a cover  204  that in all essential respects are identical to the cover  18  and housing  12  shown in  FIGS. 1-3 , except that a threaded mechanism is used to removably connect the cover  204  to the module housing  202 . Specifically, an upper portion  206  of the cover  204  may be externally threaded as shown for engaging an internally threaded lower portion  208  of the housing  202 . The male/female relationship can be reversed between the cover and housing if desired. 
         [0022]    Or, as shown in  FIG. 5  a fuel module  300  may include a module housing  302  and a cover  304  that in all essential respects are identical to the cover  18  and housing  12  shown in  FIGS. 1-3 , except that a bayonet connection mechanism is used to removably connect the cover  304  to the module housing  302 . Specifically, a generally L-shaped bayonet channel  306  with a vertical part  308  extending up from the open bottom end  310  and terminating in a generally horizontal part  312  may be formed on the housing  302 , while a detent  314  may project outwardly from the upper part of the cover  304 . To engage the cover  304  with the housing  302 , the detent  314  is slid up into the vertical part  308  of the bayonet channel  306  until it reaches the horizontal part  312 , at which time the cover  304  is rotated to slide the detent  314  to the end of the horizontal part  312 . The process is reversed to remove the cover  304  from the housing  302 . The detent may be provided on the housing and the bayonet channel on the cover if desired. 
         [0023]    A cam lock-style mechanism may also be used. Non-limiting examples of such mechanisms are given in electrical contexts in the following U.S. patents owned by the present assignee and incorporated herein by reference: U.S. Pat. Nos. 6,896,531, 6,846,191, 6,761,568, 6,422,881, and 6,193,528. 
         [0024]    While the particular FUEL MODULE WITH QUICK DISCONNECT COVER FOR EASY FILTER REPLACEMENT is herein shown and described in detail, it is to be understood that the subject matter which is encompassed by the present invention is limited only by the claims. For example, in addition to the above connection mechanisms, other quick connect/quick disconnect type of mechanisms may be used.