Patent Publication Number: US-7222610-B2

Title: Fuel feed apparatus having small sized structure

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
   This application is based on and incorporates herein by reference Japanese Patent Application No. 2003-149079 filed on May 27, 2003. 
   FIELD OF THE INVENTION 
   The present invention relates to a fuel feed apparatus that supplies fuel in a fuel tank to the outside of the fuel tank. 
   BACKGROUND OF THE INVENTION 
   An in-tank type fuel feed apparatus disclosed in U.S. Pat. No. 5,900,148, U.S. Pat. No. 5,785,032, U.S. Pat. No. 5,782,223, U.S. Pat. No. 5,778,926, and U.S. Pat. No. 5,649,514 (WO9623967A1) is accommodated in a fuel tank to supply fuel in the fuel tank to the outside of the fuel tank. In this structure, a lid of a filter housing of a fuel filter is mounted to the fuel tank, so that the lid covers an opening formed in the fuel tank. The filter housing supports the fuel pump. The filter housing has an inlet pipe that directly connects to a discharge pipe of a fuel pump. 
   As shown in  FIG. 4 , a fuel feed apparatus  200  has a conventional structure, in which a discharge port  203  of a fuel pump  202  is connected with a suction port  206  of a filter housing  205  of a fuel filter  204  through a connecting member  208 . The fuel pump  202  is supported by the filter housing  205  in the fuel feed apparatus  200 , similarly to the structure disclosed in U.S. Pat. No. 5,900,148, U.S. Pat. No. 5,785,032, U.S. Pat. No. 5,782,223, U.S. Pat. No. 5,778,926, and U.S. Pat. No. 5,649,514. A lid  210  covers an opening formed in the fuel tank (not shown). The lid  210  is connected with the filter housing  205  by welding or the like. 
   However, in the fuel feed apparatus disclosed in U.S. Pat. No. 5,900,148, U.S. Pat. No. 5,785,032, U.S. Pat. No. 5,782,223, U.S. Pat. No. 5,778,926, and U.S. Pat. No. 5,649,514, and in the fuel feed apparatus  200  shown in  FIG. 4 , a pump module, which includes the fuel pump and the fuel filter, is directly mounted to the fuel tank. Accordingly, when the pump module is used in various fuel tanks, which have depth different from each other, the height of the pump module needs to be changed corresponding to the fuel tanks. As a result, the structure of the filter housing needs to be changed for adapting to the fuel tanks. Specifically, in the fuel feed apparatus shown in  FIG. 4 , the connecting member  208  needs to be changed corresponding to the fuel tanks. Thus, in this structure, a component constructing the pump module needs to be changed in accordance with the depth of the fuel tank. As a result, commonality of components is not sufficient in this structure. 
   A fuel feed apparatus may include a supporting member that connects a lid member, which is mounted to a fuel tank to cover an opening formed in the fuel tank, with a module case of a pump module, so that the lid member supports the pump module via the supporting member. In this structure, the distance between the lid member and the pump module can be easily changed by adjusting the length of the supporting member. 
   In this structure, the fuel feed apparatus can be installed in fuel tanks, which have the depth different from each other, without changing the structure of the pump module, so that the pump module can be commonly used in various fuel tanks. The supporting member is connected with the module case. Specifically, a connecting portion is provided to laterally protrude from the sidewall of the module case, so that the module case is connected with the supporting member via the connecting portion. 
   However, in this structure, the pump module may be radially jumboized. As a result, it may be difficult to insert the pump module into the fuel tank through the opening formed in the fuel tank. The opening of the fuel tank may be widened, so that the pump module can be easily inserted into the fuel tank through the opening. However, when the diameter of the opening is increased, strength of the fuel tank may decrease, and the sealing area may increase. 
   SUMMARY OF THE INVENTION 
   In view of the foregoing and other problems, it is an object of the present invention to produce a fuel feed apparatus, in which commonality of a pump module can be easily enabled, and the pump module can be restricted from being radially jumboized. 
   According to one aspect of the present invention, a fuel feed apparatus supplies fuel in a fuel tank to an outside of the fuel tank. The fuel feed apparatus includes a lid member, a fuel pump, a module case, a pump module, and a supporting member. The lid member is mounted to the fuel tank. The lid member covers an opening of the fuel tank. The fuel pump is accommodated in the fuel tank. The fuel pump pumps fuel in the fuel tank. The module case supports the fuel pump. The pump module includes at least one fuel component protruding from a lateral side of the module case in a projection, which is viewed from a side of the lid member. The supporting member is connected with the lid member and the module case. 
   The supporting member supports the pump module in the fuel tank. The lid member supports the pump module via the supporting member. The module case includes a connecting portion that connects with the supporting member. The connecting portion protrudes from the module case to a lateral side of the module case. The connecting portion is accommodated in an imaginary circle that passes through an outer periphery of the module case and an outer periphery of the at least one fuel component in the projection. The imaginary circle accommodates the module case and the at least one fuel component therein in the projection. 
   The pump module may further include a fuel filter that removes debris contained in fuel discharged from the fuel pump. The module case may accommodate a filter element of the fuel filter as a filter case. 
   The at least one fuel component may include a level meter. The at least one fuel component may include a pressure regulator. 
   In the above structure, even when the connecting portion laterally protrudes outwardly from the module case, the pump module is not jumboized in the lateral direction thereof. Thus, the pump module can be inserted into the fuel tank without increasing the diameter of the opening formed in the fuel tank. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description made with reference to the accompanying drawings. In the drawings: 
       FIG. 1  is a partially cross sectional side view showing a pump module according to a first embodiment of the present invention; 
       FIG. 2  is a top view showing the pump module according to the first embodiment; 
       FIG. 3  is a schematic view showing components of a pump module according to a second embodiment of the present invention; and 
       FIG. 4  is a partially cross sectional side view showing a pump module according to a prior art. 
   

   DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
   (First Embodiment) 
   As shown in  FIG. 1 , a flange  12  is formed in a disc-shape, and is mounted to an upper wall of a fuel tank  1 , so that the flange  12  covers an opening formed in the fuel tank  1 . The flange  12  serves as a lid member of a fuel feed apparatus  10 . Components of the fuel feed apparatus  10  excluding the flange  12  is accommodated in the fuel tank  1 . The flange  12  has a fuel discharge pipe  14  and an electric connector  15 . Fuel is discharged from a fuel pump  21  of a pump module  20 , and the fuel is controlled in pressure by a pressure regulator  60 . The fuel passing through the pressure regulator  60  is supplied to the outside of the fuel tank  1  through a bellows pipe  16  and the fuel discharge pipe  14 . The electric connector  15  electrically connects with the fuel pump  21  and a level meter  64  via a lead wire (not shown). 
   The pump module  20  includes the fuel pump  21 , a fuel filter  23 , the pressure regulator  60 , a suction filter  62 , the level meter  64 , and the like. The pump module  20  is directly accommodated in the fuel tank  1 , so that the pump module  20  directly draws fuel in the fuel tank  1 . The fuel pump  21  receives a motor (not shown). The motor serves as an electrically driving device. The motor rotates an impeller to generate suction force to draw fuel. The impeller serves as a rotating member. 
   The fuel filter  23  includes a filter case  24  and a filter element  29 . The fuel filter  23  corrects relatively small debris, which is contained in fuel discharged from the fuel pump  21 , using the filter element  29 . The filter case  24  serves as a module case. The filter case  24  includes a cover  25 , a case body  26 , and a bracket  27 . The filter case  24  accommodates the filter element  29 . The case body  26  has an inlet port  26   a  that engages with a fuel outlet port  21   a  of the fuel pump  21 . 
   As shown in  FIG. 2 , the case body  26  has two substantially cylindrical connecting portions  28  that respectively protrude from the lateral side of the filter case  24 . Each connecting portion  28  has a through hole  28   a  that penetrates the connecting portion  28  in the axial direction thereof. As referred to  FIG. 1 , the bracket  27  supports the fuel pump  21 . 
   Each of two shafts  30  is formed of metal or the like to be in a cylindrical bar shape. The shaft  30  serves as a supporting member. The shafts  30  are connected with the flange  12  and the case body  26  of the pump module  20  respectively at two locations. The flange  12  supports the pump module  20  via the two shafts  30 . Each shaft  30  has one end that is press-inserted into a press-inserted portion  13  of the flange  12 . Each shaft  30  has the other end that is inserted into the through hole  28   a  of the connecting portion  28 . The shaft  30  has a large diameter portion  31  and a small diameter portion  32 . The diameter of the small diameter portion  32  is smaller than the diameter of the large diameter portion  31 . The small diameter portion  32  is inserted into the connecting portion  28 . 
   The connecting portion  28  has openings on both axial ends thereof. Each opening of the connecting portion  28  engages with a vibration insulator  40 . That is, the connecting portion  28  engages with the two vibration insulators  40 . The shapes of the two vibration insulators  40  are equivalent to each other. Each vibration insulator  40  is formed of an elastic material, which is excellent in oil-resistance, such as acrylonitrile-butadiene rubber (NBR), fluorocarbon rubber, or the like. Each vibration insulator  40  is formed in a cylindrical shape. The vibration insulator  40  is press-inserted into the connecting portion  28 , so that the vibration insulator  40  engages with the connecting portion  28 . Each vibration insulator  40  is interposed between the connecting portion  28  and a washer  50  on both axial end sides of the connecting portion  28 . The small diameter portion  32  of the shaft  30  is press-inserted into the inner periphery of the vibration insulator  40 . A clip  52  engages with the small diameter portion  32  of the shaft  30  on the opposite side of the vibration insulator  40  with respect to the washer  50  on the lower side in  FIG. 1 , so that the clip  52  restricts the shaft  30  from dropping out of the connecting portion  28 . 
   The pressure regulator  60  controls pressure of fuel that is discharged from the fuel pump  21  and is removed of debris through the fuel filter  23 . The pressure regulator  60  has a fuel inlet port (not shown) that directly engages with a fuel outlet port of the case body  26 . 
   The suction filter  62  corrects relatively large debris contained in fuel drawn by the fuel pump  21  from the fuel tank  1 . The level meter  64  is mounted to the shaft  30 . The level meter  64  is provided with an arm  65 . The end of the arm  65  is connected with a float (not shown). 
   Here,  FIG. 2  depicts a projection (projected view) when viewed from the side of the flange  12 . As referred to  FIG. 2 , in this embodiment, an imaginary straight line  102  is defined to pass through a center axis  100  of the fuel pump  21 . Besides, the pressure regulator  60  and the level meter  64  are arranged on one side with respect to the imaginary straight line  102  in a projection when viewed from the side of the flange  12 . The pressure regulator  60  and the level meter  64  are arranged to be in the vicinity of each other on the one side with respect to the imaginary straight line  102  in the projection. That is, the projection is divided by the imaginary straight line  102  into two regions. The pressure regulator  60  and the level meter  64  are arranged in one of the two regions in the projection. The pressure regulator  60  and the level meter  64  are arranged to be in the vicinity of each other in the one of the two regions in the projection. 
   An imaginary circle  110 , which is a perfect circle, passes through both the outer periphery of the filter case  24  and the outer periphery of the level meter  64 , which protrudes from the filter case  24  to the lateral side thereof. The imaginary circle  110  accommodates the filter case  24 , the pressure regulator  60 , and the level meter  64  therein. In this structure, the diameter of the imaginary circle  110  can be reduced to a substantially minimum diameter. 
   Here, it is conceivable to define an imaginary perfect circle and an imaginary ellipse that respectively pass through the outer periphery of the filter case  24  and the outer periphery of the level meter  64 , and respectively accommodate the filter case  24 , the pressure regulator  60 , and the level meter  64  therein. The diameter of this imaginary perfect circle is shorter than the major axis, i.e., the longer axis of this imaginary ellipse. Therefore, the perfect circle is selected as the imaginary circle  100  in this first embodiment. The connecting portions  28 , which respectively connect with the shafts  30 , are arranged in the imaginary circle  100 . Therefore, as referred to  FIG. 2 , even when the connecting portions  28  respectively radially protrude outwardly from the filter case  24 , the pump module  20  is not jumboized in the radial direction thereof. Thus, the pump module  20  can be inserted into the fuel tank  1  without increasing the diameter of an opening  1   a  of the fuel tank  1 . 
   The suction filter  62 , the float mounted to the arm  65  partially protrude laterally from the imaginary circle  110 . However, when the pump module  20  is inclined, the pump module  20  can be inserted into the fuel tank  1  from the side of both the suction filter  62  and the float through the opening  1   a.    
   Next, definition of components (fuel components) of the fuel feed system is described in detail. 
   The fuel components are defined such that the fuel components are arranged to protrude from the lateral side of the case (module case, filter case  24 ) of the pump module  20 , and are accommodated in the fuel tank  1  with the fuel pump  21 . Besides, most of the fuel components are arranged on the side of the lid member (flange  12 ) with respect to the lower end of the module case  24 . In addition, the locations of the fuel components hardly change in the radial direction with respect to the module case  24 . 
   In the first embodiment, the level meter  64  and the pressure regulator  60  are included in the fuel components. However, in the first embodiment, the bellows pipe  16 , the suction filter  62 , the arm  65 , and the float are not included in the fuel components. The reasons are as follows. The bellows pipe  16  is flexible, so that the radial position of the bellows pipe  16  can be changed with respect to a filter case  24 . The suction filter  62  is arranged such that most part of the suction filter  62  is arranged on the opposite side of the flange  12  with respect to the lower end of the filter case  24 . The arm  65  connected to the level meter  64  and the float connected to the arm  65  respectively rotate corresponding to the liquid level of fuel, so that the radial positions of the arm  65  and the float change corresponding to the liquid level. 
   (Second Embodiment) 
     FIG. 3  depicts a projection (projected view) showing the pump module  20  from the side of the flange  12 . In  FIG. 3 , the pressure regulator  60  is arranged on a substantially opposite side of the level meter  64  with respect to the filter case  24  in the radial direction of the filter case  24 . 
   An imaginary ellipse  120  passes through the outer periphery of the filter case  24 , the outer periphery of the level meter  64 , which protrude from the filter case  24  to the lateral side. The imaginary ellipse  120  accommodates the filter case  24 , the pressure regulator  60 , and the level meter  64  therein. The imaginary ellipse  120  further accommodates the connecting portions  28 . Even when the connecting portions  28  are provided to the filter case  24 , the body size of the pump module  20  is not jumboized in the radial direction thereof, as referred to  FIG. 3 . 
   Here, it is conceivable to define an imaginary perfect circle and an imaginary ellipse that respectively pass through the outer periphery of the filter case  24  and the outer periphery of the level meter  64 , and respectively accommodate the filter case  24 , the pressure regulator  60 , and the level meter  64  therein. The minor axis, i.e., shorter axis of this imaginary ellipse is shorter than the diameter of this imaginary perfect circle. Therefore, the ellipse, i.e., the oval figure is selected as the imaginary circle  120  in this second embodiment. 
   In the above structures of the embodiments, the shafts  30  respectively connect the flange  12 , which is mounted to the fuel tank  1 , with the filter case  24  of the pump module  20 . The flange  12  supports the pump module  20  via the shafts  30 . In these structures, the fuel feed apparatus can be mounted to fuel tanks, which have depth different from each other, by adjusting the length of the shafts  30 , without replacing the components of the pump module  20 . Therefore, when the fuel feed apparatus is mounted to fuel tanks, which have depth different from each other, the pump module can be commonly used. That is, commonality of the pump module can be easily enabled. 
   Furthermore, the connecting portions  28  protrude from the sidewall of the filter case  24 , so that other components do not interfere the shafts  30  and the connecting portions  28  when the shafts  30  and the connecting portions  28  are connected with each other. Therefore, the shafts  30  can be easily assembled to the connecting portions  28 . 
   In the above embodiments, the connecting portions  28  are arranged in the imaginary circle, which has the smallest diameter, passing through the outer peripheries of the filter case  24  and the components of the fuel feed system and receiving the filter case  24  and the fuel components, in the projection being viewed from the side of the flange  12 . Therefore, even when the connecting portions  28  protrude from the lateral side of the filter case  24 , the pump module  20  can be restricted from being radially jumboized. 
   In the above embodiment, one of the perfect circle and the ellipse is selected from the perfect circle and the ellipse defining the imaginary circle, which has the smallest diameter, passing through the outer peripheries of the filter case  24  and the fuel components and receiving the filter case  24  and fuel the components. The one of the perfect circle and the ellipse has the diameter that is smaller than the other one of the perfect circle and the ellipse. 
   Furthermore, the vibration insulator  40 , which is made of an elastic material such as rubber, is provided to the joining portion between each connecting portion  28  and each shaft  30 . Thereby, vibration of the pump module  20  arising in the fuel pump  21  and the pressure regulator  60  can be restricted from being transmitted from the fuel pump  21  to the fuel tank  1  via the shaft  30 . Therefore, vibration of the pump module  20  can be restricted from causing noise in the fuel tank  1 . 
   In the above embodiments, the pump module includes the fuel filter, and the filter case of the fuel filter also serves as the module case. Therefore, the pump module including the fuel pump and the fuel filter can be small sized. 
   Here, in a structure, in which the filter case of the fuel filter entirely surrounds the circumferential peripheries of the fuel pump and the fuel components, is apt to protrude to the lateral side of the module case. In addition to this structure, when the connecting portion, which connects with the supporting member (shaft), protrudes from the lateral side of the module case, the pump module may be further jumboized in the radial direction thereof due to arrangement of the connecting portion. However, in the above embodiments, the connecting portions are arranged within the smallest imaginary circle passing through the outer peripheries of the module case and the fuel components and receiving the module case and the fuel components in the projected view from the side of the lid member (flange). Therefore, even when the connecting portion laterally protrudes from the module case, the pump module can be restricted from being radially jumboized. 
   In the above embodiments, the fuel components are arranged to be in the vicinity of each other on the one side in the projection partitioned with the imaginary straight line that passes through the center axis of the fuel pump. Therefore, the pump module can be radially small sized. 
   In the above embodiments, the imaginary circle is one of the perfect circle and the ellipse. The fuel tank has the opening, which is in a shape similar to the imaginary circle. When at least one of the fuel components excessively protrude from the module case out of the imaginary circle, the module case cannot be easily inserted into the fuel tank through the opening. Specifically, when the fuel components are not accommodated in the imaginary circle, an imaginary complicated polygonal shape or the like may need to be defined to accommodate the fuel components. In this structure, the module case, which is in a complicated shape, cannot be easily inserted into the fuel tank through an opening, which is also in a complicated shape. 
   Furthermore, when the imaginary complicated polygonal shape needs to be formed to accommodate the fuel components, the shape of the opening of the fuel tank may be in a complicated polygonal shape similarly to the module case. Accordingly, it is difficult to seal between the lid member and the fuel tank to maintain air tightness therebetween. 
   In the above embodiments, the imaginary circle is the perfect circle and the ellipse, which have smooth and simple circumferential periphery. Therefore, the module case can be easily inserted into the fuel tank through the opening, and the lid member and the fuel tank can be easily sealed therebetween. 
   (Variation) 
   In the above embodiments, the filter case  24  of the fuel filter  23  surrounds substantially throughout the periphery of the fuel pump  21 . However, the filter case of the fuel filter may have a structure that surrounds a part of the outer periphery of the fuel pump  21 . The fuel filter, which removes foreign matters contained in fuel discharged from the fuel pump  21 , may not be accommodated in the fuel tank  1 . That is, the fuel filter may not be included in the pump module accommodated in the fuel tank  1 . 
   The components of the fuel feed system included in the pump module are not limited to the pressure regulator  60  and the level meter  64 . Any components included in the pump module may be another component (fuel component) of the fuel feed system. The number of the components of the fuel feed system is not limited to be greater than one. The number of the components of the fuel feed system may be one. 
   The connecting portion, which connects the shaft  30  with the case (module case) of the pump module, may be a component separated from the module case. 
   In the above embodiments of the fuel feed apparatus, the pump module is directly accommodated in the fuel tank  1 , and the pump module directly draws fuel in the fuel tank  1 . However, the pump module may be accommodated in a sub-tank, and the pump module may draw fuel in the sub-tank in the structure, in which the flange and the module case respectively connect with the shaft, which is the supporting member, and the flange supports the pump module via the shaft. 
   The structures and methods of the above embodiments can be combined as appropriate. 
   Various modifications and alternations may be diversely made to the above embodiments without departing from the spirit of the present invention.