Fuel tank and method for its production

• US 20010013516A1
• Filed: 02/12/2001
• Published: 08/16/2001
• Est. Priority Date: 02/14/2000
• Status: Active Grant

• Current Assignee: TI Group Automotive Systems Technology Center GmbH
• Original Assignee: TI Group Automotive Systems Technology Center GmbH
• Inventors: Boecker, Albert
• Granted Patent: US 6,712,234 B2
• Time in Patent Office: Days
• US Class Current: 220/562
• CPC Class Codes: B29C 2791/006 Using vacuum
• CPC Class Codes: B29C 49/04 Extrusion blow-moulding
• CPC Class Codes: B29C 49/20 of articles having inserts or reinforcements ; Handling of inserts or reinforcements
• CPC Class Codes: B29C 49/22 using multilayered preforms or parisons
• CPC Class Codes: B29L 2031/7172 Fuel tanks, jerry cans
• CPC Class Codes: B60K 15/03177 made of non-metallic material, e.g. plastics, or of a combination of non-metallic and metallic material B60K15/03006 takes precedence
• CPC Class Codes: B60K 15/03504 adapted to avoid loss of fuel or fuel vapour, e.g. with vapour recovery systems
• CPC Class Codes: B60K 15/077 with means modifying or controlling distribution or motion of fuel, e.g. to prevent noise, surge, splash or fuel starvation
• CPC Class Codes: B60K 2015/03138 Pumping means between the compartments
• CPC Class Codes: B60K 2015/03144 Fluid connections between the tanks
• CPC Class Codes: B60K 2015/03223 comprising at least two level fuel sensors
• CPC Class Codes: B60K 2015/0344 comprising baffles
• CPC Class Codes: B60K 2015/03523 Arrangements of the venting tube
• CPC Class Codes: B60K 2015/03557 comprising elements of the venting device integrated in the fuel tank, e.g. vapor recovery means
• CPC Class Codes: B60K 2015/0775 for reducing movement or slash noise of fuel
• CPC Class Codes: B60K 2015/0777 in-tank reservoirs or baffles integrally manufactured with the fuel Tank
• CPC Class Codes: F02D 33/003 Controlling the feeding of liquid fuel from storage containers to carburettors or fuel-injection apparatus control of electrical fuel pumps F02D41/3082, controlling fuel flow to a common rail F02D41/3845; Failure or leakage prevention; Diagnosis or detection of failure; Arrangement of sensors in the fuel system; Electric wiring; Electrostatic discharge
• CPC Class Codes: F02M 25/08 adding fuel vapours drawn from engine fuel reservoir electrical control of purge system F02D41/003
• CPC Class Codes: F02M 37/0011 Constructional details; Manufacturing or assembly of elements of fuel systems; Materials therefor
• CPC Class Codes: F02M 37/0082 Devices inside the fuel tank other than fuel pumps or filters electrical pumps submerged in fuel tanks F02M37/10, jet pumps F02M37/025
• CPC Class Codes: F02M 37/0094 : Saddle tanks; Tanks having partition walls
• CPC Class Codes: F02M 37/025 : Feeding by means of a liquid fuel-driven jet pump jet pumps per se F04F
• CPC Class Codes: F02M 37/103 : Mounting pumps on fuel tanks

Abstract

A fuel tank has a plurality of fuel system components therein and is formed by incorporating the fuel system components into the fuel tank as it is being formed. The fuel system components may be mounted on a carrier and then disposed with the carrier within a parison subsequently molded to form the fuel tank around the components and carrier. Desirably, all electrical, fuel and vapor lines may extend out of a single opening of the fuel tank to reduce openings in the formed fuel tank.

Claims

1. A method of making a fuel tank having at least one fuel system component therein, comprising the steps of:

providing a carrier constructed and arranged to carry at least one fuel system component;

disposing at least one fuel system component on the carrier; and

forming the fuel tank of a polymeric material to its final shape around the carrier with said at least one fuel system component thereon to provide a fuel tank with at least one fuel system component therein.

2. The method of

claim 1

wherein the step of forming the fuel tank is accomplished by providing a parison of a polymeric material around the carrier with said at least one fuel system component thereon, placing the parison with the carrier therein into a mold, and closing the mold and forming the parison to its desired final shape within the mold.

3. The method of

claim 2

wherein to form the parison to its final shape pressurized air is delivered into the parison to expand it outwardly within the mold.

4. The method of

claim 2

wherein to form the parison to its final shape a negative pressure is applied between the mold and the parison to draw the parison outwardly within the mold.

5. The method of

claim 1

wherein during the step of forming the fuel tank around the carrier the fuel tank is brought into engagement with the carrier to limit relative movement between the carrier and fuel tank.

6. The method of

claim 2

wherein during the step of forming the fuel tank the parison is brought into contact with the carrier to limit the relative movement between the carrier and the fuel tank.

7. The method of

claim 6

wherein the parison engages the carrier at a plurality of separate locations so that the carrier is connected at these locations to the fuel tank after it is formed.

8. The method of

claim 2

which also comprises the step of removing a portion of a stem of the carrier which extends out of the fuel tank after it is formed and closing and sealing off the opening created by the removal of said stem.

9. The method of

claim 2

which also comprises the step of providing a supply of pressurized air between the parison and carrier to prevent the parison from contacting the carrier before the mold is closed.

10. A plastic fuel tank having at least one fuel system component therein, comprising:

a body of a polymeric material defining an interior space constructed and arranged to store a quantity of liquid fuel therein and having an opening communicating with the interior space;

a carrier carried by the body and disposed within the interior space; and

at least one fuel system component carried by the carrier within the interior space with the carrier with the fuel system component thereon having a size preventing its insertion into the interior space through any opening in the body.

11. The fuel tank of

claim 10

wherein the carrier extends longitudinally of the fuel tank and divides the fuel tank interior into smaller volume portions.

12. The fuel tank of

claim 11

which also comprises a flow path between the carrier and the fuel tank communicating the portions of the fuel tank interior with each other to permit each portion to have the same fuel level.

13. The fuel tank of

claim 12

which also comprises feet extending from the carrier element and engaged by the body of the fuel tank to define the flow paths between the carrier and fuel tank.

14. The fuel tank of

claim 10

, which also comprises a plurality of feet, spaced apart on the carrier and extending to the fuel tank body to limit relative movement between the fuel tank and carrier.

15. The fuel tank of

claim 14

wherein the feet are connected to the fuel tank body.

16. The fuel tank of

claim 14

wherein the feet are adhered to the fuel tank body.

17. The fuel tank of

claim 10

wherein the carrier has guideways in which said at least one fuel system component is carried by the carrier to guide movement of said at least one fuel system component relative to the carrier.

18. The fuel tank of

claim 10

wherein the carrier has an internal passage communicating with said at least one fuel system component and constructed and arranged to permit fluid communication between said at least one fuel system component and another component of the fuel system.

19. The fuel system of

claim 18

wherein two fuel system components are carried by the carrier and the internal passage communicates with both of said fuel system components.

20. A method of making a fuel tank, comprising the steps of:

providing a parison of polymeric material suitable to be molded into the fuel tank;

disposing at least one fuel system component in the parison before the parison is molded into the fuel tank; and

forming the parison into the fuel tank with said at least one fuel system component therein to provide a fuel tank with at least one fuel system component therein.

21. The method of

claim 20

which also comprises the steps of providing a carrier and wherein the fuel system component is carried by the carrier with the carrier and fuel system component thereon disposed in the parison.

22. A plastic fuel tank having at least one fuel system component therein, comprising:

a body of a polymeric material defining an interior space constructed and arranged to store a quantity of liquid fuel therein and having an opening communicating with the interior space; and

at least one fuel system component carried by the body within the interior space and having a size which prevents its insertion into the interior space through any opening of the body.