Low hydrocarbon emission fuel tank with internal components

• US 20020020705A1
• Filed: 08/03/2001
• Published: 02/21/2002
• Est. Priority Date: 08/11/2000
• Status: Abandoned Application

• Current Assignee: Visteon Global Technologies Incorporated (Visteon Corporation)
• Original Assignee: Visteon Global Technologies Incorporated (Visteon Corporation)
• Inventors: Vorenkamp, Erich James, Vaughn, Lawrence Eugene III, Krell, Barbara, Fish, Duane
• Application Number:
  US09/921,541
• Publication Number:
  US 20020020705A1
• Time in Patent Office: Days
• US Class Current: 220/4.14
• CPC Class Codes: B29B 13/023 Half-products, e.g. films, plates
• CPC Class Codes: B29C 2035/0822 using IR radiation
• CPC Class Codes: B29C 2049/2017 outside the article
• 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: B29C 51/12 of articles having inserts or reinforcements
• CPC Class Codes: B29C 51/14 using multilayered preforms or sheets
• CPC Class Codes: B29C 51/267 Two sheets being thermoformed in separate mould parts and joined together while still in the mould B29C49/0691 takes precedence
• CPC Class Codes: B29C 51/421 of preforms, specially adapted for thermoforming preheating sheets in general B29B13/023; B29C51/427 takes precedence
• CPC Class Codes: B29C 65/028 making use of inherent heat, i.e. the heat for the joining comes from the moulding process of one of the parts to be joined
• CPC Class Codes: B29C 66/1312 Single flange to flange joints, the parts to be joined being rigid the parts to be joined being flexible B29C66/133
• CPC Class Codes: B29C 66/53245 said articles being hollow
• CPC Class Codes: B29C 66/61 Joining from or joining on the inside for making tubes by bending sheets and joining from the inside B29C53/387
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/7234 comprising a barrier layer
• CPC Class Codes: B29K 2023/065 HDPE, i.e. high density polyethylene
• CPC Class Codes: B29K 2023/086 EVOH, i.e. ethylene vinyl alcohol copolymer
• CPC Class Codes: B29K 2105/16 Fillers
• CPC Class Codes: B29K 2995/0067 non-permeable
• CPC Class Codes: B29K 2995/0069 non-permeable
• 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 15/03519 : Valve arrangements in the vent line
• 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 2015/03111 : Swirl pots
• CPC Class Codes: B60K 2015/0344 : comprising baffles
• CPC Class Codes: B60K 2015/0777 : in-tank reservoirs or baffles integrally manufactured with the fuel Tank
• CPC Class Codes: F16B 9/052 : the intermediate member having a radial flange secured to the flat surface
• CPC Class Codes: Y10S 264/65 : Processes of preheating prior to molding
• CPC Class Codes: Y10T 428/13 : Hollow or container type article [e.g., tube, vase, etc.]
• CPC Class Codes: Y10T 428/1352 : Polymer or resin containing [i.e., natural or synthetic]
• CPC Class Codes: Y10T 428/1383 : Vapor or gas barrier, polymer derived from vinyl chloride or vinylidene chloride, or polymer containing a vinyl alcohol unit is sandwiched between layers [continuous layer]

Abstract

A low permeation fuel tank formed with a first half and a second half includes a hydrocarbon barrier and a fuel system module. The hydrocarbon barrier reduces the emission of hydrocarbons from the fuel tank. Minimization of discontinuities in the hydrocarbon barrier is achieved by positioning the fuel system module within the fuel tank. The fuel system module includes a preformed sheet to provide flexible and rigid support to the fuel tank. In addition, the fuel system module may include fuel system components, structural enhancements of the fuel tank and/or functional features of the fuel tank to minimize production of holes or other discontinuities in the hydrocarbon barrier.

Claims

1. A container comprising:

a first half of the container;

a second half of the container coupled with the first half to define a chamber; and

a pre-formed sheet coupled with one of the first half and the second half, the pre-formed sheet positioned within the chamber to provide flexible and rigid structural support to the container.

2. The container of claim 1, wherein the pre-formed sheet is operable to exhibit rigidity to forces imparted substantially perpendicular to the preformed sheet.

3. The container of claim 1, wherein the pre-formed sheet is operable to exhibit flexibility to forces imparted substantially parallel to the preformed sheet.

4. The container of claim 1, wherein the preformed sheet comprises a fluid reservoir.

5. The container of claim 1, wherein the pre-formed sheet is operable to channel fluid within the chamber to a reservoir.

6. The container of claim 1, wherein each of the first half and the second half are formed from thermoplastic sheets.

7. The container of claim 1, wherein the first half and the second half operably cooperate to form a barrier surrounding the chamber, the barrier operable to limit migration of fluid from the chamber.

8. The container of claim 1, wherein the container comprises a low permeation plastic fuel tank.

9. A low permeation fuel tank comprising:

a fuel system module comprising a continuous pre-formed sheet; and

a first half and a second half of the low permeation fuel tank positioned to surround the fuel system module, the fuel system module formed to the contours of at least one of the first half and the second half.

10. The low permeation fuel tank of claim 9, wherein the fuel system module is operable to resist movement of the first half toward the second half.

11. The low permeation fuel tank of claim 9, wherein the fuel system module is operable to flexibly move in response to expansion of one of the first half and the second half.

12. The low permeation fuel tank of claim 9, wherein the continuous preformed sheet comprises a formation with provisions to couple with one of the first half and the second half.

13. The low permeation fuel tank of claim 12, wherein the formation comprises at least one of a weld tab, a slot and an area of the continuous preformed sheet contiguous with one of the first half and the second half.

14. The low permeation fuel tank of claim 9, wherein the fuel system module comprises thermoplastic.

15. The low permeation fuel tank of claim 9, wherein the first half and the second half comprise multiple layer thermoplastic sheets.

16. The low permeation fuel tank of claim 9, wherein the fuel system module comprises a fuel system component.

17. The low permeation fuel tank of claim 16, wherein the fuel system module is operable to temporarily maintain the fuel system component in position to weld to one of the first half and the second half.

18. The low permeation fuel tank of claim 9, wherein the fuel system module is operable to channel fuel to a fuel reservoir within the low permeation fuel tank.

20. The low hydrocarbon emission fuel tank of claim 19, wherein the preformed sheet comprises a continuous sheet in a predetermined functional shape the pre-formed sheet forming a layer between the first thermoplastic sheet and the second thermoplastic sheet.

21. The low hydrocarbon emission fuel tank of claim 19, wherein the fuel system module is coupled to the first thermoplastic sheet.

22. The low hydrocarbon emission fuel tank of claim 19, wherein the fuel system module is coupled to the second thermoplastic sheet.

23. The low hydrocarbon emission fuel tank of claim 19, wherein the fuel system module is held in position by geometric interference between formations in the pre-formed sheet and contours of the first thermoplastic sheet and the second thermoplastic sheet.

24. The low hydrocarbon emission fuel tank of claim 19, wherein the fuel system module is formed to position one of at least two fuel system components away from another of the at least two fuel system components.

25. The low hydrocarbon emission fuel tank of claim 19, wherein the fuel system module comprises a first end and a second end, one of at least two fuel system components positioned near the first end and another of the at least two fuel system components positioned near the second end.

26. The low hydrocarbon emission fuel tank of claim 19, wherein the preformed sheet comprises formations, the formations with provisions to couple the fuel system module with one of the first thermoplastic sheet and the second thermoplastic sheet.

27. The low hydrocarbon emission fuel tank of claim 26, wherein the formations are operable to allow flexible movement of the fuel system module in response to forces acting substantially parallel to surfaces of the preformed sheet.

28. The low hydrocarbon emission fuel tank of claim 26, wherein the formations are operable to resist movement of the fuel system module in response to forces acting substantially perpendicular to surfaces of the preformed sheet.

30. The fuel system module of claim 29, wherein the pre-formed sheet is operable to flexibly absorb forces applied substantially parallel to surfaces of the pre-formed sheet and rigidly withstand forces applied substantially perpendicular to surfaces of the pre-formed sheet.

31. The fuel system module of claim 29, wherein the pre-formed sheet is contiguous with the contours of the interior surface.

32. The fuel system module of claim 29, wherein the pre-formed sheet comprises thermoplastic.

33. The fuel system module of claim 29, wherein the pre-formed sheet comprises functional features of the low hydrocarbon emission fuel tank.

34. The fuel system module of claim 29, wherein the pre-formed sheet is operable as a structural support.

36. The method of claim 35, further comprising coupling the fuel system module to an interior surface of one of the first half and the second half.

37. The method of claim 35, further comprising positioning the fuel system module within a concave shape formed in one of the first half and the second half.

38. The method of claim 35, further comprising preserving a hydrocarbon barrier provided by the first half and the second half during mounting of the fuel system module.

39. The method of claim 35, further comprising applying pressure to the fuel system module to couple the fuel system module to one of the first half and the second half.

40. The method of claim 35, further comprising forming the fuel system module in a predetermined shape contiguous with the contours of at least one of the first half and the second half.

19. A low hydrocarbon emission fuel tank comprising:

a first thermoplastic sheet and a second thermoplastic sheet each comprising a plurality of layers;

a weld joint operable to couple the first thermoplastic sheet and the second thermoplastic sheet to form the fuel tank, the first and second thermoplastic sheets operable to provide a hydrocarbon barrier; and

a fuel system module positionable within the fuel tank prior to application of the weld joint to minimize discontinuities in the hydrocarbon barrier, the fuel system module comprising a pre-formed sheet and a fuel system component.

29. A fuel system module for installation in a low hydrocarbon emission fuel tank, the fuel system module comprising:

a pre-formed sheet;

the pre-formed sheet with provisions to support a fuel system component in a predetermined position; and

the pre-formed sheet formed to fit within the low hydrocarbon emission fuel tank with provisions to couple with an interior surface of the low hydrocarbon emission fuel tank.

35. A method of internalizing fuel system components, the method comprising:

forming a first half of a fuel tank;

forming a second half of the fuel tank;

mounting a fuel system module in one of the first half and the second half of the fuel tank, the fuel system module comprising a pre-formed sheet and a fuel system component; and

joining the first half and the second half to surround the fuel system module and form the fuel tank, wherein the fuel system module forms a continuous layer between the first half and the second half.

41. A method of creating a fuel system module for internalizing fuel system components, the method comprising:

forming a sheet in a predetermined shape;

creating provisions on the sheet to fixedly couple the sheet to an internal surface of a fuel tank; and

positioning a fuel system component on the sheet.

42. The method of claim 41, further comprising routing the fuel system component with the sheet.

43. The method of claim 41, wherein forming the sheet comprises forming a fuel reservoir as part of the sheet.

44. The method of claim 41, further comprising testing to verify cooperative operation of the fuel system component and the sheet.

45. The method of claim 41, wherein the sheet comprises thermoplastic and configuring the sheet comprises molding the sheet to the predetermined shape.

46. The method of claim 41, wherein forming the sheet comprises shaping formations in the sheet to provide rigidity to forces applied substantially perpendicular to a surface of the sheet and flexibility to forces applied substantially parallel to a surface of the sheet.

47. The method of claim 41, further comprising installing the sheet in a fuel tank.