Laminated fuel tank structure

• US 5,129,544 A
• Filed: 11/08/1990
• Issued: 07/14/1992
• Est. Priority Date: 11/08/1990
• Status: Expired due to Fees

• Current Assignee: Dudley L. Mccully, Thomas R. Mcculloch, Wendell L. Jacobson
• Original Assignee: Dudley L. Mccully, Thomas R. Mcculloch, Wendell L. Jacobson
• Inventors: Jacobson, Wendell L., McCulloch, Thomas R., McCully, Dudley L.
• Primary Examiner(s): Marcus, Stephen
• Assistant Examiner(s): CASTELLANO, STEPHEN J
• Application Number:
  US07/610,531
• Time in Patent Office: 614 Days
• Field of Search: 220/562, 220/563, 220/4.14, 220/4.13, 220/453, 220/DIG. 29, 220/678, 220/680, 428/35.8, 428/35.9
• US Class Current: 220/562
• CPC Class Codes: B29C 51/00 Shaping by thermoforming , i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor blow moulding of tubular preforms B29C49/00, deforming of tubular or hollow preforms B29C67/0014
• CPC Class Codes: B29C 51/06 using pressure difference for prestretching
• CPC Class Codes: B29C 51/08 Deep drawing or matched-mould forming, i.e. using mechanical means only
• CPC Class Codes: B29C 51/10 Forming by pressure difference, e.g. vacuum
• CPC Class Codes: B29C 51/14 using multilayered preforms or sheets
• CPC Class Codes: B29C 65/02 by heating, with or without pressure
• CPC Class Codes: B29C 65/08 using ultrasonic vibrations non-plastics element to plastics elements B29C65/645
• CPC Class Codes: B29C 65/16 Laser beams
• CPC Class Codes: B29C 65/48 using adhesives , i.e. using supplementary joining material; solvent bonding
• CPC Class Codes: B29C 65/4895 Solvent bonding, i.e. the surfaces of the parts to be joined being treated with solvents, swelling or softening agents, without adhesives
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• 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 66/45 Joining of substantially the whole surface of the articles methods or apparatus for laminating B32B37/00
• CPC Class Codes: B29C 66/54 Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
• CPC Class Codes: B29C 66/543 joining more than two hollow-preforms to form said hollow articles
• CPC Class Codes: B29C 66/636 using a support which remains in the joined object
• 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 66/72321 consisting of metals or their alloys
• CPC Class Codes: B29C 66/72341 for gases
• CPC Class Codes: B29C 66/83413 cooperating rollers, cylinders or drums
• CPC Class Codes: B29K 2023/06 : PE, i.e. polyethylene
• CPC Class Codes: B29K 2023/12 : PP, i.e. polypropylene
• CPC Class Codes: B29K 2027/18 : PTFE, i.e. polytetrafluorethene , e.g. ePTFE, i.e. expanded polytetrafluorethene
• CPC Class Codes: B29K 2077/00 : Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• CPC Class Codes: B29L 2009/00 : Layered products
• CPC Class Codes: B29L 2022/00 : Hollow articles tubular articles B29L2023/00; pneumatic tyres B29L2030/00
• CPC Class Codes: B29L 2031/7172 : Fuel tanks, jerry cans
• CPC Class Codes: B32B 15/088 : comprising polyamides
• CPC Class Codes: B32B 2307/584 : Scratch resistance
• CPC Class Codes: B32B 2307/7242 : Non-permeable
• CPC Class Codes: B32B 2327/18 : PTFE, i.e. polytetrafluoroethylene
• CPC Class Codes: B32B 2367/00 : Polyesters, e.g. PET, i.e. polyethylene terephthalate
• CPC Class Codes: B32B 2377/00 : Polyamides
• CPC Class Codes: B32B 2439/00 : Containers; Receptacles closures therefor B32B2435/00
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/322 : comprising halogenated polyolefins, e.g. PTFE
• CPC Class Codes: B32B 27/34 : comprising polyamides
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• 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 15/077 : with means modifying or controlling distribution or motion of fuel, e.g. to prevent noise, surge, splash or fuel starvation
• CPC Class Codes: B60K 2015/03039 : made of a combination of non metallic and metallic materials
• CPC Class Codes: B60K 2015/03046 : made from more than one layer
• CPC Class Codes: Y10T 428/1355 : Elemental metal containing [e.g., substrate, foil, film, coating, etc.]

Abstract

A novel fuel tank is disclosed for a vehicle. The fuel tank includes a first and second housing part, each having an outer peripheral flange. The flanges are adapted to abut against each other and, in doing so, form a chamber between the central portions of the housing parts. These flanges are then sealingly secured together. Each housing part is a laminate structure having an outer layer constructed of an abrasion and impact resistant material, a vapor barrier layer constructed of a material impervious to hydrocarbon vapors, and a chemically resistant layer constructed of a material resistant to erosion from hydrocarbons and conventional fuel additives. Each housing part may also have additional layers, such as a heat and light reflective layer adjacent the outermost abrasion resistant layer, as well as a structural layer to add strength and rigidity to the overall tank. Additional structures, such as reservoirs, baffles, support structures, filler tube extensions, valving and the like can also be contained within the interior of the fuel tank.

Claims

1. A fuel tank for a vehicle comprising:

a first housing part having an outer peripheral flange and a central portion extending between and offset from said flange,

a second housing part having an outer peripheral flange and a central portion extending between and offset from said flange,

said flanges on said housing parts adapted to abut against each other so that a chamber is formed between said central portions of said housing parts,

means for sealingly securing said flanges together,

wherein the central portion of each housing part is a laminate structure comprising;

an outer layer of uniform thickness constructed of a material resistant to impact and abrasion,

a heat and light reflective layer adjacent said outer layer,

a vapor barrier layer of uniform thickness constructed of a material impervious to hydrocarbon vapors adjacent said heat and light reflective layer, and

a structural layer adjacent said vapor barrier layer for increasing the strength and rigidity of said fuel tank,

a chemical resistant inner layer of uniform thickness constructed of a material resistant to erosion from hydrocarbons and conventional fuel additives,

wherein said vapor barrier layer is sandwiched between said outer layer and said inner layer so that said laminate structure has a uniform thickness, and

means for bonding said outer layer, said vapor barrier layer and said chemical resistant inner layer together.

2. The invention as defined in claim 1 wherein said outer layer of at least one housing part is light transmissive.

4. The invention as defined in claim 1 wherein said vapor barrier layer comprises teflon.

5. The invention as defined in claim 4 wherein said vapor barrier layer is between 1/1000 and 5/1000 inches thick.

6. The invention as defined in claim 1 wherein said outer layer comprises nylon 12.

7. The invention as defined in claim 1 wherein said outer layer comprises mylar.

8. The invention as defined in claim 1 wherein said outer layer comprises teflon.

9. The invention as defined in claim 1 wherein said outer layer comprises plastic.

10. The invention as defined in claim 1 wherein said outer layer includes materials for electrical conductivity.

11. The invention as defined in claim 1 wherein said outer layer comprises a non-flame supportive material.

12. The invention as defined in claim 1 wherein said outer layer is between 10/1000 and 50/1000 inches thick.

13. The invention as defined in claim 1 wherein baid chemical resistant layer comprises nylon 12.

14. The invention as defined in claim 1 wherein said chemical resistant layer comprises teflon.

15. The invention as defined in claim 1 wherein said chemical resistant layer is between 1/1000 and 5/1000 inches thick.

16. The invention as defined in claim 2 wherein said light and heat reflective layer comprises a metallic foil.

17. The invention as defined in claim 1 wherein said structural layer comprises nylon 6.

18. The invention as defined in claim 1 wherein said structural layer comprises polyethylene.

19. The invention as defined in claim 1 wherein said structural layer comprises polypropylene.

20. The invention as defined in claim 1 wherein said structural layer is between 20/1000 and 50/1000 inches thick.

21. The invention as defined in claim 1 and comprising a baffle positioned in said chamber, said baffle being sandwiched between said central portions of said housing parts.

22. The invention as defined in claim 1 and comprising a reservoir in said chamber.

23. The invention as defined in claim 1 wherein said securing means comprises a sonic weld.

24. The invention as defined in claim 1 wherein said securing means comprises a heat weld.

25. The invention as defined in claim 1 and comprising at least one support bracket in said chamber.

26. The invention as defined in claim 1 wherein said securing means comprises an adhesive.

27. The invention as defined in claim 1 wherein said securing means comprises a solvent weld.

28. The invention as defined in claim 1 wherein said securing means comprises a laser weld.

3. A fuel tank for a vehicle comprising:

a first housing part having an outer peripheral flange and a central portion extending between and offset from said flange,

a second housing part having an outer peripheral flange and a central portion extending between and offset from said flange,

said flanges on said housing parts adapted to abut against each other so that a chamber is formed between said central portions of said housing parts,

means for sealingly securing said flanges together,

wherein the central portion of each housing part is a laminate structure comprising;

an outer layer constructed of a material resistant to impact and abrasion, said outer layer being constructed of a light transmissive material,

a light reflective metal layer adjacent said outer layer,

wherein said light reflective metal layer reflects light passing inwardly though said outer layer back outwardly through said outer layer.