High performance fuel tank

• US 6,661,339 B2
• Filed: 04/26/2002
• Issued: 12/09/2003
• Est. Priority Date: 01/24/2000
• Status: Expired due to Fees

• Current Assignee: Nextreme LLC
• Original Assignee: Nextreme LLC
• Inventors: Muirhead, Scott A. W.
• Primary Examiner(s): POPE, DARYL C
• Application Number:
  US10/134,049
• Publication Number:
  US 20020113694A1
• Time in Patent Office: 592 Days
• Field of Search: 340/506, 340/3.1, 340/539.1, 220/562, 220/563, 220/86.2, 220/4.13, 220/4.14
• US Class Current: 340/505
• CPC Class Codes: B29C 51/12 of articles having inserts or reinforcements
• 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 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 66/53246 said single elements being spouts, e.g. joining spouts to containers
• CPC Class Codes: B29L 2009/00 Layered products
• 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 15/073 Tank construction specially adapted to the vehicle B60K15/077 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 2015/03111 Swirl pots
• CPC Class Codes: B60K 2015/03401 for preventing electrostatic charges
• CPC Class Codes: B60K 2015/0775 for reducing movement or slash noise of fuel
• CPC Class Codes: F02M 37/0011 Constructional details; Manufacturing or assembly of elements of fuel systems; Materials therefor
• CPC Class Codes: F02M 37/103 Mounting pumps on fuel tanks
• CPC Class Codes: G08B 13/2417 having a radio frequency identification chip
• CPC Class Codes: G08B 13/2434 Tag housing and attachment details
• CPC Class Codes: G08B 13/244 Tag manufacturing, e.g. continuous manufacturing processes
• CPC Class Codes: G08B 13/2445 Tag integrated into item to be protected, e.g. source tagging
• CPC Class Codes: G08B 13/2462 Asset location systems combined with EAS inventory, tracking, logistic G06Q10/00; entrance control systems G07C9/00

Abstract

A fuel tank and method of making the same having three polymeric sheet members arranged in a stacked relationship to define a first volume and a second volume. The first volume being separate from said second volume to provide a number of advantages, such as a barrier to prevent puncture, minimize vapor release, aid in cooling, define a reserve cavity, minimize fluid movement, and the like.

Claims

1. A fluid container for storing a fluid comprising:

a first sheet member;

a second sheet member; and

a third sheet member coupled between said first sheet member and said second sheet member, said first sheet member and said third sheet member together defining a first volume, said second sheet member and said third sheet member together defining a second volume, said first volume being fluidly isolated from said second volume.

2. The fluid container according to claim 1 wherein at least one of said first sheet member, said second sheet member, and said third sheet member is a layer capable of deflecting heat away from at least one of said first volume and said second volume.

3. The fluid container according to claim 1 wherein at least one of said first sheet member, said second sheet member, and said third sheet member is a vapor barrier.

4. The fluid container according to claim 1 wherein at least one of said first sheet member, said second sheet member, and said third sheet member is electrically conductive.

5. The fluid container according to claim 1 wherein at least one of said first sheet member, said second sheet member, and said third sheet member is made of a thermoplastic resin.

6. The fluid container according to claim 5 wherein said thermoplastic resin is chosen from the group consisting essentially of polyethylene, polypropylene, and polyolefin.

7. The fluid container according to claim 1 wherein at least one of said first sheet member, said second sheet member, and said third sheet member is made of a filled polyolefin material chosen from the group consisting essentially of talc, silica, glass fibers or beads, cellulose, natural fibers, organic matter, a thermosetting resin, carbon, a pigment, metallic particles, nanocompounds and fire retardant substances.

8. The fluid container according to claim 1, further comprising:

a radio frequency device coupled to at least one of said first sheet member, said second sheet member, and said third sheet member, said radio frequency device being operable to output a signal.

9. The fluid container according to claim 1 wherein at least one of said first sheet member, said second sheet member, and said third sheet member is made of a polymeric material.

10. The fluid container according to claim 1 wherein said first volume serves as at least a puncture barrier, a noise-dampening barrier, a structural reinforcement, a vapor barrier, or a fire barrier.

11. The fluid container according to claim 1, further comprising:

a plurality of protrusions formed in said third sheet member, said plurality of protrusions extending into said first volume, said plurality of protrusions obstructing fluid flow in said first volume.

12. The fluid container according to claim 1 wherein one of said first sheet member and said third sheet member includes a protrusion extending toward the other of said first sheet member and said third sheet member to separate said first volume into discrete volumetric sections.

13. The fluid container according to claim 1, further comprising:

a fastener coupled to said first sheet member, said fastener being separate from said second volume.

14. The fluid container according to claim 1, further comprising:

a fuel system component coupled between said first sheet member and said second sheet member.

15. The fluid container according to claim 1, further comprising:

a fourth sheet member coupled between said first sheet member and said third sheet member.

16. The fluid container according to claim 1 wherein said first sheet member, said second sheet member, and said third sheet member are simultaneously coupled together to form a unitary member.

17. A fuel tank for containing a fuel, said fuel tank comprising:

a first polymeric sheet;

a second polymeric sheet; and

a third polymeric sheet coupled between said first polymeric sheet and said second polymeric sheet, said first polymeric sheet and said third polymeric sheet together defining a first volume, said second polymeric sheet and said third polymeric sheet together defining a second volume, said first volume being isolated from said second volume.

18. The fuel tank according to claim 17 wherein said third polymeric sheet is adjacent said first polymeric sheet to define a barrier.

19. The fuel tank according to claim 18 wherein said barrier is generally heat resistant, vapor impervious, puncture resistant, or noise-dampening.

20. The fuel tank according to claim 17 wherein at least one of said first polymeric sheet, said second polymeric sheet, and said third polymeric sheet is made of a thermoplastic resin.

21. The fuel tank according to claim 20 wherein said thermoplastic resin is chosen from the group consisting essentially of polyethylene, polypropylene, and polyolefin.

22. The fuel tank according to claim 17 wherein at least one of said first polymeric sheet, said second polymeric sheet, and said third polymeric sheet is electrically conductive.

23. The fuel tank according to claim 17 wherein at least one of said first polymeric sheet, said second polymeric sheet, and said third polymeric sheet is made of a filled polyolefin material chosen from the group consisting essentially of talc, silica, glass fibers or beads, cellulose, natural fibers, organic matter, a thermosetting resin, carbon, a pigment, metallic particles, nano-compounds and fire retardant substances.

24. The fuel tank according to claim 17, further comprising:

a radio frequency device is mounted substantially between said first polymeric sheet and said third polymeric sheet, said radio frequency device being operable to output a signal.

25. The fuel tank according to claim 17, further comprising:

a plurality of protrusions formed in said third polymeric sheet, said plurality of protrusions extending into said first volume, said plurality of protrusions obstructing fluid flow in said first volume.

26. The fuel tank according to claim 17 wherein one of said first polymeric sheet and said third polymeric sheet includes a protrusion extending toward the other of said first polymeric sheet and said third polymeric sheet to separate said first volume into discrete volumetric sections.

27. The fuel tank according to claim 17, further comprising:

a fastener coupled to said first polymeric sheet, said fastener being separate from said second volume.

28. The fuel tank according to claim 17, further comprising:

a fuel system component coupled between said first polymeric sheet and said third polymeric sheet.

29. The fuel tank according to claim 17, further comprising:

a fourth polymeric sheet coupled between said first polymeric sheet and said third polymeric sheet.

30. The fuel tank according to claim 17 wherein said first polymeric sheet, said second polymeric sheet, and said third polymeric sheet are simultaneously coupled together to form a unitary member.

31. A fuel tank comprising:

at least three extruded polymeric sheets arranged to define a first tank section and a second tank section, said at least three extruded polymeric sheets being thermoformed; and

an aperture formed in one of said at least three extruded polymeric sheets to provide access to said first tank section via said second tank section.

32. The fuel tank according to claim 31, further comprising:

a hydrocarbon barrier formed on at least one of said first tank section and said second tank section, said hydrocarbon barrier operable to inhibit fluid or vapor transmission therethrough.

33. The fuel tank according to claim 31 wherein at least one of said at least three extruded polymeric sheets is made of a filled polyolefin material chosen from the group consisting essentially of talc, silica, glass fibers or beads, cellulose, natural fibers, organic matter, a thermosetting resin, carbon, a pigment, metallic particles, nano-compounds and fire retardant substances.

34. The fuel tank according to claim 31, further comprising:

a radio frequency device is mounted generally within said second tank section, said radio frequency device being operable to output a signal.

35. The fuel tank according to claim 31, further comprising:

a plurality of protrusions formed in at least one of said at least three extruded polymeric sheets, said plurality of protrusions extending into said second tank section, said plurality of protrusions obstructing fluid flow in said second tank section.

36. A fuel tank having three co-extruded thermoformed polymeric sheets, said fuel tank comprising:

a first fuel tank section having a wall operable to contain a fuel, said first fuel tank section having a first hydrocarbon barrier layer interfacially fused to an inside surface of said wall and a second hydrocarbon barrier layer interfacially fused to an outside surface of said wall; and

a second fuel tank section having a wall operable to contain escaping fuel vapors.

37. The fuel tank according to claim 36, further comprising:

a third hydrocarbon barrier layer interfacially fused to an inside surface of said wall of said second fuel tank section.

38. The fuel tank according to claim 36, further comprising:

a resealable aperture formed in said first fuel tank section that is accessible through said second fuel tank section.

39. The fuel tank according to claim 38 wherein said resealable aperture is thermoformed.

40. A method of manufacturing a fuel tank, said method comprising:

thermoforming a first polymeric sheet to a predetermined shape;

thermoforming a second polymeric sheet to a predetermined shape;

thermoforming a third polymeric sheet to a predetermined shape;

coupling said first polymeric sheet to said second polymeric sheet to form a two sheet subassembly having a first volume; and

coupling said third polymeric sheet to said two sheet subassembly to form a three sheet subassembly having a second volume, said second volume being separate from said first volume.

41. The method according to claim 40, further comprising:

coupling a radio frequency device substantially between said first polymeric sheet and said second polymeric sheet, said radio frequency device being operable to send or receive a signal.

42. The method according to claim 40, further comprising:

coupling a fuel system component coupled between said first polymeric sheet and said second polymeric sheet.

43. The method according to claim 40, further comprising:

thermoforming a fourth polymeric sheet to a predetermined shape; and

coupling said fourth polymeric sheet to said three sheet subassembly to form a four sheet subassembly having a third volume, said third volume being separate from said first volume and said second volume.

44. The method according to claim 40 wherein said thermoforming a second polymeric sheet to said predetermined shape includes forming a plurality of protrusion in said second sheet.