Fuel tank assembly

Abstract

This invention provides a low profile fuel tank assembly having an elongated fuel delivery module mounted horizontally within the fuel tank and independent from a flange which covers a sole fuel tank access hole. An integrated fuel pump and associated motor of the module dictates the length of the module. The motor and pump has a rotational axis disposed substantially horizontal within the fuel tank. Because the fuel delivery module is supported by the fuel tank shell or bottom, independent of the flange, the access hole can be located anywhere on the fuel tank in order to simplify fuel tank ingress and minimize repair procedures. During assembly, the module is preferably inserted into the fuel tank through the access hole, and is then slide and snap-locked into a bracket welded to the bottom of the fuel tank.

We claim:  
     
         1 . A fuel tank assembly comprising: 
 a fuel tank having an inner surface defining a fuel chamber; and    a fuel delivery module having a support structure engaged to the inner surface, a fuel pump motor having a rotational axis positioned substantially horizontal, and a fuel filter, wherein the fuel pump motor and the fuel filter are carried and supported by the support structure.    
     
     
         2 . The fuel tank assembly set forth in  claim 1  wherein the support structure is a can, the can defining a fuel reservoir and the fuel pump being disposed within the can.  
     
     
         3 . The fuel tank assembly set forth in  claim 2  wherein the fuel delivery module has a fuel supply pressure control assembly supported by the can.  
     
     
         4 . The fuel tank assembly set forth in  claim 3  further comprising two opposing clasps projecting into the fuel chamber from the inner surface of the fuel tank, the can of the fuel delivery module being engaged between the two opposing clasps.  
     
     
         5 . The fuel tank assembly set forth in  claim 4  further comprising an elongated bracket engaged rigidly to the inner surface of the fuel tank within the fuel chamber, the bracket having a base plate the two opposing clasps engaged unitarily to and extending longitudinally lengthwise along the base plate.  
     
     
         6 . The fuel tank assembly set forth in  claim 5  further comprising: 
 the clasp having a wall and a cross bar, the wall extended between the base plate and the cross bar, the wall projecting into the fuel chamber, the cross bar projecting outward from the wall over and spaced from the base plate; and  
 the can of the fuel delivery module having opposite longitudinal sides and spacer bars projecting outward from each respective one of the sides, and engaged to the respective cross bar of the bracket preventing movement of the fuel delivery module with respect to the bracket away from the inner surface.  
 
     
     
         7 . The fuel tank assembly set forth in  claim 6  further comprising: 
 the can having a snap clip; and  
 the bracket having a locking tab, the snap clip being locked to the locking tab preventing rearward movement of the fuel delivery module with respect to the bracket.  
 
     
     
         8 . The fuel tank assembly set forth in  claim 7  further comprising: 
 the snap clip having a base, a cantilevered arm and a lip, the base engaged between one of the longitudinal sides of the can and the cantilevered arm, the cantilevered arm disposed parallel to and extended co-longitudinally along the side, the lip engaged to a distal end of the cantilevered arm and projected laterally with respect to the side of the can; and  
 the locking tab having a contact surface facing forward, the lip being in contact with the contact face preventing rearward movement of the fuel delivery module.  
 
     
     
         9 . The fuel tank assembly set forth in  claim 8  wherein the locking tab projects into the fuel chamber away from the inner surface and from the cross bar of the clasp, and wherein the cantilevered arm projects forward along the side of the can from the base of the snap clip.  
     
     
         10 . The fuel tank assembly set forth in  claim 9  wherein the lip projects laterally outward with respect to the adjacent side, and wherein the cantilevered arm is disposed between the adjacent side and the locking tab of the clasp.  
     
     
         11 . The fuel tank assembly set forth in  claim 9  wherein the clasp has a guide member projecting rearward and angled laterally outward from the wall in the rearward direction.  
     
     
         12 . The fuel tank assembly set forth in  claim 7  further comprising: 
 the clasp having a guideway defining a channel;  
 the guideway of the clasp having an elongated rail disposed parallel to and projecting toward the base plate, the channel defined between the wall and the rail; and  
 the can of the fuel delivery assembly having a slot and an elongated interlocking rail projecting transversely from the spacer bar, the slot defined between the interlocking rail and the side of the can, the elongated rail of the clasp disposed within the slot and the interlocking rail of the can being disposed within the channel.  
 
     
     
         13 . The fuel tank assembly set forth in  claim 12  further comprising: 
 the base plate of the bracket having a forward edge extending between the two opposite edges; and  
 the bracket having a stop tang projecting unitarily from the base plate into the fuel chamber and contacting the can of the fuel delivery assembly preventing further forward movement of the fuel delivery assembly.  
 
     
     
         14 . The fuel tank assembly set forth in  claim 13  wherein the inner surface of the fuel tank has a bottom surface, the bracket being engaged to the bottom surface.  
     
     
         15 . The fuel tank assembly set forth in  claim 14  farther comprising: 
 the fuel tank having an upper side and a flange, the upper side defining an access hole through which the fuel delivery module is inserted into the fuel tank, the flange engaged to the upper side and sealably covering the hole; and  
 the fuel delivery module having a wiring harness and a fuel supply tube routed through the flange.  
 
     
     
         16 . The fuel tank assembly set forth in  claim 3  further comprising: 
 the fuel tank having an upper side and a flange, the upper side defining an access hole through which the fuel delivery module is inserted into the fuel tank, the flange engaged to the upper side and sealably covering the hole; and  
 the fuel delivery module having a wiring harness and a fuel supply tube routed through the flange.  
 
     
     
         17 . The fuel tank assembly set forth in  claim 15  wherein the fuel tank is made of blow molded plastic and the bracket is made of injected plastic.  
     
     
         18 . The fuel tank assembly set forth in  claim 3  wherein the maximum height of the fuel tank is less than the longitudinal length of the fuel delivery module.  
     
     
         19 . The fuel tank assembly set forth in  claim 18  wherein the longitudinal length of the fuel delivery module is orientated at an angle of less than ten degrees from an imaginary horizontal plane.  
     
     
         20 . The fuel tank assembly set forth in  claim 19  wherein the filter is elongated having an axis disposed parallel to the axis of the fuel pump motor.  
     
     
         21 . A fuel tank assembly comprising: 
 a fuel tank having an inner surface defining a fuel chamber;    a bracket engaged to the inner surface; and    a fuel delivery module having a can engaged to the bracket, a fuel pump motor having a rotational axis positioned substantially horizontal, a fuel filter, a fuel supply pressure control assembly, and a fuel level sensing assembly, wherein the fuel pump motor, the fuel filter, the fuel supply pressure control assembly, and the fuel level sensing assembly are carried and supported by the can.    
     
     
         22 . The fuel tank assembly set forth in  claim 21  wherein the fuel tank is made of blow molded plastic and the bracket is made of injected plastic.  
     
     
         23 . A method of manufacturing a fuel tank assembly comprising the steps of: 
 inserting a fuel delivery module into a fuel tank through a tank access hole;    positioning the fuel delivery module horizontally along a bottom surface of the fuel tank;    aligning two opposite spacer bars of an can of the fuel delivery module below two respective opposing cross bars of respective clasps engaged to the bottom surface of the fuel tank;    sliding the fuel delivery module between the clasps wherein the spacer bars engage the respective cross bars; and    snap locking the can to a locking tab of the bracket.