Urea solution tank assembly

Abstract

A tank for storing urea solution and a tank assembly for storing disparate fluids, such as diesel fluid and urea solution, are disclosed. The tank may further include a filler assembly and/or a sensor assembly, either of which are adapted to be connected to the tank without the use of separate fasteners, The tank assembly may include a reservoir and a sensor for automatically diverting non-conforming urea solution to the reservoir. A recess may be defined in the tank body in order to accommodate a strap for securing the tank to the frame of vehicle. The tank may include parallel sidewalls that include a projection on one and a corresponding indentation on the other in order to allow the tanks to be easily stacked during assembly.

1 . A tank assembly for holding both diesel fuel and urea solution, said tank assembly comprising:
 a first chamber defined within said container, said first chamber being adapted to store diesel fuel;   a first aperture defined within said first chamber for receiving diesel fuel;   a second chamber defined with said container, said second chamber and said first chamber being fluidly isolated from each other, and said first and second chambers sharing at least a first wall;   a tank positioned within said second chamber, said tank having a first hole adapted to receive a urea solution; and   a second aperture defined within said second chamber wherein said second aperture is aligned with said first hole such that urea solution can be delivered through said second aperture and said first hole into said tank.   
   
   
       2 . The tank assembly of  claim 1  wherein said tank is made from a material different from said second chamber, and said tank is made from molded plastic. 
   
   
       3 . The tank assembly of  claim 1  further including:
 a reservoir;   a sensing unit positioned adjacent said second aperture, said sensing unit adapted to detect a quality of the urea solution; and   a switch adapted to direct the urea solution to said reservoir if said sensing unit determines that the quality of the urea solution does not conform to a predetermined standard, said switch further adapted to allow the urea solution to enter said tank if said sensing unit determines the quality of the urea solution does conform to the predetermined standard.   
   
   
       4 . The tank assembly of  claim 3  wherein said switch includes a solenoid that may be selectively activated in order to direct the urea solution into either said tank or said reservoir. 
   
   
       5 . The tank assembly of  claim 4  further including a drain plug positioned at a lower region of said reservoir, said drain plug adapted to be selectively removed from said reservoir such that liquid within said reservoir may be removed through said drain plug. 
   
   
       6 . The tank assembly of  claim 1  further including:
 a second hole in said tank;   a second aperture defined in said second chamber, said second hole and said second aperture being aligned with each other; and   a sensor assembly positioned within said second hole and said second aperture, said sensor assembly adapted to detect a level of urea solution with said tank, and said sensor assembly further including a tube for transporting urea solution out of said tank.   
   
   
       7 . The tank assembly of  claim 1  wherein said tank includes a first sidewall and a second sidewall, said first and second sidewalls generally each defining first and second planes, respectively, that are parallel to each other, wherein said first sidewall includes a projection at a first location and said second sidewall includes an indentation at a second location, said first and second locations being defined such that said projection of a first one of said tanks is able to be inserted into said indentation of a second one of said tanks when a plurality of said tanks are stacked on top of each other in a position external to said second chamber. 
   
   
       8 . The tank assembly of  claim 1  further including a filler tube assembly positioned within said second aperture of said second chamber, said filler tube assembly including a filler tube, a shroud, an outer housing, and a reduction sleeve, said filler tube, shroud, outer housing, and reduction sleeve all adapted to be secured to each other without the use of separate fasteners. 
   
   
       9 . The tank assembly of  claim 1  further including a plurality of fastener apertures defined in said perimeter wall around said second aperture, said plurality of fastener apertures being adapted for securing a filler tube assembly within said second aperture, and said plurality of fastener apertures being arranged in a non-symmetrical manner such that said filler tube assembly can only be mounted within said second aperture in a single orientation. 
   
   
       10 . The tank assembly of  claim 1  further including a filler tube positioned within said second aperture, said filler tube including an anti-siphon structure adapted to hinder a hose from being inserted through said filler tube and into said tank. 
   
   
       11 . A tank assembly for storing urea solution comprising:
 a tank adapted to store urea solution, said tank comprising a first wall sidewall, a second sidewall, and a perimeter wall, said second sidewall spaced from said first sidewall, said first and second sidewalls each generally defining a first and second plane, respectively, wherein said first and second planes are parallel to each other, and said perimeter wall connecting said first and second sidewalls together;   an indentation on said first wall having a first shape; and   a projection on said second wall having a second shape, said second shape substantially matching said first shape such that said projection on a first one of said tanks may be inserted into said indentation on a second one of said tanks when a plurality of said tanks are stacked on top of each other, whereby said first tank resists movement of said second tank in any direction parallel to said first plane when said projection on said first tank is inserted into said indentation on said second tank.   
   
   
       12 . The tank assembly of  claim 11  further including an aperture defined in said perimeter wall for receiving an assembly and a plurality of fastener apertures defined in said perimeter wall around said aperture, said plurality of fastener apertures being adapted for securing the assembly within said aperture, and said plurality of fastener apertures being arranged in a non-symmetrical manner such that said assembly can only be mounted within said aperture in a single orientation. 
   
   
       13 . The tank assembly of  claim 12  wherein said assembly is one of a filler tube assembly and a sensor assembly. 
   
   
       14 . The tank assembly of  claim 11  further including:
 an L-shaped bracket adapted to be secured to a motor vehicle;   a plurality of side brackets adapted to be secured to said L-shaped bracket;   a strap adapted to be secured to said side brackets; and   a recess defined in the perimeter wall of said tank, said recess shaped to receive a portion of said strap whereby said strap and said recess cooperate to secure said tank to said L-shaped bracket and said side brackets.   
   
   
       15 . The tank assembly of  claim 14  wherein said tank is secured to said L-shaped bracket and said side brackets without the use of any fastener that pierces any portion of said tank and any one of said L-shaped bracket and said side brackets. 
   
   
       16 . The tank assembly of  claim 14  further including;
 a metal hoop secured around said perimeter wall;   a metal front cover secured to said metal hoop and positioned generally adjacent said first sidewall;   a metal rear cover secured to said metal hoop and positioned generally adjacent said second sidewall wherein said metal hoop and said metal front and rear covers, in combination, define an enclosure in which said tank is positioned; and   wherein said perimeter wall and said first and second sidewalls of said tank are made of plastic.   
   
   
       17 . The tank assembly of  14  further including a metal enclosure surrounding said tank, said metal enclosure including a first part and a second part, said first part surrounding said first sidewall and said perimeter wall of said tank, and said second part surrounding said second sidewall of said tank. 
   
   
       18 . The tank assembly of  claim 16  further including:
 a first spacer positioned between said L-shaped bracket and a first one of said side brackets, said first side bracket being secured to said L-shaped bracket by a first fastener inserted through a first set of aligned holes in said first side bracket, said first spacer, and said L-shaped bracket; and   a second spacer positioned between said L-shaped bracket and a second one of said side brackets, wherein said second side bracket is secured to said L-shaped bracket by a second fastener inserted through a second set of aligned holes in said second side bracket, said second spacer, and said L-shaped bracket   
   
   
       19 . The tank assembly of  claim 11  further including:
 a reservoir fluidly isolated from said tank;   a sensing unit positioned adjacent an aperture adapted to receive a urea solution dispensing nozzle, said sensing unit adapted to detect a quality of the urea solution dispensed from the nozzle; and   a switch adapted to direct the urea solution to said reservoir if said sensing unit determines that the quality of the urea solution does not conform to a predetermined standard, said switch further adapted to allow the urea solution to enter the tank if said sensing unit determines the quality of the urea solution does conform to the predetermined standard.   
   
   
       20 . The tank assembly of  claim 11  further including an aperture defined in said perimeter wall of said tank, and a filler tube positioned within said aperture, said filler tube including an anti-siphon structure adapted to hinder a hose from being inserted through said filler tube and into said tank. 
   
   
       21 . A tank assembly comprising:
 a tank adapted for storing urea solution;   an aperture defined within said tank for receiving urea solution;   a reservoir fluidly isolated from said tank;   a sensing unit positioned adjacent said aperture, said sensing unit adapted to detect a quality of the urea solution being delivered to the aperture; and   a switch adapted to direct the urea solution to said reservoir if said sensing unit determines that the quality of the urea solution does not conform to a predetermined standard, said switch further adapted to allow the urea solution to enter the tank if said sensing unit determines the quality of the urea solution does conform to the predetermined standard.   
   
   
       22 . The assembly of  21  wherein said tank further includes:
 a plurality of fastener holes adapted to allow said tank to be secured to a diesel fuel tank; and   a recess in a perimeter wall of said tank, said recess shaped to receive a portion of a strap whereby a strap may be used to secure the tank to a bracket for mounting to a vehicle frame; and   wherein said tank and said reservoir are both defined by a single structure made of molded plastic wherein said tank and said reservoir share at least one wall.   
   
   
       23 . The assembly of  claim 21  wherein said tank further includes:
 a first wall sidewall;   a second sidewall spaced from said first sidewall, said first and second sidewalls each generally defining a first and second plane, respectively, wherein said first and second planes are parallel to each other; and   a perimeter wall connecting said first and second sidewalls together.   
   
   
       24 . The assembly of  claim 23  further including:
 a metal hoop secured around said perimeter wall;   a metal front cover secured to said metal hoop and positioned generally adjacent said first sidewall; and   a metal rear cover secured to said metal hoop and positioned generally adjacent said second sidewall wherein said metal hoop and said metal front and rear covers, in combination, define an enclosure in which said tank is positioned.   
   
   
       25 . The assembly of  claim 23  further including a metal enclosure surrounding said tank, said metal enclosure including a first part and a second part, said first part surrounding said first sidewall and said perimeter wall of said tank, and said second part surrounding said second sidewall of said tank. 
   
   
       26 . The assembly of  24  further including:
 an L-shaped bracket adapted to be secured to a motor vehicle;   a plurality of side brackets adapted to be secured to said L-shaped bracket;   a strap adapted to be secured to said side brackets; and   a recess defined in the perimeter wall of said tank, said recess shaped to receive a portion of said strap whereby said strap and said recess cooperate to secure said tank to said L-shaped bracket and said side brackets.   
   
   
       27 . A tank assembly for storing urea solution comprising:
 a tank adapted to store urea solution, said tank comprising a first sidewall, a second sidewall, and a perimeter wall, said second sidewall spaced from said first sidewall, said first and second sidewalls each generally defining a first and second plane, respectively, wherein said first and second planes are parallel to each other, and said perimeter wall connecting said first and second sidewalls together;   an L-shaped bracket adapted to be secured to a motor vehicle;   a plurality of side brackets adapted to be secured to said L-shaped bracket;   a strap adapted to be secured to said side brackets; and   a recess defined in the perimeter wall of said tank, said recess shaped to receive a portion of said strap whereby said strap and said recess cooperate to secure said tank to said L-shaped bracket and said side brackets.   
   
   
       28 . The assembly of  claim 27  further including:
 a metal hoop secured around said perimeter wall;   a metal front cover secured to said metal hoop and positioned generally adjacent said first sidewall; and   a metal rear cover secured to said metal hoop and positioned generally adjacent said second sidewall wherein said metal hoop and said metal front and rear covers, in combination, define an enclosure in which said tank is positioned.   
   
   
       29 . The assembly of  claim 27  further including a metal enclosure surrounding said tank, said metal enclosure including a first part and a second part, said first part surrounding said first sidewall and said perimeter wall of said tank, and said second part surrounding said second sidewall of said tank. 
   
   
       30 . The tank assembly of  claim 27  further including an aperture defined in said perimeter wall for receiving a filler tube assembly and a plurality of fastener apertures defined in said perimeter wall around said aperture, said plurality of fastener apertures being adapted for securing the filler tube assembly within said aperture, and said plurality of fastener apertures being arranged in a non-symmetrical manner such that said filler tube assembly can only be mounted within said aperture in a single orientation.