GB2559349A

GB2559349A - Fuel tank apparatus and method

Info

Publication number: GB2559349A
Application number: GB1701624.7A
Authority: GB
Inventors: Towers Kyle
Original assignee: Jaguar Land Rover Ltd
Current assignee: Jaguar Land Rover Ltd
Priority date: 2017-02-01
Filing date: 2017-02-01
Publication date: 2018-08-08
Anticipated expiration: 2037-02-01
Also published as: GB2559349B; GB201701624D0

Abstract

There is a fuel tank assembly 1 for a vehicle (V figure 1). The fuel tank assembly includes a vessel 3 for storing fuel. The vessel has a first shell (1 figure 5) and a second shell (17 figure 5) which are joined together. The first shell is composed of a plastics material and the second shell is composed of a metal. The present disclosure also relates to a vehicle incorporating a fuel tank assembly and to a method of forming a fuel tank assembly. In another embodiment, there is a further fuel tank assembly in which there is a vessel moulded from plastics with one or more shield members 9-1, 9-2. The shield member is fastened to an exterior of the vessel by mechanical interlocking means 14 (see figure 3B). Also claimed is a method of forming this second fuel tank assembly and a vehicle incorporating such an assembly.

Description

(54) Title of the Invention: Fuel tank apparatus and method Abstract Title: Metal and plastics fuel tank (57) There is a fuel tank assembly 1 for a vehicle (V figure 1). The fuel tank assembly includes a vessel 3 for storing fuel. The vessel has a first shell (1 figure 5) and a second shell (17 figure 5) which are joined together. The first shell is composed of a plastics material and the second shell is composed of a metal. The present disclosure also relates to a vehicle incorporating a fuel tank assembly and to a method of forming a fuel tank assembly. In another embodiment, there is a further fuel tank assembly in which there is a vessel moulded from plastics with one or more shield members 9-1,9-2. The shield member is fastened to an exterior of the vessel by mechanical interlocking means 14 (see figure 3B). Also claimed is a method of forming this second fuel tank assembly and a vehicle incorporating such an assembly.

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FUEL TANK APPARATUS AND METHOD

TECHNICAL FIELD

The present disclosure relates to a fuel tank apparatus and method. In particular, but not exclusively, the present disclosure relates to a fuel tank assembly; to a vehicle; and to a method of forming a fuel tank assembly.

BACKGROUND

A fuel tank for an internal combustion engine is often supported under the body of a vehicle. It is known to provide a shield to protect a fuel tank of vehicle from damage. These have particular application in vehicles which may be used off-road, for example utility vehicles and sports utility vehicles. The shield may, for example, comprise a steel or aluminium panel which is attached to the body or chassis of the vehicle. Attaching the shield typically requires additional fixings and mounting members or brackets to secure the shield in position. These additional components add weight to the vehicle which is detrimental to vehicle performance.

At least in certain embodiments, the present invention seeks to overcome or ameliorate disadvantages associated with known arrangements.

SUMMARY OF THE INVENTION

Aspects of the present invention relate to a fuel tank assembly, to a vehicle and to a method of forming fuel tank assembly as claimed in the appended claims.

According to a further aspect of the present invention there is provided a fuel tank assembly for a vehicle, the fuel tank assembly comprising:

a vessel for storing fuel, the vessel comprising a first shell and a second shell; the first and second shells being joined together;

wherein the first shell is composed of a plastics material and the second shell is composed of a metal. At least in certain embodiments, the second shell may provide enhanced protection for the fuel tank assembly. For example, from the second shell may be less susceptible to damage since it is composed of a metal.

The first shell may comprise an upper wall of the vessel. The second shell may comprise at least a portion of a lower wall of the vessel. The second shell may form a shield for the fuel tank assembly. The first and second shells may each comprise a clam shell.

The first and second shells may be joined together along a circumferential joint. The circumferential joint may be at least substantially continuous.

The circumferential joint may comprise a welding joint.

The circumferential joint may comprise a mechanical interlocking joint. The first and second shells may comprise cooperating features to form said mechanical interlocking joint. The cooperating features may be integrally features of said first and second shells.

At least a portion of said second shell may be embedded in said first shell to form said mechanical interlocking joint.

The plastics material of said first shell may at least partially fills one or more aperture formed in said second shell to form said mechanical interlocking joint.

The circumferential joint may comprise an adhesive joint or a bonded joint.

The first shell may comprise a first circumferential section; and the second shell may comprise a second circumferential section. The circumferential joint may be formed between said first and second circumferential sections. The first circumferential section may comprise a first flange; and/or the second circumferential section may comprise a second flange. The first and second flanges may have cooperating features to form said mechanical interlocking joint.

The first shell may be composed of aluminium or steel, for example. The first shell may be press formed from a sheet of said metal.

According to a further aspect of the present invention there is provided a method of forming a fuel tank assembly for a vehicle, the method comprising:

forming a first shell from a plastics material;

forming a second shell from a metal; and joining said first and second shells to each other to form a vessel.

The method may comprise joining said first and second shells to form a circumferential joint.

The method may comprise welding said first and second shells together to form said circumferential joint.

The method may comprise forming a mechanical interlocking joint to form said circumferential joint.

The method may comprise embedding a portion of said second shell in said first shell to form said mechanical interlocking joint. The first shell may comprise a first circumferential portion; and said second shell may comprise a second circumferential portion. The circumferential joint may be formed between said first and second circumferential sections.

The method may comprise heating said first shell such that said plastics material is in a molten state and then forming said mechanical interlocking joint. The method may comprise performing localised heating of the first shell, for example to heat the first circumferential portion of the first shell. The heating may be performed by an external heat sources, such as a hot plate or an infrared heater.

The method may comprise bringing said first and second shells together to form said mechanical interlocking joint when the plastics material is in said molten state. A portion of said second shell may be embedded in said first shell to form said circumferential joint.

The second shell may comprise one or more projection and/or one or more aperture for cooperating with the plastics material of said first shell to form said mechanical interlocking joint. The one or more projection and/or the one or more aperture may form a key with the plastics material such that the first and second shells are mechanically interlocked. For example, the one or more projection and/or the one or more aperture may have a keyed profile, for example comprising one or more edge oriented to inhibit removal from the surrounding plastics material.

The method may comprise applying adhesive between said first and second shells to form said circumferential joint.

a moulded plastic vessel for storing fuel; and one or more shield member;

wherein said one or more shield member is fastened to an exterior of the vessel by mechanical interlocking means. At least in certain embodiments the one or more shield member is integrated into the fuel tank assembly. The one or more shield member may be permanently fastened to the vessel. The one or more shield member may thereby be integrated into the fuel tank assembly. The one or more shield member and the vessel mechanically interlock with each other to fasten the one or more shield member to the exterior of the vessel. In certain embodiments, the vessel may be over-moulded onto said one or more shield member to fasten the one or more shield member to the vessel. This may help to preserve integrity of the vessel and also fasten the one or more shield member to the exterior thereof.

The vessel may comprise a side wall, a lower wall and an upper wall. The one or more shield member may extend over at least a portion of the lower wall of said vessel. The one or more shield member may thereby protect the base of the fuel tank assembly. The one or more shield member may extend upwardly over at least a portion of the side wall of the vessel.

A joint may be formed between the vessel and each shield member. The joint could, for example, comprise a weld line or a bond line. Alternatively, or in addition, the joint may comprise a mechanical connection, for example comprising interlocking features. The mechanical interlocking means may form a joint between the vessel and each shield member. The joint may be a circumferential joint. The circumferential joint may be at least substantially continuous.

The mechanical interlocking means may comprise at least one projection disposed on said one or more shield member. The at least one projection may be at least partially encapsulated in the plastics material forming the vessel. The at least one projection may be at least partially encapsulated in the plastic forming a sidewall or a lower wall of the vessel.

The at least one projection may, for example, comprise a plurality of tabs. The at least one projection may comprise a flange. A plurality of apertures may be formed in said flange. The apertures may be internal apertures or perforations. The plastics material forming the vessel may fill said apertures. The plastics material may form webs in said internal apertures.

The flange may form a circumferential joint between the plastics material and the shield member. The joint may extend around the circumference of the shield member. The flange may extend around a circumference of the shield member. The vessel may be continuous within said closed loop to form a double walled structure. In certain embodiments, the vessel within said closed loop may be allowed to flex relatively to said shield member, for example due to changes in the internal pressure of the fuel tank assembly. Alternatively, the vessel may comprise an aperture within said closed loop. This arrangement may be used to reduce the mass of the fuel tank assembly. In certain embodiments, the shield member may replace a portion of the vessel, for example to form a lower portion of the vessel.

The mechanical interlocking means may comprise at least one aperture formed in said one or more shield member. The plastics material forming the vessel may fill said at least one aperture to fasten the one or more shield member to the vessel.

The at least one aperture may comprise a negative return angle. The at least one aperture may comprise an elongated channel arranged to form a circumferential joint between the vessel and the shield member.

The one or more shield member may comprise a metal member. Alternatively, the one or more shield member may comprise a reinforced plastic member. For example, the one or more shield member may comprise a fibre reinforced plastic member.

According to a further aspect of the present invention there is provided a vehicle comprising a fuel tank assembly as described herein.

inserting one or more shield member into a mould; introducing a plastics material into the mould; and displacing the plastics material against an inside wall of the mould to form a vessel; wherein the one or more shield member is disposed in said mould between the plastics material and the inside wall of the mould and a mechanical interlocking joint is formed to fasten the shield member to the vessel. The plastics material may be introduced into the mould in a molten state. The plastics material may be introduced into the mould in the form of a sheet. Alternatively, the plastics material may be introduced into the mould in the form of a parison. The parison comprises a tubular length of molten plastics material. The vessel may be blow moulded. A compressed gas may be introduced into the parison to displace the plastics material against the inside wall of the mould. The vessel is overmoulded onto said one or more shield member disposed in said mould. The one or more shield member may thereby be permanently fastened to the exterior of the vessel.

The mechanical interlocking means may comprise one or more projection. The one or more projection may be at least partially encapsulated in the plastics material when the vessel is formed. The one or more projection may comprise a flange or a tab, for example.

Alternatively, or in addition, the mechanical interlocking means may comprise one or more aperture. The plastics material may be introduced into said one or more aperture during the formation of the vessel when the plastics material is in a molten state.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more embodiments of the present invention will now be described, by way of example only, with reference to the accompanying figures, in which:

Figure 1 shows a schematic representation of a vehicle incorporating a fuel tank assembly in accordance with an embodiment of the present invention;

Figure 2 shows a side elevation of the fuel tank assembly shown in Figure 1 comprising a moulded plastic vessel and integrated shield members in accordance with an embodiment of the present invention;

Figure 3A shows a perspective view of the shield members incorporated into the fuel tank assembly shown in Figures 1 and 2;

Figure 3B shows a sectional view at a joint formed between the moulded plastic vessel and integrated shield members;

Figure 4 shows a side elevation of a fuel tank assembly according to a further embodiment of the present invention; and

Figure 5 shows a side elevation of a fuel tank assembly according to a further embodiment of the present invention.

DETAILED DESCRIPTION

A fuel tank assembly 1 in accordance with an embodiment of the present invention will now be described with reference to figures 1, 2 and 3. The fuel tank assembly 1 is configured to store a fuel, such as gasoline or diesel. The fuel tank assembly 1 has particular application in a vehicle V for supplying fuel to an internal combustion engine 2, as illustrated in figure 1. The vehicle V may, for example, be a sports utility vehicle (SUV) or an off-road vehicle.

With reference to figure 2, the fuel tank assembly 1 comprises a vessel 3 for storing fuel. The vessel 3 may be referred to as a fuel tank carcass. The vessel 3 comprises a sidewall 4, an upper wall 5 and a lower wall 6. As described herein, the vessel 3 is moulded from a plastics material. The fuel tank assembly 1 in the present embodiment is a saddle-type fuel tank assembly comprising first and second compartments 7-1, 7-2 for positioning on opposing sides of a driveshaft (not shown) connected to the internal combustion engine 2. The fuel tank assembly 1 is positioned under the rear seat (not shown) of the vehicle V, but other configurations are also contemplated. The first and second compartments 7-1,7-2 are connected by a central bridging section 8 which extends over the driveshaft. The fuel tank assembly 1 comprises first and second shield members 9-1,9-2 associated with the first and second compartments 7-1, 7-2 respectively. The first and second shield members 9-1, 9-2 are adapted to protect an underside of the vessel 3, for example when the vehicle V is driven off road. As described herein, first and second circumferential joints 10-1, 10-2 are formed between the vessel 3 and the first and second shield members 9-1, 9-2 respectively to permanently fasten the first and second shield members 9-1,9-2 to the exterior of the vessel 3. The first and second circumferential joints 10-1, 10-2 extend around the circumference of the first and second shield members 9-1, 9-2 respectively. The first and second shield members 9-1, 9-2 are thereby integrated into the fuel tank assembly 1. The first and second circumferential joints 10-1, 10-2 extend around the outside of the first and second compartments 7-1, 7-2 respectively. A fuel supply assembly 11 is provided in the upper wall 5 of the fuel tank assembly 1 for supplying fuel to the internal combustion engine 2. The fuel supply assembly 11 is fixedly mounted to the upper wall 5 by an encapsulated ring 12 which is incorporated into the upper wall 5 of the fuel tank assembly 1 in conventional manner.

The first and second shield members 9-1, 9-2 are fastened directly to an exterior of the vessel 3 and are external to the vessel 3. In the present embodiment, the first and second shield members 9-1, 9-2 extend over an underside of the first and second compartments 71, 7-2 respectively. With reference to Figures 3A and 3B, the first and second shield members 9-1, 9-2 are formed from a metal, such as aluminium. However, it will be understood that the first and second shield members 9-1, 9-2 may be formed from other materials, such as a reinforced plastics material. The first and second shield members 9-1,

9-2 each comprise a central panel 13; and mechanical interlocking means for fastening to the vessel 3. As shown in figure 3B, the mechanical interlocking means in the present embodiment comprise a flange 14 having a series of internal apertures or perforations 15 formed therein. The flange 14 extends around the circumference of the central panel 13 of each of the first and second shield members 9-1, 9-2 and is configured to be encapsulated within the plastics material forming the vessel 3 to form the first and second circumferential joints 10-1, 10-2. In the present embodiment, the flanges 14 are sized so as not to extend through the sidewall of the vessel 3. The internal apertures 15 are configured to allow the plastics material forming the vessel 3 to form interlocking webs to inhibit relative movement between the flange 14 and the vessel 3. It will be understood that the lower wall 6 and the central panels 13 of the respective first and second shield members 9-1, 9-2 form a doublewalled structure on the underside of the fuel tank assembly 1.

The fabrication of the fuel tank assembly 1 will now be described. The first and second shield members 9-1, 9-2 are pre-formed, for example by a metal pressing process. The flange 14 is formed integrally with the first and second shield members 9-1,9-2. The internal apertures 15 are cut-outs and may be formed simultaneously with the formation of the flange 14 or in a separate forming process. The vessel 3 is blow moulded from a parison of plastics material in a cavity formed in a mould (not shown). The first and second shield members 9-1, 9-2 are inserted into the mould cavity and held in position prior to the introduction of a tubular parison of plastics material. In the present embodiment, the first and second shield members 9-1, 9-2 are located in those portions of the mould defining the lower wall 6 of the first and second compartments 7-1, 7-2. The encapsulated ring 12 may also be introduced into the mould cavity at this time. The parison is introduced into the mould cavity, prior to closing the mould and clamping the parison. A compressed gas is introduced into the parison to displace the plastics material against the sidewall of the mould cavity and the exposed surfaces of the first and second shield members 9-1, 9-2. While the parison is molten, the plastics material encapsulates the flanges 14 of the first and second shield members 9-1, 9-2 and is displaced through the internal apertures 15. The first and second shield members 9-1, 9-2 are thereby integrated into the fuel tank assembly 1. The plastics material is allowed to cool and the fuel tank assembly 1 is then removed from the mould. It will be understood that the fittings and fixtures may be added manner after the fuel tank assembly 1 has been removed from the mould.

A further embodiment of the fuel tank assembly 1 will now be described with reference to figure 4. Like reference numerals are used for like components.

With reference to figure 4, the fuel tank assembly 1 comprises a vessel 3 for storing fuel. The vessel 3 comprises a sidewall 4, an upper wall 5 and a lower wall 6. The vessel 3 is moulded from a plastics material. The fuel tank assembly 1 according to the present embodiment comprises a single shield member 9 which extends over the lower wall 6 of the vessel 3. As shown in figure 4, the shield member 9 is configured to extend over an underside of the first and second compartments 7-1, 7-2, and the central bridging section 8. The shield member 9 is fastened directly to an exterior of the sidewall 4 of the vessel 3 by a single, circumferential joint 10 which extends around the first and second compartments 7-1, 7-2 and the central bridging section 8. The circumferential joint 10 in the present embodiment is substantially coincident with an interface between the dies of the mould used to form the vessel 3. In particular, the shield member 9 comprises mechanical interlocking means for cooperating with the plastics material forming the vessel 3. The mechanical interlocking means may have the same configuration as the previous embodiment. In particular, the mechanical interlocking means comprises a flange 14 having a series of internal apertures or perforations 15. The flange 14 is encapsulated within the plastics material of the vessel 3 to form the circumferential joint 10. The plastics material is dispersed through the internal apertures 15 and forms interlocking webs. The shield member 9 is thereby integrated into the fuel tank assembly 1 in the same manner.

In the embodiments described above, and each shield member 9 is fastened to an exterior of the vessel 3 to form a double-walled structure. It is envisaged that a portion of the vessel 3 could be formed by a shield member 9. A further embodiment of the present invention is illustrated in Figure 5. Like reference numerals are used for like components.

With reference to figure 5, the fuel tank assembly 1 comprises a vessel 3 for storing fuel. The vessel 3 comprises a sidewall 4, an upper wall 5 and a lower wall 6. The vessel 3 is formed by a first shell 16 and a second shell 17 which are joined together to form a circumferential joint 10. The circumferential joint 10 is a continuous joint extending around the first and second compartments 7-1, 7-2 and across the central bridging section 8.The first shell 16 is moulded from a plastics material, for example using vacuum forming or blowmoulding techniques. The first shell 16 forms the upper wall 5 and a portion of the sidewall 4 of the vessel 3. The second shell 17 is composed of a metal, such as aluminium or steel. The second shell 17 forms the lower wall 6 and a lower portion of the sidewall 4 of the vessel

3. The second shell 17 may be pre-formed, for example by a metal pressing operation or the like. In the present embodiment, the second shell 17 forms a shield member 9 for protecting an underside of the fuel tank assembly 1. The shield member 9 forms the lower portion of the first and second compartments 7-1, 7-2, and also an underside of the central bridging section 8. The circumferential joint 10 is formed by a mechanical interlocking of the first and second shells 16, 17.

The circumferential joint 10 comprises a welding joint. The first shell 16 comprises a first circumferential section 18; and the second shell 17 comprises a second circumferential section 19. The first shell 16 is heated to melt the plastics material forming the first circumferential section 18. The first circumferential section 18 may be heated locally to melt the plastics material. An external heat source, such as a heating plate or an infrared heater, may be used to melt the plastics material in said first circumferential section 19. The first and second shells 16, 17 are then aligned with each other and a pressure applied such that the second circumferential section 18 is at least partially embedded in the first circumferential section 19 thereby forming the circumferential joint 10. The circumferential joint 10 comprises a mechanical interlock between said first and second shells 16, 17. The second circumferential section 19 may comprise one or more apertures; and/or one or more projections which cooperate with the molten plastics material of the first circumferential section 19 to form the circumferential joint 10. For example, the plastics material may fill one or more apertures in said second circumferential section 19 to form interlocking webs. It will be understood that the circumferential joint 10 comprises a continuous seal such that the vessel 3 is sealed. The second shell 17 forms the shield member 9 which is integrated into the fuel tank assembly 1. In a variant, the first and second shells 17 could be joined together immediately after the first shell 16 is moulded and the plastics material is still in a deformable state.

Other types of joints may be used to form the circumferential joint 10. The first and second circumferential sections 18, 19 may comprise first and second flanges which form a flange joint. Alternatively, the first and second circumferential sections 18, 19 may comprise first and second walls which are aligned to form a butt joint, or which are arranged to form a lap joint. It will be understood that the first and second circumferential sections 18, 19 may have cooperating features, such as a tongue and groove arrangement.

Other methods for forming the circumferential joint 10 include the application of an adhesive or a liquid plastics material between the first and second circumferential sections 18, 19. Alternatively, the circumferential joint 10 may be formed by a secondary adhesive or friction welding. Alternatively, the second shell 17 could be heated, for example using an electrical heater, and then pressed against the first shell 16 such that the second circumferential section 19 is at least partially embedded in the first circumferential section 18 of the first shell

16.

Alternatively, the first and second shells 16, 17 may be bonded to each other. A laser joining technology, such as laser-assisted metal and plastic (LAMP) joining, may be used to directly bond the metal and plastics material to each other.

In a further alternative, the metal and plastic components may be joined prior to forming the first shell 16. In particular, the second shell 17 may be pre-formed, for example by pressing a metal sheet in a die. The pre-formed second shell 17 may be installed in a mould cavity. A sheet of molten plastics material may be introduced into the mould cavity (for example dropped from above). The mould cavity may then be closed to clamp the sheet of plastics material and the second shell 17 together. A mechanical interlock may be formed between said first and second shells 16, 17 to form the circumferential joint 10. When the sheet of plastics material and the second shell 17 are clamped together, the molten plastics material may be displaced through one or more aperture formed around the circumference of the second shell 17. Alternatively, or in addition, one or more projection formed around the circumference of the second shell 17 may be embedded in said first shell 16. A chamber is formed between the second shell 17 and the sheet of plastics material and a compressed gas is introduced into this chamber. The compressed gas displaces the molten plastics material against an interior of the mould cavity to form the first shell 16. The first and second shells 16,17 are thereby joined together to form the vessel 3.

It will be appreciated that various modifications may be made to the embodiment(s) described herein without departing from the scope of the appended claims. For example, the shield member 9 is described herein as comprising a flange 14 which is encapsulated within the plastics material forming the vessel 3. Alternatively, or in addition, the shield member 9 may comprise one or more aperture into which the plastics material forming the vessel 3 is introduced to fasten the shield member 9 to the vessel 3. The one or more aperture may have a negative return angle. The one or more aperture may comprise a channel or groove for forming a continuous seal. The shield member 9 may incorporate a flange 14 and a channel to fasten the shield member to the vessel. The flange 14 and the channel could, for example, extend parallel to each other.

Claims

CLAIMS:

1. A fuel tank assembly for a vehicle, the fuel tank assembly comprising:

wherein the first shell is composed of a plastics material and the second shell is composed of a metal.

2. A fuel tank assembly as claimed in claim 1, wherein the second shell comprises at least a portion of a lower wall of the vessel.

3. A fuel tank assembly as claimed in claim 1 or claim 2, wherein the second shell forms a shield for the fuel tank assembly.

4. A fuel tank assembly as claimed in any one of the preceding claims, wherein said first and second shells are joined together along a circumferential joint.

5. A fuel tank assembly as claimed in claim 4, wherein said circumferential joint comprises a welding joint.

6. A fuel tank assembly as claimed in claim 4 or claim 5, wherein said circumferential joint comprises a mechanical interlocking joint.

7. A fuel tank assembly as claimed in claim 6, wherein said first and second shells comprise cooperating features to form said mechanical interlocking joint.

8. A fuel tank assembly as claimed in claim 6 or claim 7, wherein at least a portion of said second shell is embedded in said first shell to form said mechanical interlocking joint.

9. A fuel tank assembly as claimed in any one of claims 6, 7 or 8, wherein the plastics material of said first shell at least partially fills one or more aperture formed in said second shell to form said mechanical interlocking joint.

10. A fuel tank assembly as claimed in any one of claims 4 to 9, wherein said circumferential joint comprises an adhesive joint or bonded joint.

11. A fuel tank assembly as claimed in any one of claims 4 to 10, wherein said first shell comprises a first circumferential section and said second shell comprises a second circumferential section; the circumferential joint being formed between said first and second circumferential sections.

12. A method of forming a fuel tank assembly for a vehicle, the method comprising: forming a first shell from a plastics material;

13. A method as claimed in claim 12 comprising joining said first and second shells to form a circumferential joint.

14. A method as claimed in claim 13 comprising welding said first and second shells together to form said circumferential joint.

15. A method as claimed in claim 13 or claim 14 comprising forming a mechanical interlocking joint to form said circumferential joint.

16. A method as claimed in claim 15 comprising embedding a portion of said second shell in said first shell to form said mechanical interlocking joint.

17. A method as claimed in claim 16 comprising heating said first shell such that said plastics material is in a molten state and then forming said mechanical interlocking joint.

18. A method as claimed in claim 17 comprising bringing said first and second shells together to form said mechanical interlocking joint when the plastics material is in said molten state.

19. A method as claimed in claim 18, wherein the second shell comprises one or more projection and/or one or more aperture for cooperating with the plastics material of said first shell to form said mechanical interlocking joint.

20. A method as claimed in any one of claims 13 to 19 comprising applying adhesive between said first and second shells to form said circumferential joint.

21. A fuel tank assembly for a vehicle, the fuel tank assembly comprising:

a vessel for storing fuel, the vessel being moulded from a plastics material; and one or more shield member;

wherein said one or more shield member is fastened to an exterior of the vessel by mechanical interlocking means.

22. A fuel tank assembly as claimed in claim 21, wherein the vessel comprises a sidewall, an upper wall and a lower wall, the one or more shield member extending over at least a portion of the lower wall of said vessel.

23. A fuel tank assembly as claimed in claim 21 or claim 22, wherein said mechanical interlocking means forms a circumferential joint between the vessel and each shield member.

24. A fuel tank assembly as claimed in any one of claims 21, 22 or 23, wherein said mechanical interlocking means comprises at least one projection disposed on said one or more shield member, the at least one projection being at least partially encapsulated in the plastics material forming the vessel.

25. A fuel tank assembly as claimed in claim 24, wherein said at least one projection comprises a flange.

26. A fuel tank assembly as claimed in claim 25, wherein a plurality of apertures are formed in said flange.

27. A fuel tank assembly as claimed in any one of claims 21 to 26, wherein said mechanical interlocking means comprises at least one aperture formed in said one or more shield member, the plastics material forming the vessel filling said at least one aperture to fasten the one or more shield member to the vessel.

28. A fuel tank assembly as claimed in claim 27, wherein said at least one aperture comprises an elongated channel arranged to form a circumferential joint between the vessel and the shield member.

29. A fuel tank assembly as claimed in any one of claims 21 to 28, wherein the one or more shield member comprises a metal member or a reinforced plastic member.

30. A vehicle comprising a fuel tank assembly as claimed in any one of claims 1 to 11 or any one of claims 21 to 29.

31. A method of forming a fuel tank assembly for a vehicle, the method comprising:

5 inserting one or more shield member into a mould;

introducing a plastics material into the mould; and displacing the plastics material against an inside wall of the mould to form a vessel; wherein the one or more shield member is disposed in said mould between the plastics material and the inside wall of the mould and a mechanical interlocking joint is 10 formed to fasten the shield member to the vessel.

32. A method as claimed in claim 31, wherein said mechanical interlocking means comprises one or more projection, the one or more projection being at least partially encapsulated in the plastics material when the vessel is formed.

33. A method as claimed in claim 31 or claim 32, wherein said mechanical interlocking means comprises one or more aperture, the plastics material being introduced into said one or more aperture when the vessel is formed.

Intellectual

Property

Office

Application No: Claims searched:

GB1701624.7

1-20 and in part claim 30