WO1990013739A1

WO1990013739A1 - Fuel supply module

Info

Publication number: WO1990013739A1
Application number: PCT/US1990/002314
Authority: WO
Inventors: Jesse L. Szwargulski; Larry Leroy Lachalmelle; John B. Fitzgerald; Gregory B. Schoenberg
Original assignee: Carter Automotive Company, Inc.
Priority date: 1989-05-05
Filing date: 1990-04-26
Publication date: 1990-11-15
Also published as: US4974570A; KR920701653A; EP0471008A1; KR960003691B1; AU640659B2; EP0471008B1; ES2044590T3; BR9007348A; JP2614364B2; DE69003677T2; JPH04507123A; CA2054733A1; AU5657190A; DE69003677D1; CA2054733C

Abstract

A vehicle fuel pumping unit (10) wherein a reserve fuel supply container (27) is located within the fuel tank (12) to supply liquid fuel to a motor-operated pump (43) when the tank is nearly empty. The invention addresses the problem of pump starvation when the tank is nearly empty and the liquid fuel is held away from the pump intake passage due to abrupt sustained turning or other maneuvers of the vehicule. In preferred practice of the invention normal fuel flow from the tank to the pump is controlled by an annular float valve (40, 42) located directly below the reserve fuel supply container. Fuel flow from the reserve containers is controlled by a pressure-responsive valve (54) located in the suction path between the container and the pump intake (46). The pressure-responsive valve is part of a sub-assembly including a liquid fuel filter screen (55) for filtering all fuel from the container and a valve seat (48) for the pressure-responsive valve.

Description

FUEL SUPPLY MODULE

TECHNICAL FIELD

This invention relates to automotive vehicle fuel systems, especially to systems wherein a motor-operated fuel pump is located in a fuel tank to pump liquid fuel (e.g. gasoline or diesel fuel) from the tank to a carburetor or fuel injector mechanism on the vehicle engine.

BACKGROUND ART

The invention is concerned primarily with a problem that occurs when the fuel tank is nearly empty and the vehicle is being driven on hilly terrain or winding roads or being held in a sustained turn as when entering a -freeway. In such situations the liquid fuel in the tank can either slosh around or be held to one side of the tank so that the fuel pump is momentarily or intermittently deprived of fuel (the pump loses its prime) . This condition can occur even though there is some fuel still in the tank; the fuel tank gage can register the existence of fuel in the tank, but still the fuel is not available to the fuel pump.

The problem has been addressed in certain prior art patents.

For example, U.S. Patent 3,443,519 to J. White shows a vehicle fuel system wherein a fuel pump having two tandem arranged pumping impellers is mounted in a casing within the fuel tank. The first impeller pumps fuel from the tank into a reservoir compartments within the casing. The second im¬ peller pumps liquid out of the fuel tank to the engine car¬ buretor or fuel injector mechanism. There is no return flow of excess fuel from the engine to the reservoir compartments. Consequently, the ability of the pump to retain its prime during this fuel starved condition is solely dependent upon the capacity of the reservoir compartment.

Likewise U.S. Patent 4,672,937 to D. Fales shows a fuel supply system including a complex two stage pump and a sole¬ noid actuated valve which, is response to a signal from a cut¬ off level flow switch, will render the pump first stage inoperative - while rendering the pump second stage operative to draw fuel from a reservoir.

U.S. Patent 4,747,388 to C. Tuckey discloses a fuel supply system comprising a single stage pump and a flexible filter screen which acts not only as the main tank fuel filter but also as a float and valve actuating mechanism to release fuel from the reservoir. Under normal operating conditions fuel will be supplied to the pump through the flexible filter screen. However, should the space below the filter screen become starved of fuel the screen will^" be lifted causing a valve to open and thereby enabling fuel to flow from a reservoir into the space above the screen and to the pump.

DISCLOSURE OF INVENTION

In our new arrangement the fuel pump is disposed in a reserve fuel supply container located within the fuel tank. The container is a vertically orientated, two-piece, spring- biased telescoping arrangement extending from the top^"of the tank to the bottom of the tank, which consequently can readily adjust to fuel tank expansion and contractions. Excess fuel from the engine is caused to flow into the reserve container such that it is always being filled so long as the engine is running. Under normal operations (with sufficient fuel in the tank) the pump intake passage is connected to a primary passage system that includes a float-operated valve. As long as there is sufficient liquid in the tank the float-operated valve supplies fluid to the pump intake passage. A secondary passage system is provided between the reserve fuel supply container and the pump intake passage, such that when the float-operated valve closes (due to insufficient fuel in the tank) an increased suction force is exerted on a normally closed secondary valve associated with the reserve fuel supply container. The secondary valve then opens so that fuel is then drawn from the reserve container through the secondary passage system into the pump. The secondary valve is a flapper type valve, simply constructed and immediately responsive to the pressure drop within the pump intake passage when the float-operated main valve closes.

In the preferred form the secondary valve is incor¬ porated into a second fuel filtering subassembly which filters the fuel in the reservoir.

One object of our invention is to provide a slosh- compensating fuel pumping system that uses a conventional geroter type positive displacement pump.

Another object is to provide a slosh-compensating fuel pumping system having filtration protection under both oper¬ ating modes, i.e. when the system is drawing liquid fuel from the tank, and also when the system is drawing liquid fuel from the auxiliary fuel supply reservoir or container.

A further object is to provide a slosh-compensating fuel pumping system.- wherein the switch over between the normal operating mode and the fuel-interrupted mode is accomplished simply and quickly.

Another object is to provide a slosh-compensating fuel pumping assembly that can be readily installed in and removed from a vehicle fuel tank.

An additional object of the invention is to provide a fuel pumping assembly that can accommodate itself to expansion or contraction of the fuel tank walls, due for example to ambient temperature changes, varying weights of fuel in the tank, partial vacuum conditions incident to withdrawal of fuel from the tank, and varying positive pressure conditions within the tank.

Yet another object is to provide a pumping system that includes a fuel level indicator referenced to the tank bottom wall, such that the indicator maintains its accuracy in spite of expansion or contraction of the tank walls.

A further object is tO provide a slosh-compensating fuel pumping assembly that incorporates an electrical liquid fuel level sensor therein, thereby obviating the need for a special access hold in the tank wall for attaching a separate sensor to the tank.

It is also an object of the invention to provide a fuel supply module requiring that, when the fuel tank and reserve container are both substantially empty, i.e. when the vehicle is truly out of fuel, only a small quantity of fuel needs to be poured into the tank to restore the pump to its normal pump¬ ing action; i.e. the pump is basically self-priming.

Other objects and features of the invention will be apparent in the following description and claims in which the principles of the invention are set forth together with details to enable a person skilled in the art to practice the invention, all in connection with the best mode presently contemplated for the invention.

BRIEF DESCRIPTION OF DRAWINGS

Fig. 1 is a fragmentary sectional view taken through a fuel pumping unit embodying our invention. „ ,_«„.,,_« PC 90/13739

-5-

Fig. 2 is an enlarged fragmentary sectional view of structural features used in the Fig. 1 assembly.

Fig. 3 is a side elevational view of a liquid level sensor unit used in the Fig. 1 assembly.

Fig. 4 shows a structural detail used in the Fig. 3 sensor unit.

Fig. 5 is an enlarged fragmentary sectional view taken in the same direction as Fig. 2.

Fig. 6 is a fragmentary top plan view of the structure shown in Fig. 5.

Fig. 7 is a fragmentary sectional view taken in the same direction as Fig. 2, but illustrating an alternative con¬ struction usable in practice of the invention.

BEST MODE FOR CARRYING OUT THE INVENTION

Fig. 1 shows a fue.l pumping unit 10 disposed within a vehicle fuel tank 12. Tank 12 comprises a floor 14 and ceil¬ ing 16; a circular access opening 17 is formed in ceiling 16 for manual insertion of the pumping unit into the fuel tank.

The pumping unit comprises a cover structure 20 sized to fit into access opening 17, with a peripheral flange 21 thereof resting on the upper flanged surface of ceiling 16. A conventional arcuate clamp 23 may be arranged around the mating flanged surfaces to releasably secure cover structure 20 in a fixed position above access opening 17.

Depending from cover structure 20 is an arcuate (sub¬ stantially cylindrical) guide means 24, preferably formed of brass or other non-corroding metal. Ears 25 extend outwardly 90/13739

-6- from the upper end of the arcuate guide means to fixedly secure the guide means to cover structure 20.

The arcuate guide means has a slidable telescopic fit on the outer edge of a vertical tubular container 27. In plan view container 27 is circular, although circularity is not essential to practice of the invention. The container has a smaller diameter than access opening 17, such that the fuel pumping unit (comprised of cover structure 20, guide means 24 and container 27) can be withdrawn as a unit through access opening 17, e.g. when it is desired to repair or replace the pumping unit.

Container 27 has an upper flanged end 28 located within the space circumscribed by arcuate guide means 24. The lower end of container 27 is disposed within a cup-shaped filter screen 30 that is designed to rest against the fuel tank floor 14. The detailed construction of the lower end of container 27 is best seen in Fig. 2.

As shown in Fig. 2, the container 27 bottom wall in¬ cludes a central wall section 29 in close proximity to tank floor 14, a tubular wall section 31 extending upwardly from wall section 29, and laterally-extending wall section 32. Wall section 32 connects with container side wall 33. In normal operation the space around container 27 contains liquid fuel. Also, some reserve fuel is contained within container "27.

A flow port 34 is formed in central wall section 29 to enable liquid fuel to flow upwardly from space 35 below wall section 29 to a central fuel chamber 37 above wall section 29. Space 35 is in open communication with fuel tank 12 via one or more openings 38 in leg structure 39.

A primary valve element 40 is arranged in central fuel chamber 37 to open or close port 34, depending on the position of attached float 42.. Valve element 40 is made of synthetic 90/13739

-7- rubber or other elastomer. It includes a cup shaped top por¬ tion defining an annular flexible outer flange, the tip of which defines a seal lip which engages and acts as a seal over port 34 in one position of the float. Depending from the top portion of valve 40 is a relatively firm annular core having a bayonet tip at its other end. The valve element 40 is fixed to a rigid plate 11 by means of a locking groove within the bayonet tip and the rigid plate 11 is in turn fixed to float 42. Thus float 42, plate 11 and valve element 40 are one subassembly. Rigid plate 11 has ports 13 arranged about its inner diameter to facilitate fuel flow through ports 34.

The float 42 is preferably an annular member, prefer¬ ably formed of a low density material. The float can be a solid structure, as shown, or a hollow structure formed by a blow molding process. The float is designed so that when the liquid level in the tank 12 falls to some predetermined low cut-off value the float drops down to the full line position (Fig. 2) to cause the attached valve element 40 to close port 34. The cut-off level is designated by numeral 41 in Fig. 2.

At normal fuel levels (above the cut-off level) float 42 is buoyed upwardly to the dashed line position 42a (Fig. 2) , to thereby cause valve element 40 to open port 34.

Arranged centrally within container 27 is a motor- operated fuel pump 43 of known construction. A preferred pump construction is offered by the Carter Automotive Company of St. Louis, Missouri under the tradename CARotor. The pump is a geroter-type positive displacement pump that includes a male gear eccentrically disposed within an annular internal gear for achievement of a liquid pump action; an electric motor is located within the upper section of the pump body to drive the gears. Such a pump is shown in U.S. Serial No. 101,265 filed September 25, 1987, now U.S. Patent No. 4,820,138. The preferred pump 43 is supported near its upper end by means of a ring 44 and spoke structure 45 extending inward¬ ly from container side wall 33. At its lower end the pump has a tubular liquid intake passage 46 extending downwardly through an annular valve-filter assembly 47.

The illustrated assembly 47 comprises a flat annular plate 48 having an annular upstanding peripheral flange 49 sealably engaged with the inner surface of container 27. An annular spacer member 50 is positioned on plate 48 to support an annular filter screen 55. Members 48, 50 and 55 are pre¬ ferably plastic components secured together with solvent adhe¬ sives. Member 50 includes two concentric annular sections 5₁ and 52 interconnected by three circumferentially spaced radial ribs 53, only one of which appears in the drawings at Fig. 6. Illustrated rib 53 forms a mounting means for an elastometrie deflectable disk-shaped reserve valve element 54 similar to valve 40 whose outer peripheral edge seals against the lower face of plate 48. A circular port 58 is formed in plate 48. Also, an annular flanged seal member 56 (as seen in Fig. 5) is carried on spacer member 50 to preclude downflow of liquid fuel along the outer surface of pump intake passage 46.

The space in container 27 above strainer screen 55 is normally filed with liquid fuel. However the flow resistance offered valve element 54 is higher than the resistance offer¬ ed by flow port 34 when the flow port is open (with float 42 buoyed up to the dashed line position in Fig. 2) . Therefore, when port 34 is opened all of the liquid flowing upwardly into intake passage 46 will be coming from port 34. None of the liquid will be coming from container 27.

Motor-operated pump 43 has an output passage (spigot) 58(a) at its upper end. A flexible flow tube 57 extends upwardly from passage 58(a) to a fuel outflow spigot 59 that extends through cover structure 20; spigot 59 is only partially visible in Fig. 1. Another return fuel flow spigot 60 extends through cover structure 20 to connect with a second flexible flow tube 61. Tube 61 extends downwardly into container 27 to deliver pump overflow liquid back into the container.

The illustrated pumping unit delivers liquid fuel through spigot 59 to a line leading to the engine (carburetor or fuel injector mechanism) . Excess fuel not used by the engine is returned through a line that connects to spigot 60. The excess fuel is thus fed back into container 27, such that container 27 is ordinarily always filled to its upper edge 28 as a constant running condition. The excess fuel overflows edge 28 -through open areas of guide means 24 and spills back into the fuel tank.

Electrical power is delivered to the pump motor through spade terminals 63 located at the upper end of the pump cas¬ ing. Electrical current is supplied from an outside source (the vehicle battery) to pin terminal 65 in an electrical re¬ ceptacle 66; flexible wiring 67 transmits the power to spade terminals 63.

During normal operations (with sufficient fuel in tank 12) float 42 is buoyed up so that valve element 40 is open. Liquid fuel is supplied to pump intake passage 46 through port 34. Container 27 will be completely filled with liquid fuel. However, the flexural resistance of valve element 54 is such that no liquid is taken from container 27 into space 37 below pump intake passage 46. As fuel is used by the engine, container 27 will remain filled while the level in tank 12 drops.

When the liquid level in tank 12 drops below the cut¬ off level 41 (Fig. 2) float 42 moves down to cause valve ele¬ ment 40 to close port 34. The pump suction in central fuel chamber 37 is then applied solely to the underside of deflect¬ able valve element 54, such that liquid fuel is then drawn from container 27, through filter screen 55 and around edge areas of valve element 54 into central fuel chamber 37. The pump is able to continue pumping liquid upwardly through flexible flow tube 57, even though the fuel in tank 12 is sloshing or draining away from the space below port 34 due to vehicle turning maneuvers. The vehicle can be kept running until substantially all the total system fuel is empty, including that in the return loop and the reserve container.

In connection with the operation of valve element 54, it should be noted that the undersurface of element 54 is exposed to the liquid head in tank 12 (through port 34) , where¬ as "the upper surface of element 54 is exposed to the liquid head in container 27. The port opening in plate 48 limits the surface area exposure of element 54, such that element 54 will be maintained in a closed position even when the liquid head in tank 12 is less than the liquid head in container 27. However, when valve element 40 closes port 34 the undersurface of element 54 is no longer exposed to the tank liquid head. The pressure head in container 27 quickly opens element 54.

Should tank 12 and container 27 be entirely emptied when the vehicle is in an area away from a vehicle service area it is then necessary to pour a small quantity of fuel into the tank so that the vehicle can be driven to a service station. A gallon of fuel is sufficient in most instances to raise float 42 and thereby open valve element 40 and prime the system. At this time valve element 54 is closed.

Under some conditions the minute openings in screen 30 may be clogged with liquid fuel at the time new fuel is being poured into tank 12; additionally the space 35 circumscribed by screen 30 may be air-filled. Under the worst case situa¬ tion the liquid poured into tank 12 will be unable to flow into space 35. To avoid an air-lock condition in space 35 a small slot-like air vent passage 69 (Fig. 2) may be formed in container wall 33; this slot-like passage will act to vent air 90/13739

-11- from space 35 out into the tank, thereby enabling new fuel to readily flow into space 35.

When pump 45 is operated the pump suction will be ex¬ erted on the liquid at flow opening 34. The pump is_. able to draw fuel through the intake passage 46 and thus keep the vehicle running until the motorist reaches the nearest gas station.

In a preferred form of our invention the fuel pumping unit (comprising guide means 24 and container 27) acts as a mounting device for a "tank liquid level sensor. The sensor can be connected to a fuel quantity gage and/or a low level alarm (not shown) . The sensor shown in Figs. 1 and 3 comprises a mounting plate 75 having a screw type attachment to a flat flanged section formed on the side of container 27'. A steel pin 76 is embedded into plate 75 to form a pivot structure for a rotary hub structure 77.

Integrally connected to hub structure 77 is a plastic plate 78 of wing-like configuration (Fig. 3) . A rod-like arm 79 has an arcuate curve end section 81 curled around hub structure 77 to affix the rod-like arm and hub structure together. In order to prevent undesired wobble of arm 70 the rod is trained through two upstanding gripper fingers 83 form¬ ed integrally with plate 78. Arm 79 and hub structure 77 rotate as a unit around the pivot axis defined by steel pin 76.

As best seen in Fig. 4, the free end of arm 79 is turn¬ ed, as at 84, to extend through a paddle-shaped float 85. Localized areas of arm 79 are flattened, as at 86, to retain the float on the arm. However, the float can rotate on arm section 84 so as to remain "flat" on the liquid level surface as arm 79 swings between its limiting positions, shown in dashed lines in Fig. 3. 90/13739

-12-

The ends of wing-shaped plate 78 are arranged to con¬ tact stop surfaces (upstanding shoulders) 91 formed on mount¬ ing plate 85. Stop surfaces 91 define the motion limits for arm 79.

Electrical spade terminals 88 are suitably mounted in plate 75 to form electrical connectors to an electrical slider and associated potentiometer resistance. The potentiometer resistance comprises one or more arcuate conductive strips 89 formed on the outer face of plastic plate 75. The electrical slider is a thin copper strip extending from hub structure 77 in the space behind plastic plate 78. A flexible lead wrre 90 connects the electrical slider to a terminal 88.

Alternatively, a slider-slip ring electrical connection can be substituted for the flexible wire 90.

Electrical liquid level signals are transmitted from the sensor mechanism through multi-strand flexible wiring 92 that connect terminals 88 to selected pin terminals in receptacle 66. The electrical liquid level sensor mechanism is thereby operatively located on the fuel pumping unit, thus avoiding the necessity for a separate mounting structure (and electrical wiring connectors) for the liquid level sensor.

The pumping unit shown in Fig. 1 can be installed into the fuel tank (or removed from the fuel tank) by moving the unit through access opening 17 in tank ceiling 16. Float 85 extends a short distance laterally beyond the plan dimension of the pumping unit. However, it is possible to tilt the unit slightly to enable the float the move through access opening 17. It is not necessary to disassemble the float or mounting plate 75 to install the pumping unit into the fuel tank.

The fuel tank is often formed of plastic or other material subject to deformation (buckling) , due for example to thermal contraction or expansion, or the weight of fuel in the 90/13739

-13- tank, or semi-vacuum conditions due to withdrawal of liquid from the tank. Such conditions can cause the space between the tank floor 14 and ceiling 16 to vary from time to time.

In order to keep container 27 a constant predetermined distance above tank floor 14 our pumping unit comprises spring means 94 for biasing container 27 downwardly toward floor 14. As shown in Fig. 1 the spring means comprises an annular compression spring 94 surrounding arcuate guide means 24. The upper end of spring 94 engages a seat structure formed by tangs 95 struck outwardly from the surface of guide means 24. The lower end of spring 94 engages a seat structure formed by an annular flange 97 formed on container 27.

Spring 94 exerts a downward force on container 27, whereby the container maintains a predetermined spatial rela¬ tionship to tank floor 14 in spite of variations in the spacing between floor 14 and ceiling 16. The liquid level sensor is referenced to floor 14 such that fuel tank deformation has minimal effect on the readout.

Fig. 7 illustrates a second form that the invention can take. The structure is substantially the same as the Fig. 2 structure except that valve-filter assembly 47 is replaced by a secondary valve means having no filter and comprising only an annular plate 70 having flow openings 72 therethrough. An elastomeric valve element 73 similar to valve element^" 54 is suitably attached to the undersurface of plate 70 such that liquid in the reservoir 27 exerts a force through flow openings 72 onto the upper face of the disc.

Flow openings 72 are segmental openings defined by spoke sections of plate 70; the central hub area within openings 72 acts as a mounting mechanism for a central rigid section of elastomeric valve element 73. The peripheral sections of valve element 73 are deflectable downwardly away from the valve seat 90/13739

-14- defined by plate 70 as a response to the weight of liquid in reservoir 27.

With primary valve 40 in an open position, valve ele¬ ment 73 will remain closed as long as the level of liquid in container 27 is below a predetermined value, e.g. up to about seven inches above plate 70. Should the container liquid level exceed that predetermined value the increased weight of liquid will act through flow openings 72 to deflect the peripheral areas of valve element 73 downwardly. The secondary valve will thereby supply some liquid to space 37 below the pump intake passage.

When the liquid level in tank 12 drops below cut-off level 41 primary valve 40 closes. An increased suction force is thereby applied to the undersurface of secondary valve disc 73. The increased force completely opens the valve element 73 and holds it open even though the liquid^"level in container 27 may drop below the aforementioned seven inch level. As with the system shown in Fig. 2 fuel will be supplied from reservoir 27 through valve element 73 until all fuel in the system is used.

While the best mode for carrying out the invention has been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the inventϊon as disclosed by the following claims.

Claims

WHAT IS CLAIMED IS:

1. A reserve fuel system (10) for a fuel tank (12), comprising a fuel supply reserve container (27) adapted to be positioned in said tank (12) , a fuel pump (43) operatively associated with said reserve container (27) , float valve means

(40,42) operatively associated with said pump (43), said float valve means^' (40, 42) adapted to provide liquid fuel to . said pump (43) at tank fuel levels above a predetermined fuel level

(41) and to block liquid fuel from said pump (43) below said predetermined fuel level (41) characterized by a pressure responsive reserve valve (54) arranged within said system (10) for delivering liquid fuel from said reserve container (27) to said pump (43) at fuel levels below said predetermined fuel level (41) .

2. The system of claim 1 and further comprising a filter screen (55) arranged in said reserve container (27) to intercept and filter liquid fuel flowing across the reserve valve (54) .

3. The system of claim 2 wherein said reserve con¬ tainer (27) includes an outlet port (58) ; said fuel pump (43) being located within said reserve container (27) and having an intake passage (46) ; said float valve means (40, 42) being mounted within said reserve container (27) and below the pump intake passage (46) ; and said reserve valve (54) being responsive to changes in pump intake pressure for delivering fuel from the reserve container (27) through said outlet port (58) to the pump intake passage (46) when the tank liquid level falls below said predetermined fuel level (41) .

4. The system of claim 3 wherein said outlet port (58) defines a valve seat means (48) , said reserve valve (54) being arranged below said valve seat means (48) such that liquid fuel within said reserve container (27) exerts a force tending to move said reserve valve (54) to an open position.

5. The system of claim 4 wherein the reserve valve (54) is an elastomer and includes a relatively rigid central section and a deflectable peripheral section; said valve (54) being constructed so that the peripheral section deflects downwardly away from the aforementioned valve seat means (48) when the liquid level in the tank (12) drops below said predetermined fuel level (41) .

6. The system of claim 3 wherein the pump intake passage (46) comprises a vertical tube arranged substantially on the central axis of the reserve container (27) ; said pump intake passage, said float valve means (40, 42) and said reserve valve (54) all communicating with a common central fuel chamber (37) ; and said float valve means (40, 42) comprising a valve-float assembly centered on the axis of said vertical tube.

7. The system of claim 6 wherein said valve-float assembly includes an annular float (42) and an associated valve (40) located within the space circumscribed by the annular float (42) , said associated valve (40) acting to close said central fuel chamber (37) to create a pressure drop across said reserve valve (54) and thereby provide fuel from the reserve container (27) to said pump intake passage (46) .