U.S. patent application number 09/776555 was filed with the patent office on 2001-07-19 for fuel delivery module for an automotive fuel system.
This patent application is currently assigned to Ford Motor Company. Invention is credited to Gaston, Robert Duane, Yu, Dequan.
Application Number | 20010008135 09/776555 |
Document ID | / |
Family ID | 25353287 |
Filed Date | 2001-07-19 |
United States Patent
Application |
20010008135 |
Kind Code |
A1 |
Gaston, Robert Duane ; et
al. |
July 19, 2001 |
Fuel delivery module for an automotive fuel system
Abstract
A fuel delivery module for an automotive fuel delivery system
includes a reservoir and a fuel pump. The fuel pump delivers fuel
from the tank to the reservoir via a fuel tank inlet and reservoir
outlet and from the reservoir to the engine via a reservoir inlet
and engine outlet. The reservoir is formed with a plurality of
contaminant traps for collecting contaminants contained in the fuel
as the fuel is pumped through the reservoir such that the
contaminants settle unto said contaminant traps thereby reducing
the amount of contaminants entering the reservoir inlet.
Inventors: |
Gaston, Robert Duane;
(Dearborn Heights, MI) ; Yu, Dequan; (Ann Arbor,
MI) |
Correspondence
Address: |
John A. Artz
Artz & Artz
Suite 250
28333 Telegraph Road
Southfield
MI
48304
US
|
Assignee: |
Ford Motor Company
Dearborn
MI
|
Family ID: |
25353287 |
Appl. No.: |
09/776555 |
Filed: |
February 2, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09776555 |
Feb 2, 2001 |
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09645286 |
Aug 24, 2000 |
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09645286 |
Aug 24, 2000 |
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08869298 |
Jun 4, 1997 |
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6170472 |
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Current U.S.
Class: |
123/509 ;
123/518 |
Current CPC
Class: |
F02M 37/106 20130101;
Y10T 137/8013 20150401; B60K 2015/03105 20130101; F02M 37/32
20190101; Y10T 137/86212 20150401; F02M 37/18 20130101; F02M 37/22
20130101 |
Class at
Publication: |
123/509 ;
123/518 |
International
Class: |
F02M 025/08; F02M
037/04 |
Claims
We claim:
1. A fuel delivery module for a fuel system in an automotive
vehicle, the fuel system including a fuel tank for storing fuel and
the vehicle including an engine, with said fuel delivery module
comprising: a reservoir having a bottom and a side, with said
reservoir storing a portion of the fuel stored in the fuel tank; a
means for pumping fuel from the fuel tank to said reservoir and
from said reservoir to the engine; and, a contaminant trap formed
in said bottom of said reservoir for collecting contaminants
contained in the fuel as fuel is pumped through said reservoir by
said means for pumping fuel from the tank to the reservoir such
that the contaminants settle into said contaminant traps thereby
reducing the amount of contaminants entering said means for pumping
fuel from said reservoir to the engine.
2. A fuel delivery module according to claim 1 wherein said
contaminant trap has a generally oblong-shaped cross-section for
enhancing retention of the fuel contaminants within said trap.
3. A fuel delivery module according to claim 1 wherein the inside
surface of said bottom of said reservoir is formed with a recess
and wherein said fuel delivery module further comprises a
contaminant trap cover, with said cover cooperating with said
recess to define said contaminant trap.
4. A fuel delivery module according to claim 3 further comprising a
second contaminant trap, wherein the inside surface of said bottom
of said reservoir is formed with a second recess and wherein said
fuel delivery module further comprises a second contaminant trap
cover, with said second cover cooperating with said second recess
to define said second contaminant trap and wherein said second
recess forms a second protrusion on the outer surface of said
bottom, with said protrusions cooperating with said bottom to
define a fluid flow channel to allow fuel from said tank to flow
under said reservoir so that the fuel may be pumped into said
reservoir.
5. A fuel delivery module according to claim 1 further comprising a
directional control deflector disposed within said reservoir, with
said directional control deflector cooperating with said means for
pumping fuel from the tank to said reservoir so as to impart a
rotational flow on the fuel thereby inducing settlement of the
contaminants into said contaminant trap.
6. A fuel delivery module according to claim 1 further comprising a
directional control deflector disposed within said reservoir, with
said directional control deflector cooperating with said means for
pumping fuel from the tank to said reservoir so as to divert the
fuel containing said contaminants toward said contaminant trap.
7. A fuel delivery module according to claim 1 wherein said means
for pumping fuel from said reservoir to the engine comprises a
vapor purge orifice and wherein said fuel delivery module further
comprises a fuel vapor management section communicating with said
vapor purge orifice for collecting fuel vapor purged from said
vapor purge orifice and directing said vapor away from said means
for pumping fuel from said reservoir to the engine.
8. A fuel delivery module according to claim 1 wherein said means
for pumping fuel comprises: a motor; a shaft axially extending from
said motor; a regenerative turbine impeller coupled to said shaft
and disposed within said reservoir for pumping fuel from the
reservoir to the engine; and, an axial flow impeller coupled to
said shaft and disposed outside said reservoir for pumping fuel
from the tank to the reservoir, with said axial flow impeller
having a plurality of vanes each having a leading edge, with said
leading edge being generally rounded such that said contaminants
have substantially no wear impact on said axial flow impeller as
said axial flow impeller pumps fuel containing said contaminants
from said tank to said reservoir.
9. A fuel delivery module for a fuel delivery system in an
automotive vehicle, the fuel delivery system including a fuel tank
for storing fuel and the vehicle including an engine, with said
fuel delivery module collecting contaminants contained within fuel,
with said fuel delivery module comprising: a reservoir having a
bottom and a side, with said reservoir storing a portion of the
fuel stored in the fuel tank; a fuel pump disposed within said
reservoir and having a fuel tank inlet, a reservoir outlet, a
reservoir inlet and an engine outlet, with said pump pumping fuel
containing contaminated fuel from the fuel tank to said reservoir
via said fuel tank inlet and said reservoir outlet and for pumping
fuel containing substantially no contaminants from said reservoir
to the engine via said reservoir inlet and said engine outlet; and,
a plurality of contaminant traps formed in said bottom of said
reservoir for collecting contaminants contained in the fuel as fuel
is pumped through said reservoir such that the contaminants settle
into said contaminant traps thereby reducing the amount of
contaminants entering said reservoir inlet.
10. A fuel delivery module according to claim 9 wherein each said
contaminant trap has a generally oblong-shaped cross-section for
enhancing retention of the fuel contaminants within said trap.
11. A fuel delivery module according to claim 9 wherein the inside
surface of said bottom of said reservoir is formed with a plurality
of recesses and wherein said fuel delivery module further comprises
a plurality of contaminant trap covers, with each said cover
cooperating with each aid recess to define each said contaminant
trap.
12. A fuel delivery module according to claim 9 wherein said
recesses form protrusions on the outer surface of said bottom, with
said protrusions cooperating with said bottom to define a fluid
flow channel to allow fuel from said tank to flow under said
reservoir so that the fuel may be pumped into said reservoir.
13. A fuel delivery module according to claim 9 further comprising
a directional control deflector disposed within said reservoir,
with said directional control deflector cooperating with said
reservoir outlet of said fuel pump so as to impart a rotational
flow on the fuel thereby inducing settlement of the contaminants
into said contaminant traps, and divert the fuel containing said
contaminants toward said contaminant traps.
14. A fuel delivery module according to claim 9 wherein said fuel
pump comprises a vapor purge orifice and wherein said fuel delivery
module further comprises a fuel vapor management section
communicating with said vapor purge orifice for collecting fuel
vapor purged from said vapor purge orifice and directing said vapor
away from said reservoir inlet.
15. A fuel delivery module according to claim 9 wherein said fuel
pump comprises: a motor; a motor shaft axially extending from said
motor, with said motor shaft having a threaded coupling; a
regenerative turbine impeller coupled to said shaft and disposed
within said reservoir for pumping fuel from the reservoir to the
engine; and, an axial flow impeller having a threaded coupling
engaging said threaded coupling on said motor shaft, with said
axial flow impeller being disposed outside said reservoir for
pumping fuel from the tank to the reservoir, with said axial flow
impeller having a plurality of vanes each having a leading edge,
with said leading edge being generally rounded such that said
contaminants have substantially no wear impact on said axial flow
impeller as said axial flow impeller pumps fuel containing said
contaminants from said tank to said reservoir.
16. A fuel delivery module according to claim 15 wherein said motor
rotates in a direction opposite to the direction of both said
threaded couplings such that said axial flow impeller is retained
on said motor shaft as said motor rotates.
17. A fuel delivery system for an automotive engine comprising: a
fuel tank for storing fuel; a reservoir disposed within said fuel
tank for storing a portion of the fuel stored in said fuel tank,
with said reservoir having a bottom and a side, with an inside
surface of said bottom of said reservoir being formed with a
plurality of contaminant trapping recesses; a fuel pump disposed
within said reservoir and having a fuel tank inlet, a reservoir
outlet, a reservoir inlet and an engine outlet, with said pump
pumping fuel containing contaminants from said fuel tank to said
reservoir via said fuel tank inlet and said reservoir outlet and
for pumping fuel from said reservoir to the engine via said
reservoir inlet and said engine outlet; and, a plurality of
contaminant trap covers cooperating with each said contaminant
trapping recess to define a plurality of contaminant traps for
collecting contaminants contained in the fuel as fuel is pumped
through said reservoir such that the contaminants settle into said
contaminant traps thereby reducing the amount of contaminants
entering said reservoir inlet, with each said contaminant trap
having a generally oblong-shaped cross-section for enhancing
retention of contaminants within said trap, with a top of each said
cover being coplanar with the inside surface of said bottom end
with said top of said contaminant trap covers being spaced from a
wall of said recess to define a contaminant trap aperture to allow
contaminants to enter said traps.
18. A fuel delivery system according to claim 17 wherein said
contaminant trapping recesses form protrusions on the outer surface
of said bottom, with said protrusions cooperating with said bottom
to define a fluid flow channel to allow fuel from said tank to flow
under said reservoir so that the fuel may be pumped into said
reservoir.
19. A fuel delivery module according to claim 17 further comprising
a directional control deflector disposed within said reservoir,
with said directional control deflector cooperating with said
reservoir outlet of said fuel pump so as to impart a rotational
flow on the fuel thereby inducing settlement of the contaminants
into said contaminant traps, and divert the fuel containing said
contaminants toward said contaminant traps.
20. A fuel delivery module according to claim 17 wherein said fuel
pump comprises: a motor; a shaft axially extending from said motor;
a regenerative turbine impeller coupled to said shaft and disposed
within said reservoir for pumping fuel from the reservoir to the
engine; and, an axial flow impeller coupled to said shaft and
disposed outside said reservoir for pumping fuel from the tank to
the reservoir, with said axial flow impeller having a plurality of
vanes each having a leading edge, with said leading edge being
generally blunt such that said contaminants have substantially no
wear impact on said axial flow impeller as said axial flow impeller
pumps fuel containing said contaminants from said tank to said
reservoir.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to fuel delivery
modules for automotive fuel systems, and, more particularly, to
fuel delivery modules having contaminant collection traps.
BACKGROUND OF THE INVENTION
[0002] Automotive fuel systems typically include a reservoir in the
fuel tank and a primary fuel pump submerged in the reservoir to
supply fuel to the engine. The purpose of the reservoir is to keep
the primary pump inlet submerged under operating conditions which
could otherwise expose the inlet, such as when the vehicle is
parked on an incline with an almost empty fuel tank or during
cornering maneuvers wherein fuel moves away from the fuel inlet. A
secondary pump is dedicated to filling the reservoir. In such
systems, the primary pump delivers fuel from the reservoir to the
engine and the secondary pump delivers fuel from the tank to the
reservoir. In addition, filters may be used in cooperation with the
inlet to the pumps to filter any contaminants in the fuel. The
reservoir, fuel pumps and other components are typically,
collectively referred to as a fuel delivery module, which will be
used herein.
[0003] The inventors of the present invention have recognized
certain disadvantages with these systems. For example, because the
inlets to the primary and secondary pumps may require a filter, the
fuel delivery module may include a large number of associated
component parts resulting in a relatively large size to accommodate
the components and filters. In addition, the filters may become
prematurely occluded with contaminants due to the relatively large
amount of contaminants that may be contained within the fuel,
thereby decreasing the service life of the filter. Also, these
filters may not be effective in filtering relatively small
contaminants, which may prematurely wear the components of the
primary pump, such as the fuel pump impeller, as well as adversely
effect the fuel system. Thus, it is desirable to collect and trap
contaminants in the fuel prior to the contaminants reaching the
inlet to the primary pump.
SUMMARY OF THE INVENTION
[0004] An object of the present invention is to reduce the amount
of contaminants entering a primary fuel pump. This object is
achieved, and disadvantages of prior art approaches are overcome,
by providing a novel fuel delivery module for an automotive fuel
system. In one particular aspect of the invention, the fuel
delivery module includes a reservoir having a bottom and a side.
The reservoir stores a portion of the fuel stored in the fuel tank.
A fuel pump is disposed within the reservoir and has a fuel tank
inlet, a reservoir outlet, a reservoir inlet and an engine outlet.
The fuel pump pumps fuel from the tank to the reservoir via the
fuel tank inlet and reservoir outlet and pumps fuel from the
reservoir to the engine via the reservoir inlet and engine outlet.
The fuel delivery module also includes a plurality of contaminant
traps formed in the bottom of the reservoir for collecting
contaminants contained in the fuel as fuel is pumped through the
reservoir such that the contaminants settle into the contaminant
traps thereby reducing the amount of contaminants entering the
reservoir inlet of the fuel pump. In a preferred embodiment, the
contaminant traps have an oblong-shaped cross-section for enhancing
retention of the fuel contaminants within the traps.
[0005] Also, in a preferred embodiment, the fuel delivery module
includes a deflector disposed within the reservoir for directing
contaminants away from the reservoir inlet of the fuel pump and
toward the contaminant traps.
[0006] An advantage of the present invention is that the number of
fuel filters used for the fuel delivery module is reduced.
[0007] Another advantage of the present invention is that the
service life of the primary pump filter is increased.
[0008] Still another advantage of the present invention is that
small contaminants are collected and contained so that it is
unlikely that they will pass through the primary pump filter.
[0009] Other objects, features and advantages of the present
invention will be readily appreciated by the reader of this
specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention will now be described, by way of example, with
reference to the accompanying drawings, in which:
[0011] FIG. 1 is a schematic representation of an automotive fuel
delivery system;
[0012] FIG. 2 is a partial cross-sectional perspective view of a
fuel delivery module according to the present invention;
[0013] FIG. 3 is a cross-section of the fuel delivery module taken
along line 3-3 of FIG. 2;
[0014] FIG. 4 is a cross-section of the fuel delivery module taken
along line 4-4 of FIG. 3;
[0015] FIGS. 5-7 are views of contaminant traps incorporated in a
fuel delivery module according to the present invention;
[0016] FIG. 8 is an enlarged alternative embodiment of the area
encircled by line 8 of FIG. 3; and,
[0017] FIG. 9 is an exploded cross-sectional view of a fuel pump
according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] Fuel system 10, shown in FIG. 1, includes fuel delivery
module 12 disposed within fuel tank 14 for delivering fuel through
fuel line 16 to engine 18 of an automotive vehicle. Fuel delivery
module 12 includes fuel pump 20, which, in this example, is an
electric fuel pump controlled by an engine controller (not shown),
submerged within reservoir 22 for supplying fuel to engine 18.
Reservoir 22 is in fluid communication with fuel tank 14 and is
used to keep reservoir inlet 24 of fuel pump 20 submerged under
certain vehicle operating conditions, such as low fuel, cornering
maneuvers and other such conditions known to those skilled in the
art and suggested by this disclosure. In the example described
herein, fuel pump 20 pumps fuel from tank 14 to reservoir 22 and
from reservoir 22 to engine 18. Those skilled in the art will
recognize in view of this disclosure that other pumps, such as a
jet pump, may be used to pump fuel from tank 14 to reservoir 22.
The fuel system described herein is a returnless fuel system.
However, those skilled in the art will recognize in view of this
disclosure that a return type fuel system may be used, with the
return fuel being returned directly to reservoir 22, tank 14, or to
the jet pump (not shown) as desired.
[0019] Referring now to FIGS. 2 and 3, fuel pump 20 is mounted
within reservoir 22. As best shown in FIG. 3, pump 20 has casing 26
for containing motor 28, which is mounted within motor space 30.
Motor 28 has shaft 32 extending therefrom in a direction from
engine outlet 34 to reservoir inlet 24. Primary pumping element 36,
preferably an impeller, or, alternatively, a regenerative turbine,
is slidingly engaged on to shaft 32 and is encased within pump
housing 38, which is composed of pump bottom 40 and pump cover 42.
Primary impeller 36 pumps fuel from reservoir 22, through reservoir
inlet 24, through engine outlet 34 and onto engine 18. Shaft 32
passes through shaft opening 34 of pump cover 42 through bottom 43
of reservoir 22 to engage secondary impeller 44 which is disposed
outside of reservoir 22. In this example, secondary impeller 44 is
an axial-flow multi-blade helical impeller. Reservoir 22 is formed
with tank inlet area 46 and reservoir outlet 48. Thus, fuel pump
20, via the operation of secondary impeller 44, pumps fuel from
tank 14, through tank inlet area 46, through reservoir outlet 48,
and into reservoir 22. Reservoir outlet 48 may be fitted with hose
50 for delivering fuel to the top of reservoir 22 (see FIG. 2).
[0020] Referring briefly to FIG. 9, shaft 32 may compose two shaft
portions, 32a and 32b, coupled together by threads. According to
the present invention the direction of the threads joining shafts
32a and 32b is opposite to the direction of rotation of pump 20. In
this example, the threads are formed with a conventional, right
hand thread and the pump rotates in a left hand direction. Thus as
fuel pump 20 rotates to pump fuel to engine 18, the connection of
secondary impeller 44 to motor shaft 32 is assured because the
rotation of pump 20 tends to tighten secondary impeller 44 to motor
shaft 32.
[0021] Continuing with reference to FIGS. 2 and 3, fuel supplied to
secondary impeller 44 is intentionally not filtered, allowing any
contaminants in the fuel to be pumped from tank 14 to reservoir 22.
According to the present invention, reservoir 22 includes
contaminant traps 54 formed in bottom 43 of reservoir 22 for
collecting contaminants entering reservoir 22 from tank 14 through
the operation of pump 20 as previously described. Contaminants
circulating within reservoir 22 settle toward bottom 43 and pass
through openings 56 and enter contaminant traps 54. In a preferred
embodiment, contaminant traps 54 have a generally oblong-shaped
cross section. This oblong-shape effectively prevents contaminants
from escaping once they have entered contaminant traps 54. That is,
swirling fuel in traps 54, which follows the oblong-shape thereof,
effectively reduces the amount of contaminants escaping through
openings 56.
[0022] As best shown in FIG. 2, fuel delivery module 12 further
includes directional control deflector 60 attached to the inner
sidewall 62 of reservoir 22. Deflector 60 cooperates with hose 50
so as to impart a rotational flow on the fuel as well as divert the
fuel toward contaminant traps 54 such that any contaminants within
the fuel is desirably directed toward contaminant traps 54.
[0023] Turning now to FIGS. 4-7, a preferred embodiment of the
present invention is shown. Bottom 43 of reservoir 22 is formed
with a plurality of recesses 70 which form part of contaminant
traps 54. In addition, contaminant trap covers 72 are fitted within
recesses 70 and cooperate with recesses 70 so as to complete
contaminant traps 54 together with openings 56. That is, each cover
72 has a top surface 73, such that when each cover 72 is placed
over recess 70, top 73 is coplanar with inside surface 75 of bottom
43. Also, covers 72 include tabs 77, which space covers 72 away
from wall 79 of recess 70 as to define holes 56. Further, as best
shown in FIG. 4, recesses 70 formed in reservoir bottom 43 result
in protrusions 74 on the outer surface of bottom 43. Protrusions 74
cooperate with bottom 43 to define a fluid flow channel 76 to allow
fuel from tank 14 to flow under reservoir 22 so that fuel may be
pumped into reservoir 22 by secondary impeller 44.
[0024] Because contaminants in the fuel are collected in
contaminant traps 54, reservoir inlet filter 80, which is attached
to inlet 24 (see FIG. 3), may be made smaller as a result of the
decreased amount of contaminants within the fuel in reservoir 22.
In addition, because secondary impeller 44 pumps contaminants in
the fuel from tank 14 through reservoir 22, leading edges 82 of
secondary impeller are generally constructed with a rounded edge to
withstand the wear effects of the contaminants.
[0025] Referring now to FIG. 8, contaminant traps 54 are shown
having an alternative configuration. In this embodiment, inwardly
extending tab 86 extends into trap 54 to further inhibit
contaminants from escaping therefrom. Tab 86 may be formed on cover
70, as shown.
[0026] Referring again now to FIG. 3, in a preferred embodiment,
fuel delivery module 12 further includes vapor management section
90 for collecting and venting fuel vapor to the vehicle's fuel
vapor recovery system. Fuel pump cover 42 includes vapor purge
orifices 92 for purging any vapor generated in the pumping chamber
of primary impeller 36. This purged vapor is collected within vapor
chamber 94 and is eventually directed away from fuel pump 20 via
vapor purge line 96, which may be connected to the fuel vapor
recovery system.
[0027] While the best mode for carrying out the invention has been
described in detail, those skilled in the art in which this
invention relates will recognize various alternative designs and
embodiments, including those mentioned above, in practicing the
invention that has been defined by the following claims.
* * * * *