Fuel tank
This invention relates to vehicle fuel tanks and, more particularly, to a fuel tank having a flexible bladder. 
     There have been numerous proposals for vehicle fuel tanks in which a flexible bladder contains the fuel and is disposed within a protective metal shell. In general, however, such proposals have not encompassed protection against abnormal circumstances which might tend to cause collapse of the bladder within the shell. 
     This invention provides a fuel tank comprising a flexible bladder containing a fuel level sensor and a fender suspended adjacent the sensor to preclude interference between the bladder and the sensor should the bladder collapse. 
    
    
     The details as well as other objects and advantages of this invention are set forth in the remainder of the specification and are shown in the drawings in which: 
     FIG. 1 is an environmental view of a fuel tank constructed according to this invention as it may be mounted within a vehicle; 
     FIG. 2 is a longitudinal sectional view of the FIG. 1 fuel tank illustrating the fuel level sensor, the fender, and other features of the tank; 
     FIG. 3 is a top plan view of a portion of the FIG. 1 tank further illustrating the fender and other features of the tank; 
     FIG. 4 is a sectional view taken along line 4--4 of FIG. 2 additionally illustrating the fuel level sensor and the fender and other features of the tank; 
     FIG. 5 is an enlarged sectional view of a tank vent control valve; and 
     FIG. 6 is an enlarged sectional view, taken along line 6--6 of FIG. 3, showing the interconnection of the bladder, the metal shell, and a closure plate. 
    
    
     Referring first to FIG. 1, an automobile 10 has a body 12 mounted on a pair of longitudinal frame members 14 interconnected by transverse frame members 16. A metal cover 18 is mounted upon frame members 14 and 16 within body 12 and encloses a fuel tank 20. 
     As shown in FIG. 2, fuel tank 20 is supported on the rear frame member 16 and on a cross member 22 and is secured thereto by a pair of straps 24 hooked at one end 26 into cross member 22 and bolted at the other end 28 to rear member 16. Antisqueak pads 29 are disposed between tank 20 and members 16 and 22. 
     Tank 20 includes a flexible bladder 30 disposed within a rigid shell 32. An aperture 34 in the top of fuel tank 20 provides access through shell 32 and bladder 30 to the interior 35 of the tank and is covered by a rigid closure plate 36. As shown in FIGS. 2, 3 and 4, closure plate 36 carries a filler neck 38 through which fuel is delivered to the tank, a fuel line 40 through which fuel is delivered from the tank, a return line 42 through which fuel vapor entrained in liquid fuel is returned to the tank, and a vent line 44 through which fuel vapor is discharged from and air is admitted to the tank. Access openings 45 at each end of cover 18 permit fuel line 40, return line 42, and vent line 44 to extend to the engine compartment. 
     A boot 46 with its inner periphery 48 fitting snugly around filler neck 38 and its outer rim 50 biased against cover 18 about the access opening 51 therein, collects any fuel which may be spilled from filler neck 38. A drain line 52 extends downwardly from boot 46 to discharge any fuel which may be collected. 
     Vent line 44 extends from a block 54 which is received in a recess 56 formed in the top of closure plate 36. Block 54 has an internal passage 55 which communicates with the interior 35 of tank 20 through a restricted opening 58 formed in a vent control valve assembly 60. As shown in FIG. 5, valve assembly 60 has a hollow body 62 which guides a valve member 64 contained therein. Valve member 64 is operated by a weighted ball 66 which is retained in a cup 68 secured to the lower end of body 62. A plurality of apertures 70 in body 62, together with a drain hole 71 and a plurality of apertures 72 in cup 68, permit vapor flow from the interior 35 of tank 20 through restricted opening 58 to vent line 44 and permit air flow from vent line 44 through restricted opening 58 into tank 20. However, should tank 20 be inverted, ball 66 will force valve member 64 to engage and close restricted openings 58, thus obstructing flow of liquid fuel into vent line 44. 
     It will be appreciated that valve assembly 60 may not be required in some applications and thus may be replaced by an upwardly concave sheet metal stamping secured to the underside of closure plate 36 and providing limited access to passge 55 through a bottom drain hole and a few small peripherally spaced holes. 
     As shown in FIG. 3, a pressure balance line 74, containing a restrictor 76, interconnects vent line 44 and the space 78 between bladder 30 and shell 32. Pressure balance line 74 assures that the pressure outside of bladder 30 follows the pressure inside bladder 30 to minimize the possibility that bladder 30 might collapse within shell 32. 
     Fuel line 40 extends to the bottom of tank 20 and receives fuel through a strainer 80. A conventional fuel level sensor assembly 82 is supported on fuel line 40 and has a rearwardly extending arm 84. One end86 of arm 84 is pivotally mounted in a housing 87 and constrains arm 84 to movement within a vertical plane. The transversely extending free end 88 of arm 84 is encompassed by a cylindrical float 90 which is retained by a clip 92. Float 90 rides at or near the surface of the fuel contained within tank 20 and moves the free end 88 of arm 84 through a vertical arcuate path 93. The pivoted end 86 of arm 84 actuates an electrical contact within housing 87 to provide an electrical signal indicative of the fuel level; the signal is transmitted to a fuel level gauge through a conductor 94 and appropriate wiring (not shown) which may extend through cover access openings 45 to the instrument panel. 
     A fender 96 is suspended within tank 20 by a pair of flanges 98 which are welded to closure plate 36 as shown in FIG. 3. Fender 96 has a rear wall 100 depending adjacent and contoured to follow the curvature of path 93. As shown in FIG. 4, a plurality of transversely extending, vertically spaced, elongated slots 102 allow fuel to pass through fender 96 and thus minimize the hydraulic effects created by fender 96 which might otherwise affect float 90. Rear wall 100 extends transversely at least coterminously with end 88 of arm 84 and float 90, and a pair of side walls 104 extend forwardly from rear wall 100 to at least partially overlap the free end 88 of arm 84 and the ends of float 90. 
     As shown in FIGS. 2 and 4, the lower edge 106 of fender 96 is disposed at approximately the same height as the pivoted end 86 of arm 84. 
     Bladder 30, while being considered flexible, has sufficient rigidity to remain in contact with shell 32 under normal circumstances. However, certain abnormal circumstances may create a tendency for bladder 30 to collapse within shell 32. Yet even under such abnormal circumstances, the fuel in tank 20 will maintain at least the lower portion of bladder 30 in contact with the lower portion of shell 32. Thus even under abnormal circumstances, only the upper portion of bladder 30 would tend to separate from shell 32. 
     In the event the upper portion of bladder 30 were to collapse away from shell 32, fender 96 would hold it away from arm 84 and float 90. Fender 96 thus precludes interference between bladder 30 and arm 84 of fuel level sensor assembly 82. 
     FIG. 6 illustrates the interconnection of bladder 30, shell 32 and closure plate 36. It may be noted that bladder 30 has a double thickness 108 which is vulcanized to a die-cast oval collar 110. A gasket 112, also vulcanized to bladder 30 and collar 110, extends back over the top of shell 32. Closure plate 36 has a rim 114 carrying a plurality of bolts 116 which extend through rim 114, gasket 112, shell 32, and the double thickness 108 of bladder 30 and are received in collar 110. Conical washers 118 are disposed between closure plate rim 114 and the heads of bolts 116 and compress O-rings (not shown) against closure plate rim 114.