DESC:FORM 2

THE PATENTS ACT, 1970

(39 of 1970)

&

THE PATENT RULES, 2003

COMPLETE SPECIFICATION

[See Section 10 and Rule 13]

TITLE:

“A BRUSHLESS DIRECT CURRENT ELECTRIC FUEL PUMP WITH ENHANCED CONCENTRICITY”

APPLICANT:

PV CLEAN MOBILITY TECHNOLOGIES PRIVATE LIMITED
A company incorporated under the Indian Companies Act, 2013
having address at
9.1 Mile Stone, Gurgaon Farookhnagar Road, Village Dhankot, Gurgaon 122001, Haryana, India

PREAMBLE TO THE DESCRIPTION:
The following specification particularly describes the invention and the manner in which it is to be performed:

FIELD OF THE INVENTION
The present invention relates to brushless direct current electric fuel pump. More particularly, the present invention relates to a brushless direct current (BLDC) electric fuel pump for achieving enhanced concentricity by using three stage molding technique that results in reduced friction among the components of the pump and improvement in the overall performance.

BACKGROUND OF THE INVENTION
A pump is a device used for transferring fluids or gases by mechanical action. An electric pump converts the electric energy into hydraulic energy for transferring fluids or gases. The electric pump is used in automobiles, cooling systems, water production equipment, hot tubs, fountains, water tanks and alike.
Electric pumps are widely used in the field of automobiles for pumping fuel from the fuel tank to fuel injector. The electric pumps are connected with an electronic control drive unit that controls the operations of the pump through command signals. Few components of electric pumps that most commonly available in the market are manufactured through over molding process. Over molding is an injection molding process that produces a seamless combination of several materials into a single unit, which includes a solid, plastic-based component. A primary reason for manufacturing few components of the electric pump through over molding is enhanced product performance, but it was observed, there is a reduction in concentricity which increases the friction among the components and finally leads to a reduction in performance, as due to increased friction, more energy is required to energize the coil. Additionally, the shaft inside the pump tends to tilt during active conditions, which causes hindrance in the performance.
US8979504B2 discloses about a pump assembly and a method for assembly the pump assembly. The pump assembly includes a stator assembly, a lower pump housing, an upper pump housing, a rotor assembly, and an isolation cup. The method includes coupling the stator assembly to the lower pump housing, over molding an over mold material over the stator assembly and the lower pump housing, positioning the isolation cup over the over mold, and positioning the rotor assembly inside the isolation cup. The method further includes placing the upper pump housing over the rotor assembly and coupling the upper pump housing to the lower pump housing, but due to over molding, there is a decrease in concentricity that upsurges the friction among the components and finally result in sin reduction in performance, as due to increased friction, additional energy is required to energize the coil. Additionally, due to over molding the shaft inside the pump tends to tilt during active conditions, which causes hindrance in the performance.
US9562534B2 discloses about a dual pump using two (or more) electric motors (e.g. brushless DC motors) driving the pumps independently, including integration of hydraulic and electrical components and connectors. The illustrated arrangements include an in-line single shaft version, a parallel side-by-side shaft version, and an inside-outside version. Each configuration includes a housing supporting formation of shared structural support for the pumps and motors (e.g., bearings, stator, relationship of components), fluid pump and hydraulic system (e.g., fluid passageways, ports connectors) and motor electrical control (e.g., control circuitry and sensory components).
Therefore, there is a need of a brushless direct current (BLDC) electric fuel pump for achieving enhanced concentricity that results in reduction in friction among the components of the pump by using three stage molding technique, due to which said pump operates on a desired RPM without any obstruction resulting in improvement in overall performance of the pump.

OBJECT OF THE INVENTION
The main object of the present invention is to provide a brushless direct current (BLDC) electric fuel pump for achieving enhanced concentricity by using three stage molding technique.
Another object of the present invention is to provide a BLDC electric fuel pump for reducing friction related issues among the components of the pump.
Yet another object of the present invention is to provide a BLDC electric fuel pump due to which said pump operates on a desired RPM without any obstruction.
Yet another object of the present invention is to provide a BLDC electric fuel pump for pumping fuel from fuel tank and fuel injector with enhanced performance.
Still another object of the present invention is to provide a BLDC electric fuel pump that eliminates the issue of shaft tilting.

SUMMARY OF THE INVENTION
The main object of the present invention is to provide a brushless direct current (BLDC) electric fuel pump for achieving enhanced concentricity by using three stage molding technique.
Another object of the present invention is to provide a BLDC electric fuel pump for reducing friction related issues among the components of the pump.
Yet another object of the present invention is to provide a BLDC electric fuel pump due to which said pump operates on a desired RPM without any obstruction.
Yet another object of the present invention is to provide a BLDC electric fuel pump for pumping fuel from fuel tank and fuel injector with enhanced performance.
Still another object of the present invention is to provide a BLDC electric fuel pump that eliminates the issue of shaft tilting.

BRIEF DESCRIPTION OF THE DRAWINGS
An understanding of the brushless direct current (BLDC) electric fuel pump of the present invention may be obtained by reference to the following drawings:
Fig. 1 is a cut section view of the brushless direct current (BLDC) electric fuel pump according to an embodiment of the present invention.
Fig. 2 is a flow diagram of three stage molding of the brushless direct current (BLDC) electric fuel pump according to an embodiment of the present invention.
Fig. 3 is an outer view of the brushless direct current (BLDC) electric fuel pump according to an embodiment of the present invention.
Fig. 4 is an exploded view of the brushless direct current (BLDC) electric fuel pump according to an embodiment of the present invention.
Fig. 5 is a perspective view of the brushless direct current (BLDC) electric fuel pump according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION
The present invention will now be described hereinafter with reference to the accompanying drawings in which a preferred embodiment of the invention is shown. This invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough, and will fully convey the scope of the invention to those skilled in the art.
Many aspects of the invention can be better understood with references made to the drawings below. The components in the drawings are not necessarily drawn to scale. Instead, emphasis is placed upon clearly illustrating the components of the present invention. Moreover, like reference numerals designate corresponding parts through the several views in the drawings. Before explaining at least one embodiment of the invention, it is to be understood that the embodiments of the invention are not limited in their application to the details of construction and to the arrangement of the components set forth in the following description or illustrated in the drawings. The embodiments of the invention are capable of being practiced and carried out in various ways. In addition, the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
The present invention provides a brushless direct current (BLDC) electric fuel pump pumping fuel from a fuel tank to a fuel injector that uses a three stage molding technique for achieving enhanced concentricity that results in reduction in friction among the components of the pump, due to which less energy is required to energize the coil windings resulting in improvement in overall performance of the pump.
The present invention provides a brushless direct current (BLDC) electric fuel pump (100), comprising: an outer housing (1); and a lamina sub assembly (14); wherein: said lamina sub assembly (14) is fitted with a lamina stack (22) forming a lamina assembly (13) by carrying out a primary over molding and a plurality of terminal (9, 10, 11) is press fitted on said lamina stack (22) along with a copper wire (12) to form a coil sub assembly (23); said coil sub assembly (23) is fitted with a connecting piece sub assembly (24a) having a molding of a bush (7) acting as an inner cover (21) and forming a housing sub assembly (8) which result in enhanced concentricity; said housing sub assembly (8) is attached with a housing assembly (24b) by performing secondary over molding which results in decrease in friction among said bush (7), a rotor sub assembly (15) and a guiding pin (16) as said rotor sub assembly (15) is precisely fitted with said (7) that prevents hindrance between said lamina sub assembly (14) and said rotor sub assembly (15) and due to which said pump operates on a desired RPM without any obstruction; and said pump (100) comprise of a stopper pin (18), an impeller (19), which are encapsulated by said outer housing (1), an outlet port (25), and an inlet port (26).
Referring to Fig. 1, a cut section view of the BLDC electric fuel pump is depicted. The brushless direct current (BLDC) electric fuel pump (100) comprises of an outer housing (1), a spring holder (2), a spring (3), a seal sub assembly (4), a seal holder pin (5), a connecting pipe (6), a bush (7), a housing sub assembly (8), a connecting piece sub assembly with terminals (9, 10, 11), a copper wire (12), a shaft, a moving core, a lamina assembly (13) with a lamina stack (22), a lamina sub assembly (14), a rotor sub assembly (15), a stopper pin (18), an impeller (19), a guiding pin (16), an inner cover (20), a bush acting as inner cover (21) and an outer cover (17).
Referring to Fig. 2, a flow diagram of the brushless direct current (BLDC) electric fuel pump is depicted. The brushless direct current (BLDC) electric fuel pump (100) uses a three stage molding technique in which first stage involves over molding of lamina stack to form lamina sub assembly and press fitting of terminals (9, 10, 11) in the lamina stack (22) to form a coil sub assembly (23), second stage involves insert molding of the bush (7) is in a connecting piece sub assembly (24a) that results in enhanced concentricity, third stage involves over molding of the housing assembly (24b) that results in decrease in the friction issues among said bush (7), a rotor sub assembly (15) and a guiding pin (16) as said rotor sub assembly (15) is precisely fitted with said (7) that prevents hindrance between said lamina sub assembly (14) and said rotor sub assembly (15), due to which said pump operates on a desired RPM without any obstruction that final results in an improvement in the overall performance of the brushless direct current (BLDC) electric fuel pump.
Referring to Fig. 3, an outer view of the brushless direct current (BLDC) electric fuel pump is depicted, comprising of an outlet port (25), an inlet port (26), an outer housing (1), the connecting piece sub assembly (24a), an over molded pump housing (24b), plurality of terminals (9, 10, 11), wherein said guiding pin (16) maintain original position without tilting, thereby reducing the chances of hindrance.
Referring to Fig. 4, an exploded view of the brushless direct current (BLDC) electric fuel pump is depicted. The brushless direct current (BLDC) electric fuel pump (100) includes the connecting piece sub assembly (24a) with housing assembly (24b), coil sub assembly (23), rotor sub assembly (15), an inner cover (20), and an outer cover (17).
Referring to Fig. 5, a perspective view of the brushless direct current (BLDC) electric fuel pump is depicted. The brushless direct current (BLDC) electric fuel pump (100) is used for pumping fuel from a fuel tank to a fuel injector that further comprise a pump outlet (28) and a strainer at a flanged inlet (29), wherein the strainer ranges from 8 to 10 Microns.
The concentricity in conventional pump having single stage molding lies between 0.10mm to 0.12mm whereas the present invention having three stage molding achieve enhanced concentricity in range from 0.02mm to 0.04mm.
Therefore, the present invention provides a brushless direct current (BLDC) electric fuel pump for pumping fuel from a fuel tank to a fuel injector, that uses by using three stage molding technique that results in increase in concentricity, which reduces friction and due to which said pump operates on a desired RPM without any obstruction resulting in improvement in overall performance of the pump.
Many modifications and other embodiments of the invention set forth herein will readily occur to one skilled in the art to which the invention pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
The foregoing description of embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. The embodiments were chosen and described in order to explain the principals of the invention and its practical application to enable one skilled in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated.
,CLAIMS:CLAIMS

We claim:
1. A brushless direct current (BLDC) electric fuel pump (100), comprising:
an outer housing (1); and
a lamina sub assembly (14);
wherein:
said lamina sub assembly (14) is fitted with a lamina stack (22) forming a lamina assembly (13) by carrying out over molding and a plurality of terminal (9, 10, 11) is press fitted on said lamina stack (22) along with a copper wire (12) to form a coil sub assembly (23);
said coil sub assembly (23) is fitted with a connecting piece sub assembly (24a) having a molding of a bush (7) that act as an inner cover (21) and forms a housing sub assembly (8) resulting in enhanced concentricity;

said housing sub assembly (8) is attached with a housing assembly (24b) by performing over molding which results in decrease in friction among said bush (7), a rotor sub assembly (15) and a guiding pin (16) as said rotor sub assembly (15) is precisely fitted with said (7) that prevents hindrance between said lamina sub assembly (14) and said rotor sub assembly (15) and due to which said pump operates on a desired RPM without any obstruction; and

said pump (100) comprise of a stopper pin (18), an impeller (19), which are encapsulated by said outer housing (1), an outlet port (25), and an inlet port (26).
2. The brushless direct current (BLDC) electric fuel pump as claimed in claim 1, wherein said guiding pin (16) maintains original position without tilting, thereby reducing the hindrance.

3. The brushless direct current (BLDC) electric fuel pump as claimed in claim 1, wherein said pump (100) comprises a spring holder (2), a spring (3) fitted together inside a connecting piece assembly (6), a seal sub assembly (4), a seal holder pin (5).

4. The brushless direct current (BLDC) electric fuel pump as claimed in claim 1, wherein said pump (100) achieve enhanced concentricity in range from 0.02 mm to 0.04 mm.