[0001] The invention relates to vehicle fuel tank arrangement for a commercial vehicle, and more specifically, to a fuel tank assembly with integration of baffles inside shell to arrest baffle movements without any spot or tag welding.
BACKGROUND OF THE INVENTION
[0002] Heavy-duty powered commercial vehicles use externally mounted fuel tanks that are typically cylindrical / rectangular in shape and mounted longitudinally on a vehicle frame. These fuel tanks are metal fuel tanks (i.e. diesel fuel tanks) being used in various truck and bus applications. Fuel tanks (12) are fixed to the vehicle frame (15) through mounting brackets (11) and mounting straps (13), as shown in Fig. 1, which illustrates a typical fuel tank arrangement (10) in a truck.
[0003] It is well-known that heavy-duty trucks and buses are commercially used for transportation to cover long distance with minimum fuel filling during transit, which results in the fuel tanks (12) formed with huge capacity to store the fuel in it. Typically, these fuel tanks (12) range as high as 800-900L for the commercial vehicle, especially long haulage tractor trailer combination vehicles. Since the fuel capacity is high in the truck and bus fuel tanks (12), baffles or baffle plates (24) are placed within the fuel tanks (12) to reduce effect of sloshing during transit and are used to flow fuel from one section to another section in the fuel tank (12). The baffle plates (24) in the fuel tanks (12) act as stiffeners to mount the fuel tanks (12) at vehicle chassis integration points through the mounting brackets and straps (11, 13).
[0004] Also, the fuel tanks (12) are subjected to various forces such as internal fluid pressure, temperature loads due to hot return fuel from a vehicle engine, vacuum

inside the fuel tanks, structural loads transmitted to the fuel tanks though vehicle suspension and chassis structure. Fuel tanks have to be designed in a most cost effective way with prerequisite of meeting subject road and load conditions. Fig. 2 illustrates a typical construction of the metal fuel tank (12) in the commercial vehicle, where the fuel tank (12) generally consists of shell (25), 2 or 3 inner baffles (24), end plates (19), fuel filler neck (16) with cap (27) and stiffener (30), fuel inlet/suction and return pipes (28, 29) fixed through flanges (18) and washers (17), fuel level indicating sensor (14) mounted using a sensor mounting flange (26) and vent valves or sump (20) provided with a drain plug (22) mounted on a drain plug adapter (21) through a washer (23). Due to cost and manufacturing aspects, coated/stainless steel sheets with 1.00 to 1.6 mm thickness are widely used as shell and baffle materials for these fuel tanks (12) of the commercial vehicle.
[0005] Baffles (24) and various components are being integrated into the shell (25) of the fuel tank (12) by means of welding process. While the welding process is common and most popular in the fuel tank arrangement, but it leads to the disadvantage of melting of coated steel in weld region, which reduces coated steel corrosion resistance effectiveness and also prominent failure location while subjected various road and load conditions.
[0006] In the fuel tank (12), the end plates (19) are seem welded to the fuel tank shell (25) to prevent any fuel leak from the tanks (12), whereas the baffles (24) are spot welded or tag welded to restrict the effect of sloshing by preventing the movement of the baffles (24) within the tanks (12). In these conventional approaches, due to the spot or tag welding to integrate the baffle (24) with the shell (25), the fuel tank (12) losses its corrosion resistance and structural durability in the weld area, which increases the probability of failures and damages to the baffles (24) and to the fuel tank (12) and thus results in degradation of life time of the vehicle fuel tank (12). Further, it requires a highly skilled person to do complex welding process for the integration of the baffles (24) inside the fuel tank (12). Also, if the baffles (24) are not welded inside the fuel tanks (12), the baffles (24) can move or get tilted while assembling the fuel tank (12) into the vehicle or during vehicle movement, which

increases slosh force inside the fuel tank (12) during operation and thus degrades fuel tank life.
[0007] Therefore, it is necessary to provide a fuel tank assembly with weldless baffles for a commercial vehicle which can overcome the above mentioned drawbacks and disadvantages, i.e. unique integration of baffles inside the tank shell without spot or tag welding.
SUMMARY OF THE INVENTION
[0008] The following summary is provided to facilitate an understanding of some of the innovative features unique to the disclosed embodiments and is not intended to be a full description. A full appreciation of the various aspects of the embodiments disclosed herein can be gained by taking the entire specification, claims, drawings, and abstract as a whole.
[0009] A primary objective of the present invention is to provide a fuel tank assembly for a commercial vehicle, which is capable of integrating baffles within fuel tank without any welding process, and arresting movement and tilting of the baffles inside the fuel tank.
[0010] Another objective of the present invention is to provide a fuel tank assembly, which eliminates degradation of corrosion resistance and structural durability due to weld area formed in the fuel tank.
[0011] Another objective of the present invention is to provide a fuel tank assembly, which prevents slosh force inside the fuel tank during vehicle operation.
[0012] Another objective of the present invention is to provide a fuel tank assembly, which increases life time of the fuel tank.
[0013] According to the embodiment of the present invention to achieve the objective of the invention, a fuel tank assembly is provided for a commercial vehicle.

The fuel tank assembly comprises a rectangular or cylindrical-shaped shell enclosed by at least two end plates to form a fuel tank for storing liquid fuel therein. A plurality of grooves is formed on an outer surface of the shell and spaced apart each other along a longitudinal axis of the fuel tank. A plurality of intermediate baffles each is mounted at right angles to the inner region of the shell, where the baffles are spaced apart each other along the longitudinal axis of the fuel tank. One or more stiffener tube members are positioned between the baffles and placed in a horizontal plane through a center of the fuel tank. The fuel tank is assembled in such a way that the grooves are respectively placed near the seating area of the intermediate baffles and the plurality of intermediate baffles is securely connected with each other through the stiffener tube members, which restricts the movement of intermediate baffles inside the shell of the fuel tank. Thus, this fuel tank assembly is capable of integrating the baffles within the fuel tank without any welding process, and arresting movement and tilting of the baffles inside the fuel tank. It also eliminates degradation of corrosion resistance and structural durability due to weld area formed in the fuel tank, and prevents slosh force inside the fuel tank during vehicle operation.
[0014] Further, the intermediate baffles are placed in between the end plates that are mounted to an interior wall edge of the shell. Each intermediate baffle is positioned at equidistance with respect to the longitudinal axis of the fuel tank in such a way that each intermediate baffle acts as stiffeners for attaching the fuel tank to a vehicle frame through brackets and straps. Each intermediate baffle is located within the interior of the shell to divide the fuel tank into individual chambers for storing the liquid fuel therein. The intermediate baffles are formed of disc-shaped baffles whereas the stiffener tube members are formed of rod-shaped tube members. The stiffener tube members are fixed to the intermediate baffles by bolts and washers or by welding.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The disclosed embodiments may be better understood by referring to the figures, in which like reference numerals refer to identical or functionally-similar

elements throughout the separate views, further illustrate the present invention and, together with the detailed description of the invention, serve to explain the principles of the present invention.
[0016] FIG. 1 illustrates a typical fuel tank arrangement in a truck, in accordance with the prior art;
[0017] FIG. 2 illustrates a typical construction of a metal fuel tank in a commercial vehicle, in accordance with the prior art;
[0018] FIG. 3 illustrates a perspective view of a fuel tank assembly of a commercial vehicle, in accordance with an exemplary embodiment of the present invention; and
[0019] FIG. 4 illustrates an exploded view of the fuel tank assembly of the commercial vehicle, in accordance with an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The particular values and configurations discussed in these non-limiting examples can be varied and are cited merely to illustrate at least one embodiment and are not intended to limit the scope thereof.
[0021] In the following, numerous specific details are set forth to provide a thorough description of various embodiments. Certain embodiments may be practiced without these specific details or with some variations in detail. In some instances, certain features are described in less detail so as not to obscure other aspects. The level of detail associated with each of the elements or features should not be construed to qualify the novelty or importance of one feature over the others.

[0022] The claimed subject matter has been provided here with reference to one or more features or embodiments. Those skilled in the art will recognize and appreciate that, despite of the detailed nature of the exemplary embodiments provided here; changes and modifications may be applied to said embodiments without limiting or departing from the generally intended scope. These and various other adaptations and combinations of the embodiments provided here are within the scope of the disclosed subject matter as defined by the claims and their full set of equivalents. Like numbers refer to like elements throughout.
[0023] The present invention of a fuel tank assembly is used in a commercial vehicle for storing high capacity of fuel within a fuel tank. The fuel tank assembly is provided with weldless baffles, which is capable of arresting movement and tilting of the baffles inside the fuel tank without any welding process, which prevents slosh force inside the fuel tank during operation even with different load, road and vehicle configurations. The present invention mainly focuses on eliminating degradation of corrosion resistance and structural durability in weld area in the fuel tank due to non-welding process in the integration of baffles inside the fuel tank. Also, the present invention eliminates the need for highly skilled persons to do complex welding process for the integration the baffles inside the fuel tank. Thus, it eliminates failures and damages to the baffles and to the fuel tank, which results in increasing the life time of the vehicle fuel tank.
[0024] FIG. 3 illustrates a perspective view of a fuel tank assembly (100) of a commercial vehicle, in accordance with an exemplary embodiment of the present invention. The fuel tank assembly (100) of this present invention is typically designed for the commercial vehicle with usual components and parts along with unique arrangement and integration of baffles with the fuel tank (112). The fuel tank (112) is commonly a metal fuel tank (112) (steel fuel tank) with rectangular or cylindrical in shape being used in various truck and bus applications, where the fuel tank (112) is mounted externally and longitudinally on a vehicle frame through mounting brackets (11) and mounting straps (13). Please note that same reference numerals for some of the existing components of the fuel tank assembly illustrated in FIGS. 1-2 that

describes the background of the invention are also used and referred in the description only for the purpose of clarity and better understanding of the present invention.
[0025] FIG. 4 illustrates an exploded view of the fuel tank assembly (100) of the commercial vehicle, in accordance with an exemplary embodiment of the present invention. The fuel tank assembly (100) generally consists of a cylindrical-shaped shell (125), two or three intermediate baffles (124), fuel level indicating sensor (14), fuel filler neck (116), fuel suction pipe (128), fuel return pipe (129) and sump (120). The cylindrical-shaped shell (125) is enclosed by two end plates (119), which is formed as a fuel tank (112) for storing liquid fuel in it, where this stored fuel is pumped and supplied to the engine by means of various vehicle components for vehicle operation and movement. The two end plates (119) are generally mounted to an interior wall edge of the shell (125) by means of welding process, where the cylindrical-shaped shell (125) acts as a main body for the fuel tank (112).
[0026] The fuel level indicating sensor (14) is affixed into the shell (125) through a sensor mounting flange (127) for sensing and indicating the fuel level inside the fuel tank (112), where this fuel level indicating sensor (14) is electrically connected to an electronic cluster panel in vehicle dashboard to indicate the fuel level to a vehicle operator. The fuel filler neck (116) along with a cap (129) is placed and attached to the shell (125) usually at its center, where the fuel is filled into the fuel tank (112) through the fuel filler neck (116) that can be closed after filing by threading the cap (129) on it. The fuel inlet or suction pipe (128) and the fuel return pipe (129) are respectively inserted and secured to the shell (125) through flanges (126) using washers or sealing rings, where these suction and return pipe (128, 129) are placed and spaced apart from each other. The fuel suction pipe (128) is fitted in such a way that the open end of the fuel suction pipe (128) inside the fuel tank (112) are almost in close proximity to or in contact with the bottom inner surface of the fuel tank (112). At edge of the open end of the fuel suction pipe (128) inside the fuel tank (112), the sump (120) is placed and fixed to the shell (125), where the sump (120) is provided with a drain plug (122) mounted on a drain plug adapter (121) through a washer or

sealing ring. The drain plug (122) is removed to completely drain out the liquid fuel from the fuel tank (112) during vehicle maintenance/service.
[0027] In this present invention, a plurality of grooves (132, 133) is formed on an outer surface of the shell (125), i.e. on the circumference of the shell (125), which makes a projection inside the shell (125). These grooves (132, 133) are spaced apart each other along a longitudinal axis of the fuel tank (112), i.e. each groove (132, 133) is formed at a radial distance from each end plate (119) of the fuel tank (112). A plurality of intermediate or inner baffles (124) is inserted and placed in between the end plates (119) inside the fuel tank shell (125), where the baffles (124) are also referred as baffle plates. Each of these intermediate baffles (124) is mounted at right angles to the inner wall region of the fuel tank shell (125), where the baffles (124) are spaced apart each other along the longitudinal axis of the fuel tank (112). The shell (125) and the baffles (124) are usually made of coated/stainless steel sheets with 1.00 to 1.6 mm thickness. In particular, each intermediate baffle (124) is positioned at equidistance with respect to the longitudinal axis of the fuel tank (112) in such a way that each intermediate baffle (124) acts as stiffeners for attaching the fuel tank (112) to the vehicle frame through the mounting brackets and the mounting straps (11, 13), i.e. the baffles (124) also act as stiffeners to mount the fuel tank (112) at vehicle chassis integration points.
[0028] Further, each intermediate baffle (124) is located within the interior of the shell (125) to divide the fuel tank (112) into individual chambers (151, 152, 153) for storing the liquid fuel in these individual chambers (151, 152, 153). As shown in FIGS. 3 and 4, there are two grooves (132, 133) formed on the shell (125) near the seating area of the intermediate baffles (124) and there are two baffles (124) are placed between the end plates (119) inside the shell (125), which divides and separates the fuel tank (112) into three chambers, i.e. left-side chamber (151), middle chamber (152) and right-side chamber (153). These three chambers (151, 152, 153) are fluidly connected together by the two intermediate baffles (124), through which the fuel flows from one chamber to another chamber of the fuel tank (112) via one or more

through holes (preferably at least two through holes) (155) being provided in each of the baffles (124), which is clearly shown in FIG. 4.
[0029] In the preferred embodiment of the fuel tank construction of the present invention shown in FIG. 4, the fuel filler neck (125) and the fuel level indicating sensor (14) are spaced apart and placed in the middle chamber (152) at its top circumference. The fuel suction pipe (128) is placed in the left-side chamber (151) at its top circumference whereas the sump (120) is directly placed opposite to the fuel suction pipe (128) at the bottom circumference of the left-side chamber (152). Finally, the fuel return pipe (129) extended from a vehicle engine compartment is placed in the right-side chamber (153) at its top circumference.
[0030] The fuel tank assembly (100) comprises one or more stiffener tube members (especially two stiff ener tube members) (130) that are positioned in between the intermediate baffles (124) and placed in a horizontal plane through a center of the fuel tank (112). The stiffener tube members (130) are fixed to the intermediate baffles (124) by bolts and washers or by welding, where the intermediate baffles (124) are formed of disc-shaped baffles (124) whereas the stiffener tube members (130) are formed of rod-shaped tube members. The fuel tank (112) is assembled in such a way that the grooves (132, 133) are respectively placed near the seating area of the intermediate baffles (124) and the plurality of intermediate baffles (124) is securely connected with each other through the stiffener tube members (130), which restricts the movement of intermediate baffles (124) inside the shell (125) of the fuel tank (112).
[0031] In this fuel tank assembly (100) of the present invention, the baffles (124) are placed and integrated inside the fuel tank shell (125) through the stiffener tube members (130) in such a way that the movement of these baffles (124) is arrested by the grooves (132, 133) formed on the shell (125). In particular, the groove (132) on left-side arrests movement of one of the baffles (124) towards right whereas the groove (133) on right-side arrests movement of another baffle (124) towards left. The fuel tank assembly (100) disclosed in the present invention is capable of integrating

the baffle (124) within the fuel tank shell (125) without any welding process, i.e. avoiding spot or tag welding for attaching the baffles (124) with the fuel tank shell (125). Thus, it prevents the movement and tilting of the baffles (124) within the fuel tank (112) while assembling the fuel tank (112) into the vehicle, which reduces effect of fuel sloshing inside the fuel tank (112) during the vehicle operation.
[0032] The present invention is a fuel tank assembly (100) for the commercial vehicle to integrate the baffles (124) within the fuel tank shell (125) without any spot or tag welding. Therefore, the present invention is not limited to the embodiments herein before described which may be varied in both construction and detail within the scope of the appended claims. Many modification and other embodiments of the invention may come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and associated drawings. In addition, some changes may be made to these specific embodiments, and such modifications are contemplated by the principle of the present invention. In addition, it is to be understood that the present invention is applicable for all the range of commercial vehicles with different configuration of front and rear axles. 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.

We Claim:
1. A fuel tank assembly (100) for a commercial vehicle, comprising:
a rectangular or cylindrical-shaped shell (125) enclosed by at least two end plates (119) to form a fuel tank (112) for storing liquid fuel therein;
a plurality of grooves (132, 133) formed on an outer surface of the shell (125) and spaced apart each other along a longitudinal axis of the fuel tank (112);
a plurality of intermediate baffles (124) each mounted at right angles to the inner region of the shell (125), where the baffles (124) are spaced apart each other along the longitudinal axis of the fuel tank (112); and
one or more stiffener tube members (130) positioned between the baffles (124) and placed in a horizontal plane through a center of the fuel tank (112),
wherein the fuel tank (112) is assembled in such a way that the grooves (132, 133) are respectively placed near the seating area of the intermediate baffles (124) and the plurality of intermediate baffles (124) is securely connected with each other through the stiffener tube members (130), which restricts the movement of intermediate baffles (124) inside the shell (125) of the fuel tank (112).
2. The fuel tank assembly (100) as claimed in claim 1, wherein the intermediate baffles (124) are placed in between the end plates (119) that are mounted to an interior wall edge of the shell (125).
3. The fuel tank assembly (100) as claimed in claim 1, wherein each intermediate baffle (124) is positioned at equidistance with respect to the longitudinal axis of the fuel tank (112) in such a way that each intermediate baffle (124) acts as stiffeners for attaching the fuel tank (112) to a vehicle frame through brackets and straps.
4. The fuel tank assembly (100) as claimed in claim 1, wherein each intermediate baffle (124) is located within the interior of the shell (125) to divide the fuel tank (112) into individual chambers (151, 152, 153) for storing the liquid fuel therein.

5. The fuel tank assembly (100) as claimed in claim 1, wherein the intermediate baffles (124) are formed of disc-shaped baffles whereas the stiffener tube members (130) are formed of rod-shaped tube members.
6. The fuel tank assembly (100) as claimed in claim 1, wherein the stiffener tube members (130) are fixed to the intermediate baffles (124) by bolts and washers or by welding.