TITLE OF THE INVENTION : SYSTEM TO PREVENT FUEL LEAKAGE AND FUEL THEFT IN THE FUEL TANK OF A VEHICLE

FILED OF THE INVENTION

The present invention relates generally to a system that prevents fuel leakage and fuel theft in the fuel tank of a vehicle.

BACKGROUND OF THE INVENTION

Existing fuel tank systems are extremely prone to fuel leakage through capillary action. Moreover, they are also prone to fuel theft as well. Given the rising cost of fuel, fuel leakage and fuel theft can be extremely expensive to bear in the long run, especially in the case of vehicles with high fuel tank capacities that are filled to the brim. Further, the fuel leakage has adverse impacts on the environment as well..

Thus, there is a need in the art for a system that prevents fuel leakage and fuel theft, thus helping a user of a vehicle save a lot of money in the long run.

OBJECTIVES OF THE INVENTION

An objective of the present invention is to provide a system that prevents fuel leakage in the fuel tank of a vehicle.

Another objective of the present invention is to provide a system that prevents fuel theft in the fuel tank of a vehicle.

SUMMARY OF THE INVENTION

In order to overcome the drawbacks of the prior art and achieve the above mentioned objectives, a system to prevent fuel leakage and fuel theft in the fuel tank of a vehicle is disclosed. The system comprises a fuel tank comprising a top tank that is associated with a bottom tank and an overflow unit that facilitates closed loop circulation of fuel inside the fuel tank. The top tank comprises a breather assembly, a sensor assembly and a cap.

The breather assembly comprises a breather that breathes out air at a predetermined pressure, wherein the breather is associated with a breather adaptor flange and a uniquely configured breather adaptor for preventing fuel theft.

The sensor assembly comprises a lever, a float associated, a float housing and a sensor adapter that is configured to prevent fuel leakage through capillary action. The sensor adaptor comprises a plurality of screw holes onto which the entire sensor assembly is mounted by means of a plurality of fastening screws that are mounted on the plurality of screw holes.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 depicts an embodiment of the system to prevent fuel leakage and fuel theft.

Figure 2 depicts an embodiment of the breather assembly.

Figure 3 depicts the breather adaptor comprising a plurality of equidistantly spaced holes

Figure 4 depicts an exploded view of the system shown in Figure 1.

Figure 5 depicts an embodiment of the sensor assembly

DETAILED DESCRIPTION OF THE DRAWINGS

Throughout this specification, the use of the word "comprise" and variations such as "comprises" and "comprising" may imply the inclusion of an element or elements not specifically recited.

As illustrated in Figure 1, an embodiment of the system for preventing fuel leakage and fuel theft comprises a fuel tank (1) for storing fuel comprising a breather assembly (2), a sensor assembly (3) and a cap (4) for closing the fuel tank (1). In an embodiment, the fuel tank (1) has a capacity of 38 litres. The minimum capacity of the fuel tank (1) is at least 16 litres. The preferred range of capacity of the fuel tank is minimum 16 litres to maximum 70 litres. However, the system is not limited only to vehicles whose fuel tank capacities fall within the specified range

As illustrated in Figures 2a and 2b, an embodiment of the breather assembly (2) comprises a breather (21) that is associated with a breather adaptor flange (22) and a breather adaptor (23) that prevents direct flashing of fuel to the breather (21). Preferably, the height of the breather adaptor flange (22) may vary from 12 mm (Figure 2b) to 20 mm (Figure 2a). The breather (21) breathes out air at a certain predetermined pressure. Preferably, the predetermined pressure is 0.3 bar.

As shown in Figure 3, the breather adaptor (23) is uniquely configured with respect to two aspects. First, the breather adaptor (23) comprises a plurality of equidistantly spaced holes (24) on its sides that facilitate the breather (21) to breathe air. Second, the breather adaptor (23) is closed from the bottom to prevent fuel theft.

As illustrated in Figure 4, the fuel tank (1) further comprises a top tank (11) and a bottom tank (12) that are fastened together. The top tank (11) comprises the breather assembly (2), the sensor assembly (3) and the cap (4). In an embodiment, the top tank (11) and the bottom tank (12) are made of tin plates. Preferably, the tin plates comprise 20% tin. In other embodiments, the top tank (11) and the bottom tank (12) may be made of lead alloy (preferably comprising 1 % tin and 6% antimony) or nickel coated electro-galvanized double layer zinc. The bottom tank (12) comprises a fuel outlet (5) that provides fuel supply through a plurality of pipes (not shown) that are connected to the fuel outlet (5). Optionally, the bottom tank (12) may be made structurally rigid by welding a stiffener (8) inside the bottom tank (12). The stiffener material may be tin plates (preferably comprising 20% tin), lead alloy (preferably comprising 1% tin and 6% antimony) or nickel coated electro-galvanized double layer zinc.

As shown in Figures 4 and 5, the sensor assembly (3) comprises a lever that can travel between a first position (31a) and a second position (31b), a float associated with the lever that can also travel between a first position (32a) and a second position (32b), a float housing (33) and a sensor adapter (34) comprising a plurality of screw holes (36) onto which the entire sensor assembly (3) is mounted by means of a plurality of fastening screws (35) that are mounted on the plurality of screw holes (36). In an embodiment, there are six fastening screws (35) and six corresponding screw holes (36). The sensor assembly (3) accurately indicates fuel levels inside the fuel tank (1) without opening the cap (4). The configuration of the sensor adaptor (34) ensures that the sensor adaptor (34) does not come in direct contact with fuel inside the fuel tank (1) and thus there is no leakage of fuel through capillary action. This configuration is achieved by raising the height of the sensor adaptor (34) with respect to the surface of the top tank (11). The float is preferably hard rubber sponge.

The sensor adaptor (34) may be located outside the fuel tank (1) surface (Figure 5a), inside the fuel tank (1) surface (Figure 5b) or at any intermediate location relative to the fuel tank (1) surface (Figure 5c).

In an embodiment, the float housing (33) comprises a potentiometer (not shown) that is associated with one end of the lever. The level of fuel inside the fuel tank (1) is measured/calibrated based on contact of the lever with the potentiometer. In another embodiment, the float housing (33) is made of Type 'D' steel. Similarly, the lever may be made of Spring Steel Grade II (IS 4454). Optionally, the steel used for both the float housing (33) and the lever may be coated with zinc plates and subject to trivalent passivation to prevent it from getting rusted.

If the level of fuel inside the fuel tank is very low (minimum of four litres, maximum may vary depending on user), the lever and the float move to their respective first positions (31a and 32a), thus causing the lever and the float to have minimum contact with the potentiometer. This causes a low resistance to be created in the float housing (33). As a result, a "LOW FUEL" warning is generated.

Similarly, in case of high fuel level (90-100% of fuel tank (1) capacity), the lever and the float move to their respective second positions (31b and 32b), thus causing the lever and the float to have maximum contact with the potentiometer. This causes a high resistance to be created in the float housing (33). As a result, a "FULL FUEL" indication is generated.

In all other cases, the lever and the float may be in intermediate positions between their respective first positions (31a and 32a) and their respective second positions (31b and 32b).

The "LOW FUEL" warning and the "FULL FUEL" indication may be audio indications such as a beep, visual indications such as LED indications, or both.

A baffle plate (6) is permanently associated with the bottom tank (12), preferably by means of welding (Figure 4). The main purpose of the baffle plate (6) is to prevent the fuel flowing/ rushing from one end of fuel tank (1) to the other end during inclined runs or pitching of a vehicle comprising the fuel tank (1). The baffle plate (6) comprises a plurality of large holes (not shown) to cause free flow of fuel. This also prevents swirling of the fuel and prevents noise caused by fuel splashing.

An overflow unit (7) is attached before a reserve tank (not shown) such that the fuel circulates in a closed loop. The fuel flows from fuel outlet (5) to an engine (not shown) via a filter (not shown) and a fuel injection pump (FIP) (not shown), the excess fuel in the FIP flows back via the reserve tank and an overflow pipe (not shown) to the fuel tank (1) and thus forms a closed loop.

It will be apparent to a person skilled in the art that the above description is for illustrative purposes only and should not be considered as limiting. Various modifications, additions, alterations, and improvements without deviating from the spirit and the scope of the invention may be made by a person skilled in the art.

LIST OF REFERENCE NUMERALS

1 - Fuel Tank

11 - Top Tank

12 -Bottom tank

2 - Breather Assembly

21 - Breather

22 - Breather Adaptor Flange

23 - Breather Adaptor

24 - Plurality of equidistantly spaced holes

3 - Sensor Assembly

31a - First position of lever

31b - Second position of lever

32a - First position of float

32b - Second position of float

33 - Float housing

34 - Sensor Adaptor

35 - Plurality of fastening screws

36 - Plurality of screw holes

4 -Cap

5 - Fuel Outlet

6 - Baffle Plate

7 - Overflow unit

8 - Stiffener


We claim:

1. A system to prevent fuel leakage and fuel theft in fuel tank of vehicle, said system comprising a fuel tank (1) comprising a top tank (11) that is associated with a bottom tank (12) and an overflow unit (7) that facilitates closed loop circulation of fuel inside the fuel tank (1) wherein:

the top tank (11) comprises a breather assembly (2), a sensor assembly (3) and a cap (4);

the breather assembly (2) comprises a breather (21) that breathes out air at a predetermined pressure, wherein the breather (21) is associated with a breather adaptor flange (22) and a uniquely configured breather adaptor (23), said breather adaptor (23) being closed from the bottom to prevent fuel theft and comprising a plurality of equidistantly spaced holes (24) that facilitate the breather (21) to breathe air;

the sensor assembly (3) comprises a lever that can travel between a first position (31a) and a second position (31b), a float associated with the lever that can also travel between a first position (32a) and a second position (32b), a float housing (33) and a sensor adapter (34) that is configured to prevent fuel leakage through capillary action by raising the height of the sensor adaptor (34) with respect to the top tank (11) surface, wherein the sensor adaptor (34) comprises a plurality of screw holes (36) onto which the entire sensor assembly (3) is mounted by means of a plurality of fastening screws (35) that are mounted on the plurality of screw holes (36);

the bottom tank comprises a fuel outlet that supplies fuel through a plurality of pipes that are connected to the fuel outlet (5); and

a baffle plate (6) is permanently associated with the bottom tank (12) to prevent rushing of the fuel from one end of fuel tank (1) to the other end during inclined runs of said vehicles.

2. The system to prevent fuel leakage and fuel theft in fuel tank of vehicle as claimed in claim 1, wherein the fuel tank (1) has a capacity ranging from 16 litres to 70 litres..

3. The system to prevent fuel leakage and fuel theft in fuel tank of vehicle as claimed in claim 1, wherein the top tank (1) and the bottom tank (2) are made of tin plates comprising 20% tin, lead alloy comprising 1% tin and 6% antimony or nickel coated electro-galvanized double layer zinc.

4. The system to prevent fuel leakage and fuel theft in fuel tank of vehicle as claimed in claim 1, wherein the bottom tank (12) further comprises a stiffener (8) that is welded inside the bottom tank (12) to increase the structural rigidity of the bottom tank (12).

5. The system to prevent fuel leakage and fuel theft in fuel tank of vehicle as claimed in claim 4, wherein the stiffener (8) used is tin plates comprising 20% tin, lead alloy comprising 1% tin and 6% antimony or nickel coated electro-galvanized double layer zinc.

6. The system to prevent fuel leakage and fuel theft in fuel tank of vehicle as claimed in claim 1, wherein the predetermined pressure is 0.3 bar.

7. The system to prevent fuel leakage and fuel theft in fuel tank of vehicle as claimed in claim 1, wherein the height of the breather adaptor flange (22) varies from 12 mm to 20 mm.

8. The system to prevent fuel leakage and fuel theft in fuel tank of vehicle as claimed in claim 1, wherein the system comprises six fastening screws (35) and six corresponding screw holes (36).

9. The system to prevent fuel leakage and fuel theft in fuel tank of vehicle as claimed in claim 1, wherein the float is hard rubber sponge.

10. The system to prevent fuel leakage and fuel theft in fuel tank of vehicle as claimed in claim 1, wherein the sensor adaptor (34) is located outside the surface of the fuel tank(1).

11. The system to prevent fuel leakage and fuel theft in fuel tank of vehicle as claimed in claim 1, wherein the sensor adaptor (34) is located inside the surface of the fuel tank (1).

12. The system to prevent fuel leakage and fuel theft in fuel tank of vehicle as claimed in claim 1, wherein the float housing (33) comprises a potentiometer that is associated with one end of the lever, said potentiometer capable of measuring the level of fuel inside the fuel tank (1) based on contact of the lever with the potentiometer.

13. The system to prevent fuel leakage and fuel theft in fuel tank of vehicle as claimed in claim 12, wherein a "LOW FUEL" warning is generated when the lever is in the first position (31a).

14. The system to prevent fuel leakage and fuel theft in fuel tank of vehicle as claimed in claim 1, wherein the float housing is made of Type 'D' Steel, said steel being coated with zinc plates and subject to trivalent passivation to prevent the steel from getting rusted.

15. The system to prevent fuel leakage and fuel theft in fuel tank of vehicle as claimed in claim 1, wherein the lever is made of Spring Steel Grade II (IS 4454), said steel being coated with zinc plates and subject to trivalent passivation to prevent the steel from getting rusted.