Fuel Pump Driver Mounting Inside Tank
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Solution Overview
Problem
The existing fuel pump modules for vehicles face space limitations and performance degradation due to the external installation of the driver for the BLDC fuel pump, leading to voltage drops and efficiency losses from long connecting wires, as well as vulnerability to vibrations and electromagnetic interference.
Innovation Solution
The driver is mounted between the flange and reservoir within the fuel tank, reducing wire length, using epoxy to seal and stabilize the driver, and employing a heat-conductive case cover to manage heat radiation, thus minimizing performance degradation and enhancing stability against vibrations and electromagnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the driver is mounted outside the fuel tank, then it is easier to install and access, but it increases wire length causing voltage drop and efficiency degradation
Solution Approach 1:
The driver is merged with the fuel pump module and installed inside the fuel tank, combining two separate components into one integrated assembly. This eliminates the need for long external wiring while maintaining installation feasibility through the unified structure.
Solution Approach 2:
The driver is relocated from the external three-dimensional space to the internal space of the fuel tank, changing its spatial dimension relative to the fuel pump. This dimensional repositioning reduces wire length while keeping the driver accessible through the flange structure.
2Temperature
If the driver is mounted outside the fuel tank, then heat dissipation is easier, but it increases exposure to vibrations and electromagnetic interference
Solution Approach 1:
The fuel that surrounds the driver inside the tank is converted from a potential source of electromagnetic interference into a beneficial heat dissipation medium. The fuel acts as both a cooling agent and an electromagnetic shield, transforming a harmful factor into a protective one.
Solution Approach 2:
The fuel tank structure serves as an intermediary between the driver and external vibrations, isolating the driver from mechanical shocks. The fuel itself acts as a damping medium that absorbs vibration energy before it reaches the driver circuitry.
3Loss of energy
If the driver is installed inside the fuel tank, then wire length is reduced minimizing voltage drop, but space availability is limited
Solution Approach 1:
The driver is nested within the fuel pump module structure, which itself is installed inside the fuel tank. This nested arrangement allows the driver to occupy the internal space efficiently without requiring additional external mounting volume.
Solution Approach 2:
The driver housing is segmented into multiple sections that can be assembled in a compact configuration within the limited tank space. The segmented design allows for optimized space utilization while maintaining all necessary functional components.
4Reliability
If the driver is sealed with epoxy inside the fuel tank, then protection against fuel exposure is improved, but heat dissipation may be affected
Solution Approach 1:
The epoxy sealing is applied locally only to specific areas of the driver housing that require protection from fuel exposure, rather than completely encapsulating the entire driver. This selective sealing maintains electrical protection while preserving thermal pathways for heat dissipation.
Solution Approach 2:
The driver housing uses composite material construction combining epoxy-coated sections for fuel protection with thermally conductive sections for heat dissipation. This composite structure simultaneously achieves both sealing and thermal management requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration addresses space limitations, reduces voltage drops and efficiency losses, provides stability against vibrations and electromagnetic interference, and ensures effective heat dissipation, enhancing the overall performance and reliability of the BLDC fuel pump module.
Implementation Method 1
achieving a sufficient heat radiation effect by directly transferring the heat energy generated from electrical devices such as FET, MCU, or the like, mounted in the driver to the fuel in the fuel tank through the case cover
Implementation Method 2
epoxy is filled between the top surface of the driver and the inner top surface of the case main body through an epoxy injection hole formed in the driver in order to prevent the injection of fuel
Data Source
AI summary
Provided is a fuel pump module used for a car, and more particularly, to a fuel pump module with a driver equipped inside a fuel tank capable of solving a problem of space limitation due to the installation of the driver by disposing the driver for controlling a BLDC fuel pump between a flange and a reservoir and mounting it in the fuel tank, minimizing the degradation in performance of the BLDC fuel pump caused by voltage drop and efficiency degradation due to a wire by reducing a length of a wire for electrically connecting the driver with the BLDC fuel pump, and achieving a sufficient heat radiation effect by directly transferring the heat energy generated from electrical devices such as FET, MCU, or the like, mounted in the driver to the fuel in the fuel tank through the case cover.