Abstract: A fuel pump for supplying diesel fuel to an engine includes a pump housing, a motor mounted within the housing, a shaft extending from the motor, an impeller slidably attached to the shaft which has a prime number of vanes spaced unevenly about its circumference, a chamber body, and a chamber cover with a bleed orifice. The chamber body and cover form a chamber for the impeller and are held together by the housing. The chamber body and cover have pump channels of constant depth and are made of phenolic with fiberglass fill. The impeller is made of phenolic with fiberglass fill and granular fill.

Abstract: A fuel pump has a motor mounted within a housing with a shaft extending therefrom to which a helically shaped impeller is fitted having at least two turns for pumping fuel from a fuel tank to an automotive engine. The impeller has an involute shaped leading edge designed to efficiently scoop fuel from an inlet into a pumping chamber formed between the helically shaped blade turns comprising the impeller. A trailing edge on the impeller has a narrowed width which increases the effective flow cross-sectional area, thus increasing the fuel pressure. The helically shaped impeller needs no separate casing, as is typically required for conventional fuel pumps employing regenerative turbines, gerotors, roller vanes, or the like, and increases fuel pressure over a longer circumferential distance thus decreasing cavitation.

Abstract: A fuel pump has a motor mounted within a housing with a shaft extending therefrom to which a helically shaped impeller is fitted for pumping fuel from a fuel tank to an automotive engine. An end section of the housing has an inlet leading from the fuel tank to a pre-swirl fuel channel or trough located at the radially outermost perimeter of an impeller mating face on the end section. The trough has an inlet ramp which routes fuel to an inclined section with an axial grade to force the fuel to flow in the direction of impeller rotation. A trough termination ramp between the inclined section and the inlet ramps fuel toward the impeller at a steeper grade than the inclined section such that the fuel trough becomes flush with the impeller mating face. Fuel can thus be picked-up by the impeller throughout at least 340.degree. of rotation.

Abstract: A float rod and float body are fastened together by means of a two-point attachment in which a substantially straight remote end of the float rod is inserted into a rod receiving passage simultaneously with a grasping point on the float rod being received by a snap-in retainer on a portion of the float rod separated from the remote end by a bend in the float rod. Fastening of the parts is thus achieved in a single linear motion for ease of assembly. The snap-in retainer preferably is comprised of a fork whereby the float body is retained on the float rod against forces in any direction after being assembled. The float body can be filled with an appropriate filling material to provide the desired buoyancy in the liquid to be measured. An embodiment particularly adapted to fuel level measurement in vehicle fuel tanks is described.

Abstract: A sensor assembly is provided for determining the level of liquid, such as fuel, in a tank such as a motor vehicle fuel tank. A mounting bracket has a support end adapted to be supported from the tank and also has a distal connection end. A liquid level sensor has lower and upper ends and a resistor element extending therebetween, and is connected to the connection end of the mounting bracket by a shaft. A torsional spring is disposed around the shaft, and biases the liquid level sensor from a retracted position and toward a deployed position. In the retracted position, the sensor assembly is insertable through an access hole in the tank. In the deployed position, the upper end of the liquid level sensor is disposed generally above the shaft and the resistor element is disposed generally vertically to provide the greatest resolution possible with both linear and angular sweep floats.

Abstract: A liquid level sensor is disclosed for measuring the amount of fuel remaining in the fuel tank of a motor vehicle. The liquid level sensor comprises a vertically oriented resistor element, a float, and a contact assembly. A conductive strip and a continuous pad resistive strip are both located on the same side of the resistor element. The contact assembly is removably locked in the float, and is movable with the float along the resistor element. A contact connected to the end of a contact arm of the contact assembly is biased against the conductive strip, and another contact is biased against the resistive strip. At any point along the resistor element, the contact assembly electrically connects the conductive strip and the resistive strip to complete a circuit having a resistance proportional to the height of the float to indicate the level of liquid in the vessel.

Abstract: A fuel tank assembly has a reservoir mounted to the bottom wall of a fuel tank, with a fuel pump unit and fuel sender unit both mounted to the reservoir. The fuel pump unit is removably mounted to the reservoir by a fuel pump bracket and the fuel sender unit is removably mounted to the reservoir by a fuel sender bracket The reservoir, fuel pump bracket and fuel sender bracket can be composed of materials compatible with alcohol fuels or other fuel compositions.

Abstract: A smooth resistance characteristic, a reduction in component cost, and high durability are achieved for a variable resistor card formed using thick-film silk screen deposition. An arcuate wiper track and radial extension areas are all formed of a resistance material deposited using silk screen techniques. Laser trimming of the extension areas provides a desired characteristic of resistance versus sweep angle for the variable resistor. The resistance characteristic is continuous and nonstepped, thereby avoiding the creation of spikes caused by small circuit breaks during sweeping movement of the wiper contact.

Abstract: A resistor card for a fuel tank level sensor configured to reduce wear between an electrical contact wiper and metalized conductor pads formed on a substrate, by the deposition of thick film resistive material on the individual pads. The resistive material forms a protective coating on the pads to protect the metalized pads from excessive wiper wear.

Abstract: A fuel sender assembly using a wiper contact to generate a resistance proportional to fuel level in a fuel tank has a bent float rod engaged by a fork and a bore of a carrier element which rigidly carries a spring contact. The spring contact slidably engages a resistor on a resistor card within a housing. The carrier element extends through a slot in the housing such that it abuts the ends of the slot to provide rotational limits for the float rod. The carrier element retains the float rod such that the float rod is allowed to move over a limited distance in the direction coaxial with the portion of the float rod about which the other movable parts rotate. All other movement of the float rod, except the sweeping movement related to fuel level, are substantially prevented. Vibrational wear of the resistor card is thus avoided.

Abstract: A fuel sender assembly using a wiper contact to generate a resistance proportional to fuel level in a fuel tank has a bent float rod engaged by a fork and a bore of a carrier element which rigidly carries a spring contact. The spring contact slidably engages a resistor on a resistor card within a housing. The carrier element extends through a slot in the housing such that it abuts the ends of the slot to provide rotational limits for the float rod. The resulting fuel sender assembly can be installed in a fuel tank with no electrical calibration being needed.