Fuel tank assembly and method of assembly

Abstract

The present invention relates to a fuel tank assembly and method of securing a component in a fuel tank using induction welding. The method generally includes the steps of placing a component in contact with an inner surface of a fuel tank and inductively welding the component to the inner surface of the fuel tank. The fuel tank assembly generally includes a fuel tank having a wall having a cavity, an inner surface, an outer surface, and an access opening extending through the wall and communicating with the cavity and a component inductively welded to said inner surface.

1 . A method of attaching a component to a fuel tank having a wall defining a tank cavity, an inner surface, an outer surface, and an access opening extending through the wall, said method comprising: 
 placing the component in contact with the inner surface of the fuel tank; and    inductively welding the component to the inner surface of the fuel tank.    
     
     
         2 . The method of  claim 1  wherein said step of inductively welding the component further includes the steps of: 
 energizing an emitter coil to heat an induction receiver positioned in welding proximity to a weld surface of the component to weld the component to the inner surface; and    deenergizing the induction coil after the component is welded to the fuel tank.    
     
     
         3 . The method of  claim 1  wherein said step of placing the component in contact with the inner surface of the fuel tank further includes inserting the component through the access opening and offsetting the component from the access opening.  
     
     
         4 . The method of  claim 1  further including: 
 gripping the component with a holder;    inserting the holder into the access opening; and    displacing the holder to a position offset from the access opening before welding the component to the inner surface.    
     
     
         5 . The method of  claim 4  wherein one of the holder and component include an induction receiver in welding proximity to a weld surface of the component and wherein said step of induction welding further includes: 
 energizing an emitter coil to heat the induction receiver coupled to the arm; and    deenergizing the emitter coil after the component is inductively welded to the inner surface of the fuel tank.    
     
     
         6 . The method of  claim 1  further including the steps of: 
 coupling the component with a holder on an arm;    inserting the component and holder into the access opening defined by the fuel tank; and    manipulating the arm to position the component in contact with the inner surface at a location offset from the access opening.    
     
     
         7 . The method of  claim 6  further including manipulating the arm to remove the holder from the fuel tank after inductively welding the component.  
     
     
         8 . A fuel tank assembly comprising: 
 a fuel tank having a wall having a cavity, an inner surface, an outer surface, and an access opening extending through said wall and communicating with said cavity; and    a component inductively welded to said inner surface.    
     
     
         9 . The fuel tank assembly of  claim 8  wherein said component is offset from said access opening.  
     
     
         10 . The fuel tank assembly of  claim 8  wherein said component includes a weld surface and an induction receiver fixed to said component in welding proximity to said weld surface.  
     
     
         11 . The fuel tank assembly of  claim 8  wherein said induction receiver includes an induction element integrally molded into said component.