US-20260124907-A1 - FAST FILL SYSTEM FOR REPLACEMENT FUEL TANK

US20260124907A1US 20260124907 A1US20260124907 A1US 20260124907A1US-20260124907-A1

Abstract

A fast fill system is provided. The fast fill system includes first and second high flow roll-over valves, each coupled to flexible tubes. The system includes a replacement fuel tank with first and second inserts on top. The high flow roll-over valves couple to the replacement fuel tank through the respective inserts. The valves with flexible tubes allow the replacement fuel tank to expel up to 400% more air when refueling than without them. This enables filling by high-flow truck stop pumps at rates of 25+ gallons per minute without pressure buildup or spillage.

Inventors

James E. Patience
Woodruff D. Smith

Assignees

SUPERTANKS LLC

Dates

Publication Date: 20260507
Application Date: 20251031

Claims (20)

1 . A fast fill system comprising: a first high flow roll-over valve; a first flexible tube coupled to the first high flow roll-over valve; a second high flow roll-over valve; a second flexible tube coupled to the second high flow roll-over valve; a replacement fuel tank comprising a first insert and a second insert on a top of the replacement fuel tank, wherein: the first high flow roll-over valve is coupled to the replacement fuel tank through the first insert; the second high flow roll-over valve is coupled to the replacement fuel tank through the second insert; and the first and second high flow roll-over valves with the first and second flexible tubes are configured to allow the replacement fuel tank to expel up to 400% more air when refueling than without the first and second high flow roll-over valves.
2 . The fast fill system of claim 1 , further comprising a first coupler connected to an end of the first flexible tube and a second coupler connected to an end of the second flexible tube.
3 . The fast fill system of claim 2 , wherein the first coupler and the second coupler are configured to be coupled together when the fast fill system is not in use for refueling.
4 . The fast fill system of claim 1 , wherein the first and second flexible tubes are configured to allow air to be expelled therethrough during refueling operations.
5 . The fast fill system of claim 1 , wherein the replacement fuel tank is configured to be filled at high pressure truck stop nozzles that pump fuel at 25+ gallons per minute.
6 . The fast fill system of claim 1 , wherein the first and second inserts are positioned on a top surface of the replacement fuel tank.
7 . The fast fill system of claim 6 , wherein the first and second high flow roll-over valves are threaded into the first and second inserts respectively.
8 . A replacement fuel tank comprising: a tank body formed of high-density cross-linked polyethylene; a first insert and a second insert positioned on a top surface of the tank body; a first high flow roll-over valve coupled to the tank body through the first insert; a second high flow roll-over valve coupled to the tank body through the second insert; a first flexible tube coupled to the first high flow roll-over valve; and a second flexible tube coupled to the second high flow roll-over valve, wherein the first and second high flow roll-over valves with the first and second flexible tubes enable the replacement fuel tank to be filled by high-flow truck stop pumps at rates of 25+ gallons per minute.
9 . The replacement fuel tank of claim 8 , further comprising a first coupler connected to an end of the first flexible tube and a second coupler connected to an end of the second flexible tube.
10 . The replacement fuel tank of claim 9 , wherein the first coupler and the second coupler are configured to be coupled together when the replacement fuel tank is not being refueled.
11 . The replacement fuel tank of claim 8 , wherein the first and second flexible tubes are configured to allow air to be expelled therethrough during refueling operations.
12 . The replacement fuel tank of claim 8 , wherein the first and second high flow roll-over valves are threaded into the first and second inserts respectively.
13 . The replacement fuel tank of claim 8 , wherein the first and second high flow roll-over valves with the first and second flexible tubes are configured to allow the replacement fuel tank to expel up to 400% more air when refueling than without the first and second high flow roll-over valves.
14 . The replacement fuel tank of claim 13 , wherein the replacement fuel tank is configured to prevent pressure buildup and spillage during high-flow refueling operations.
15 . A method of installing a fast fill system on a replacement fuel tank, comprising the steps of: removing a plug from a first insert on a top of the replacement fuel tank; removing a plug from a second insert on the top of the replacement fuel tank; setting up a system to catch plastic shavings; drilling a first hole in the first insert; drilling a second hole in the second insert; trimming inside edges of the first and second holes; cleaning the replacement fuel tank of debris; threading a first high flow roll-over valve into the first hole; threading a second high flow roll-over valve into the second hole; coupling a first flexible tube to the first high flow roll-over valve; and coupling a second flexible tube to the second high flow roll-over valve.
16 . The method of claim 15 , wherein the step of setting up a system to catch plastic shavings comprises placing a rag inside the replacement fuel tank beneath drilling locations.
17 . The method of claim 15 , wherein the step of drilling the first hole and the step of drilling the second hole each comprise starting with a pilot drill bit and gradually increasing drill bit size to achieve a desired hole diameter.
18 . The method of claim 17 , wherein the step of drilling further comprises applying grease to the drill bit to catch plastic shavings.
19 . The method of claim 15 , further comprising the steps of connecting a first coupler to an end of the first flexible tube and connecting a second coupler to an end of the second flexible tube.
20 . The method of claim 15 , wherein the step of cleaning the replacement fuel tank comprises using compressed air to remove all plastic shavings and debris from inside the replacement fuel tank.

Description

CROSS-REFERENCE TO RELATED APPLICATION(S) This application claims priority to U.S. Provisional Application No. 63/716,095, filed Nov. 4, 2024, the disclosure of which is hereby incorporated entirely herein by reference. TECHNICAL FIELD The present disclosure relates to fuel tank systems, and more particularly to a fast fill system for replacement fuel tanks that enables high-flow refueling at truck stop pumps. STATE OF THE ART Diesel-powered vehicles, particularly heavy-duty trucks and commercial vehicles, rely on fuel tank systems that can accommodate the demands of high-volume refueling operations. Modern truck stops and commercial fueling stations are equipped with high-flow fuel dispensing systems capable of delivering fuel at rates exceeding 25 gallons per minute. These high-flow systems enable rapid refueling of large-capacity fuel tanks, reducing downtime and improving operational efficiency for commercial vehicle operators. Replacement fuel tanks for diesel vehicles present unique challenges in fuel system design. Unlike original equipment manufacturer tanks that are specifically engineered for particular vehicle applications, replacement tanks must accommodate various vehicle configurations while maintaining compatibility with existing fuel system components. The design of replacement tanks involves considerations such as tank capacity, mounting configurations, fuel pickup systems, and venting arrangements. Fuel tank venting systems play a role in the refueling process by allowing air to escape from the tank as fuel enters. During high-flow refueling operations, the rate at which air must be expelled from the tank increases proportionally with the fuel flow rate. Conventional venting systems may become restrictive during high-flow refueling, potentially leading to pressure buildup within the tank, reduced fuel flow rates, or premature shut-off of the fuel dispensing nozzle. The automotive aftermarket includes various replacement fuel tank options for diesel vehicles, with some tanks offering increased capacity compared to original equipment tanks. These larger capacity tanks, often referred to as extended range or XXL tanks, provide benefits such as increased driving range and reduced refueling frequency. However, the design of such tanks must address the challenges associated with proper venting during refueling operations, particularly when used with high-flow fuel dispensing systems. Roll-over valves are commonly used in fuel tank systems to prevent fuel spillage in the event of vehicle rollover while also serving as venting components during normal operation. The design and sizing of these valves can influence the overall venting capacity of the fuel tank system and its compatibility with different refueling scenarios. Accordingly, there is a need for an improved fast fill system for use with a replacement fuel tank. SUMMARY OF THE INVENTION According to an aspect of the present disclosure, a fast fill system is provided. The fast fill system comprises a first high flow roll-over valve and a first flexible tube coupled to the first high flow roll-over valve. The system further comprises a second high flow roll-over valve and a second flexible tube coupled to the second high flow roll-over valve. The system includes a replacement fuel tank comprising a first insert and a second insert on a top of the replacement fuel tank. The first high flow roll-over valve is coupled to the replacement fuel tank through the first insert, and the second high flow roll-over valve is coupled to the replacement fuel tank through the second insert. The first and second high flow roll-over valves with the first and second flexible tubes are configured to allow the replacement fuel tank to expel up to 400% more air when refueling than without the first and second high flow roll-over valves. According to another aspect of the present disclosure, a replacement fuel tank is provided. The replacement fuel tank comprises a tank body formed of high-density cross-linked polyethylene and a first insert and a second insert positioned on a top surface of the tank body. The tank includes a first high flow roll-over valve coupled to the tank body through the first insert and a second high flow roll-over valve coupled to the tank body through the second insert. The tank further comprises a first flexible tube coupled to the first high flow roll-over valve and a second flexible tube coupled to the second high flow roll-over valve. The first and second high flow roll-over valves with the first and second flexible tubes enable the replacement fuel tank to be filled by high-flow truck stop pumps at rates of 25+ gallons per minute. According to a further aspect of the present disclosure, a method of installing a fast fill system on a replacement fuel tank is provided. The method comprises the steps of removing a plug from a first insert on a top of the replacement fuel tank and removing a plug from a second insert on the top of the re