US-20260124909-A1 - UNIVERSAL PICKUP TUBE AND RETURN SYSTEM

US20260124909A1US 20260124909 A1US20260124909 A1US 20260124909A1US-20260124909-A1

Abstract

A universal pickup tube and return system is provided. The system includes a pickup tube with a pickup fitting coupled to the first end, configured as a universal fitting for vehicle pickup fuel lines. A return fitting couples to the vehicle's return fuel line. The pickup tube inserts into the replacement fuel tank's pickup insert with the pickup fitting extending from the top. The return fitting couples to the tank's return insert for fuel return. The pickup tube extends to the tank's lowest portion to draw fuel as levels drop. Both fittings are compatible with aftermarket high-pressure fuel systems, providing plug and play installation without requiring custom components.

Inventors

James E. Patience
Woodruff D Smith

Assignees

SUPERTANKS LLC

Dates

Publication Date: 20260507
Application Date: 20251031

Claims (18)

1 . A universal pickup tube and return system for a replacement fuel tank, comprising: a pickup tube having a first end and a second end; a pickup fitting coupled to the first end of the pickup tube, the pickup fitting being a universal fitting configured to couple to a pickup fuel line of a vehicle; and a return fitting configured to couple to a return fuel line of the vehicle, wherein the pickup tube is configured to be inserted into a pickup insert of the replacement fuel tank with the pickup fitting extending from a top side of the replacement fuel tank, and the return fitting is configured to be coupled to a return insert of the replacement fuel tank to act as a fuel return.
2 . The universal pickup tube and return system of claim 1 , wherein the pickup tube is configured to extend to a lowest portion of the replacement fuel tank to draw fuel as a fuel level drops.
3 . The universal pickup tube and return system of claim 1 , wherein the pickup fitting and the return fitting are configured for compatibility with aftermarket high-pressure fuel systems.
4 . The universal pickup tube and return system of claim 1 , wherein the pickup tube includes a coupler at the second end configured to connect to the pickup fitting.
5 . The universal pickup tube and return system of claim 1 , wherein the pickup insert and the return insert are positioned on a top surface of the replacement fuel tank.
6 . The universal pickup tube and return system of claim 1 , wherein the system is configured to provide a plug and play installation without requiring custom built components for individual vehicles.
7 . A replacement fuel tank system, comprising: a replacement fuel tank having a tank body with a pickup insert and a return insert disposed on a top portion of the tank body; a pickup tube inserted into the pickup insert and extending toward a bottom portion of the tank body; a pickup fitting coupled to an end of the pickup tube and extending from the top portion of the replacement fuel tank at the pickup insert, the pickup fitting being a universal fitting configured to couple to a pickup fuel line of a vehicle; and a return fitting coupled to the return insert, the return fitting being a universal fitting configured to couple to a return fuel line of the vehicle.
8 . The replacement fuel tank system of claim 7 , wherein the pickup tube extends to a lowest portion of the tank body to draw fuel as a fuel level drops.
9 . The replacement fuel tank system of claim 7 , wherein the pickup fitting and the return fitting are configured for compatibility with aftermarket high-pressure fuel systems.
10 . The replacement fuel tank system of claim 7 , wherein the replacement fuel tank is constructed from High-Density Cross-Linked Polyethylene.
11 . The replacement fuel tank system of claim 7 , wherein the pickup insert and the return insert are positioned to allow drilling access for installation of the pickup tube and the return fitting.
12 . The replacement fuel tank system of claim 11 , wherein the pickup insert is located above a fuel trap within the tank body.
13 . A method of installing a universal pickup tube and return system in a replacement fuel tank, comprising: drilling a hole in a pickup insert located on a top portion of the replacement fuel tank; inserting a pickup tube through the drilled hole such that the pickup tube extends toward a bottom portion of the replacement fuel tank; coupling a pickup fitting to an end of the pickup tube that extends from the top portion of the replacement fuel tank, the pickup fitting being a universal fitting configured to couple to a pickup fuel line of a vehicle; and coupling a return fitting to a return insert on the top portion of the replacement fuel tank, the return fitting being a universal fitting configured to couple to a return fuel line of the vehicle.
14 . The method of claim 13 , further comprising a step of setting up a system to catch plastic shavings during the drilling step to prevent debris from entering the replacement fuel tank.
15 . The method of claim 14 , wherein the step of setting up a system to catch plastic shavings comprises placing a rag inside the replacement fuel tank beneath a drilling location.
16 . The method of claim 13 , further comprising a step of applying thread seal tape to threads of the pickup fitting before the coupling step.
17 . The method of claim 13 , further comprising a step of trimming an inside edge of the drilled hole with a razor blade to ensure a flush fit with threads and remove rough edges.
18 . The method of claim 17 , further comprising a step of cleaning the replacement fuel tank to remove all plastic debris after the trimming step.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority U.S. Provisional Application No. 63/715,924, filed November 4, 2024, the disclosure of which is hereby incorporated entirely herein by reference. TECHNICAL FIELD The present disclosure relates to fuel tank systems for vehicles, and more particularly to a universal pickup tube and return system for replacement fuel tanks that provides compatibility with high-pressure fuel systems and aftermarket fuel system components. State of the Art Fuel systems in modern vehicles, particularly those equipped with diesel engines and fuel injection systems, commonly incorporate pickup tubes and return lines to facilitate proper fuel delivery and circulation. These components work together to draw fuel from the tank and return excess fuel back to the tank, maintaining optimal fuel pressure and system performance. Many vehicle owners seek to increase their fuel capacity by installing replacement fuel tanks that offer greater storage volume than the original equipment manufacturer tanks. These aftermarket replacement tanks provide extended range capabilities, which can be particularly beneficial for commercial vehicles, recreational vehicles, and long-distance travel applications. However, replacement fuel tanks typically do not include integrated pickup tubes or return systems that are compatible with the wide variety of fuel systems found across different vehicle makes and models. This creates challenges for vehicle owners who wish to upgrade their fuel capacity while maintaining proper fuel system functionality. The situation becomes more complex when considering high-pressure fuel systems and aftermarket fuel system components. These systems, which may include various brands and configurations of fuel pumps and filtration systems, often have specific connection requirements and flow characteristics that differ from standard fuel systems. Conventional approaches to addressing these compatibility issues often involve custom fabrication or modification of components for each specific vehicle and fuel system combination. This process can be time-consuming, costly, and may require specialized knowledge or equipment that is not readily available to all installers or end users. Additionally, the installation of pickup tubes and return systems in replacement tanks typically involves drilling holes and making permanent modifications to the tank structure. These modifications must be performed carefully to maintain the integrity of the tank while providing secure, leak-free connections for the fuel system components. Accordingly, there is a need for an improved universal pickup tube and return system for utilization in replacement fuel tanks. SUMMARY OF THE INVENTION According to an aspect of the present disclosure, a universal pickup tube and return system for a replacement fuel tank is provided. The system comprises a pickup tube having a first end and a second end. A pickup fitting is coupled to the first end of the pickup tube, with the pickup fitting being a universal fitting configured to couple to a pickup fuel line of a vehicle. A return fitting is configured to couple to a return fuel line of the vehicle. The pickup tube is configured to be inserted into a pickup insert of the replacement fuel tank with the pickup fitting extending from a top side of the replacement fuel tank, and the return fitting is configured to be coupled to a return insert of the replacement fuel tank to act as a fuel return. According to another aspect of the present disclosure, a replacement fuel tank system is provided. The system comprises a replacement fuel tank having a tank body with a pickup insert and a return insert disposed on a top portion of the tank body. A pickup tube is inserted into the pickup insert and extends toward a bottom portion of the tank body. A pickup fitting is coupled to an end of the pickup tube and extends from the top portion of the replacement fuel tank at the pickup insert, with the pickup fitting being a universal fitting configured to couple to a pickup fuel line of a vehicle. A return fitting is coupled to the return insert, with the return fitting being a universal fitting configured to couple to a return fuel line of the vehicle. According to a further aspect of the present disclosure, a method of installing a universal pickup tube and return system in a replacement fuel tank is provided. The method comprises drilling a hole in a pickup insert located on a top portion of the replacement fuel tank. A pickup tube is inserted through the drilled hole such that the pickup tube extends toward a bottom portion of the replacement fuel tank. A pickup fitting is coupled to an end of the pickup tube that extends from the top portion of the replacement fuel tank, with the pickup fitting being a universal fitting configured to couple to a pickup fuel line of a vehicle. A return fitting is coupled to a return insert on the top portion of the replacemen