Apparatus and methods for permanently attaching fuel delivery system components to fuel tanks

1. A fuel tank, comprising:

a plurality of walls composed of a first thermoset material, the plurality of walls defining a cavity;

an insert material integrally formed with at least a portion of a wall of the fuel tank such that the insert material is positioned between an outer surface of the wall and an inner surface of the wall, the inner surface defining a portion of the cavity, the insert material comprises:

a first layer material having a low permeation characteristic;

a second layer material adjacent the first layer material having a relatively lower melting point than a melting point of the first layer material, the second layer to permanently attach a coupling apparatus to the wall of the fuel tank by melting at least a portion of the second layer material and at least a portion of the coupling apparatus; and

a third layer material composed of a second thermoset material substantially similar to the first thermoset material of the walls, the third layer material being adjacent the first layer material, the third layer material defining a portion of the outer surface of the wall when the coupling apparatus is not attached to the fuel tank, wherein the first layer material is different than the second layer material, the second layer material is different than the third layer material, and the third layer material is different than the first layer material.

2. A fuel tank of claim 1 , wherein the first layer material comprises a copolymer material.

3. A fuel tank of claim 2 , wherein the copolymer material comprises Ethylene Vinyl Alcohol.

4. A fuel tank of claim 1 , wherein the second layer material comprises a thermoplastic material.

5. A fuel tank of claim 4 , wherein the thermoplastic material comprises a high density polyethelyne.

6. A fuel tank of claim 1 , further comprising a fourth layer material adjacent the first layer material.

7. A fuel tank of claim 6 , wherein the first layer material is disposed between the second and fourth layer materials.

8. A fuel tank of claim 6 , wherein the fourth layer material comprises a thermoplastic material.

9. A fuel tank of claim 1 , wherein the second layer material has a relatively lower melting point compared to a melting point of the third layer material.

10. A fuel tank of claim 1 , wherein the third layer material has a relatively high-temperature resistance characteristic.

11. A fuel tank of claim 1 , wherein the second thermoset material comprises a cross-linked polyethylene copolymer material.

12. A fuel tank of claim 1 , wherein second layer is melted to enable permanent attachment of the coupling apparatus to the surface of the fuel tank via plastic welding.

13. A fuel tank of claim 1 , wherein the first layer material is embedded within the second layer material.

14. A fuel tank of claim 1 , wherein the third layer is substantially flush with the outer surface of the fuel tank.

15. A fuel tank of claim 1 , wherein the coupling apparatus comprises a fuel component having a flange, the fuel component to project inside the cavity of the fuel tank and the flange to be substantially flush mounted relative to the outer surface, the flange to be melted along with the second layer to enable the flange to integrate with the second layer and form a bond to couple the fuel component to the wall of the fuel tank.

16. A fuel tank of claim 1 , further comprising a fourth layer material adjacent the first layer material, the fourth layer material defining a portion of the inner surface of the wall when the coupling apparatus is not attached to the fuel tank via the insert material, the fourth layer material being composed of a material substantially similar to the third layer material.

17. A fuel tank, comprising:

means for containing a liquid defining a plurality of walls and a cavity, the plurality of walls composed of a first thermoset material;

means for permanently attaching a coupling apparatus to the means for containing, the means for permanently attaching being integrally formed between an outer surface and an inner surface of a wall of the fuel tank, the means for permanently attaching includes:

means for enabling permanent attachment of the coupling apparatus to the wall of the fuel tank via plastic welding,

means for preventing permeation of a vapor or a gas, and

means for resisting greater temperatures and greater impact forces relative to the means for preventing permeation and the means for enabling permanent attachment, the means for resisting composed of a second thermoset material and defining an outer surface of the wall, the means for enabling permanent attachment having a lower melting temperature than the means for resisting.

18. A fuel tank comprising:

a plurality of walls defining a cavity;

an insert integrally formed with a wall of the fuel tank, the wall being composed of a first thermoset material, the insert having a first layer composed of a material configured to prevent permeation of a gas or vapor through the insert, second and third layers each composed of a first thermoplastic material to enable permanent attachment of a fluid component to a surface of the wall, the first layer being positioned between the second and third layers, and fourth and fifth layers each composed of a second thermoset material, the second and third layers being positioned between the fourth and fifth layers such that the fourth layer defines at least a portion of an outer surface of the wall and the fifth layer defines at least a portion of an inner surface of the wall; and

a fuel delivery system component having a portion composed of a second thermoplastic material and attached to the second and third layers via plastic welding.

19. A fuel tank of claim 18 , wherein an end of the fuel delivery system component is positioned in the insert.

20. A fuel tank of claim 18 , wherein the insert is insert molded with the wall of the fuel tank.

21. A fuel tank of claim 18 , wherein the second thermoset material comprises a copolymer material.

22. A fuel tank of claim 18 , wherein the thermoplastic material of the portion of the fuel delivery system component is substantially similar to the thermoplastic material of the second and third layers.