Low hydrocarbon emission fuel tank with internal components

A low hydrocarbon emission fuel tank comprising:

• a first thermoplastic sheet and a second thermoplastic sheet each comprising a plurality of layers;
• a weld joint operable to couple the first thermoplastic sheet and the second thermoplastic sheet to form the fuel tank, the first and second thermoplastic sheets operable to provide a hydrocarbon barrier;
• and
• a fuel system module positionable within the fuel tank prior to application of the weld joint to minimize discontinuities in the hydrocarbon barrier, the fuel system module comprising a pre-formed sheet and a fuel system component.

A fuel system module for installation in a low hydrocarbon emission fuel tank, the fuel system module comprising:

• a pre-formed sheet;
• the pre-formed sheet with provisions to support a fuel system component in a predetermined position;
• and
• the pre-formed sheet formed to fit within the low hydrocarbon emission fuel tank with provisions to couple with an interior surface of the low hydrocarbon emission fuel tank.

A method of internalizing fuel system components, the method comprising:

• forming a first half of a fuel tank;
• forming a second half of the fuel tank;
• mounting a fuel system module in one of the first half and the second half of the fuel tank, the fuel system module comprising a pre-formed sheet and a fuel system component;
• and
• joining the first half and the second half to surround the fuel system module and form the fuel tank, wherein the fuel system module forms a continuous layer between the first half and the second half.

A method of creating a fuel system module for internalizing fuel system components, the method comprising:

• forming a sheet in a predetermined shape;
• creating provisions on the sheet to fixedly couple the sheet to an internal surface of a fuel tank;
• and
• positioning a fuel system component on the sheet.