“Polymeric fuel containers are being used because they can be manufactured in a cost-efficient manner, are of high mechanical stability and readily deformable in accidents, and greatly inhibit hydrocarbon permeation. The best results as to the overall qualities of the polymeric fuel containers have been obtained by a six-layer so-called COEX-structure. This is a multi-layer system manufactured in a single process (co-extrusion) and including two layers of high density polyethylene (HDPE) which enclose a barrier-layer of an ethylene vinyl alcohol copolymer (EVOH) and a layer of treated, recycled or "re-grind" plastic material.” 
(Neghandhi and Zhu, US Patent 7,771,805, 8/10/20100)

Recent US Patents

12/19/2010
7,807,006
Process for manufacturing a multilayer plastic fuel tank

Dubois and Ferhatovic of Inergy Automotive Systems Research, Belgium  have developed a multilayer plastic fuel tank with  a sulphonated part closing off an opening in the wall of the tank. The sulphonated part was manufactured independently and welded to the tank. (RDC 12/19/2010)

8/10/2010
7,771,805
Low organic vapor permeation resin composition

Negandhi and Zhu of Ovation Polymer Technology have developed a material for gas tanks based on coeextruding a polyphthalamide with other polyamides, polyesters and other modifiers with improved barrier properties, impact strengths and heat distortion temperatures.  This is used in gas tanks for gasoline engines such and lawn mowers and other garden machinery.  (RDC 10/12/2010)