Note: Descriptions are shown in the official language in which they were submitted.
CA 02271328 1999-OS-07
FUEL REFILLING ASSEMBLY
RELATED APPLICATION
This patent application claims priority to and all the benefits of
United States Provisional Patent Application Serial No. 60/084,670, filed on
May
7, 1998 and entitled "Fuel Filler Inlet".
TECHNICAL FIELD
The subject invention relates to a fuel refilling assembly for filling
a fuel tank of an automotive vehicle.
BACKGROUND OF THE INVENTION
Vehicle fuel tanks generally include a filler neck extending from the
tank to allow a user to refill the tank with liquid fuel. Some type of cap or
cover is
placed over the filler neck in order to seal the fuel tank from the
atmosphere.
Conventional gas cap assemblies are typically threaded onto the filler neck
and
include some type of locking handle. The typical function of a gas cap is to
seal the
fuel tank from outside impurities, such as dirt and dust, and to also maintain
fuel
vapor within the fuel tank. A predetermined pressure is usually maintained by
a
valve mechanism located within the cap. When the pressure within the fuel tank
reaches a predetermined super-atmospheric level, the valve mechanism
automatically opens to release the pressure. When the pressure within the fuel
tank
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drops to a predetermined sub-atmospheric level, the valve mechanism opens to
equalize the pressure.
Before the filling of the fuel tank a user completely removes the gas
cap from the filler neck and then inserts a filling nozzle. The fuel tank is
then filled
to the desired level. As appreciated, pressure may build-up within the fuel
tank but
still be below the super-atmospheric level.
Many prior art refueling systems include a sealing flap door mounted
within the filler neck. The filling nozzle opens the flap door when inserted
into the
filler neck. When the flap door is closed, the flap door seals the filler neck
from the
atmosphere and contains the built-up pressure within the fuel tank. Just
before
insertion of the filling nozzle, some fuel may drip or spill from the filling
nozzle
onto the flap door. This creates a potentially dangerous situation.
Specifically,
when the filling nozzle opens the flap door, the seal between the flap door
and filler
neck is broken which releases the built-up pressure in the fuel tank. This
escaping
vapor can spray the spilled fuel toward the user. Certain injury can result
such as
affixation, burning and scorching.
Accordingly, it is desirable to have a fuel refilling assembly which
incorporates a fast pressure decay within the fuel filler neck and fuel tank
prior to
completely inserting the filling nozzle. Even more preferably, this pressure
decay
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should automatically be triggered when the filling process is initiated by the
user.
In addition, the fuel refilling assembly should incorporate a valve mechanism
for
automatically equalizing the pressure within the fuel tank.
SUMMARY OF THE INVENTION
A fuel refilling assembly for selectively receiving a filling nozzle to
open and close a filler neck of a fuel tank. The refilling assembly comprises
a
housing adapted for attachment to the filler neck to selectively receive the
filling
nozzle. At least one sealing device is movably mounted to the housing and
moveable between seated and unseated positions for selectively equalizing
pressure
within the filler neck. The refilling assembly is characterized by an actuator
movably mounted to the housing and selectively engaging the sealing device for
automatically lifting the sealing device from the seated position to the
unseated
position when the filling nozzle is partially received within the filler neck,
thereby
venting any pressurized fluid from the filler neck before the filling nozzle
opens the
filler neck.
Accordingly, the subj ect invention provides a fuel refilling assembly
having a valve mechanism for automatically equalizing the pressure within the
fuel
tank and incorporates a fast pressure decay within the fuel filler neck and
fuel tank
prior to completely inserting the filling nozzle. The pressure decay is
automatically
triggered when the filling nozzle engages the actuator.
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BRIEF DESCRIPTION OF THE DRAWINGS
Other advantages of the present invention will be readily appreciated
as the same becomes better understood by reference to the following detailed
description when considered in connection with the accompanying drawings
wherein:
Figure 1 is a side view of a vehicle fuel tank incorporating a fuel
refilling assembly ofthe subject invention;
Figure 2 is a partially cross-sectional side view of the fuel refilling
assembly;
Figure 3 is a top view taken along line 3-3 of Figure 2;
Figure 4 is a top view taken along line 4-4 of Figure 2;
Figure 5 is a partially cross-sectional side view of a lower housing
portion with first and second flaps;
Figure 6 is a partially cross-sectional side view of the lower housing
portion with only the second flap;
Figure 7 is a side view of an alternative embodiment of the fuel
refilling assembly in a completely closed condition;
Figure 8 is a side view of the alternative embodiment of Figure 7 in
a partially open condition;
Figure 9 is a side view of the alternative embodiment of Figure 7 in
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a fully open condition;
Figure 10 is a cross-sectional side view of an alternative embodiment
of a housing;
Figure 11 is a top view taken along line 11-11 of Figure 7;
Figure 12 is a detailed view of a vacuum opening of the alternative
embodiment of Figure 7; and
Figure 13 is a detailed view of a pressure opening of the alternative
embodiment of Figure 7.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the Figures, wherein like numerals indicate like or
corresponding parts throughout the several views, a fuel refilling assembly is
generally shown at 20 in Figures 1 and 2. The refilling assembly 20
selectively
receives a filling nozzle 22 to open and close a filler neck 24 of a fuel tank
26. The
filler neck 24 is actually an extension of a filler pipe 25 which extends
directly from
the fuel tank 26. For illustrative purposes, the filling nozzle 22 is only
shown in the
alternative embodiments of Figures 8 and 9. The fuel tank 26, filler pipe 25
and
filler neck 24 axe shown schematically and may be of any conventional type as
is
known in the art.
The refilling assembly 20 comprises a housing for attachment to the
filler neck 24 to selectively receive the filling nozzle 22. The housing
includes an
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upper housing portion 28 and a lower housing portion 30. The upper housing
portion 28 is mounted within the filler neck 24 by any suitable means such as
crimping, locking forgers and/or a separable fastener. The lower housing
portion 30
is in turn snap fit into the upper housing portion 28 by an annular rib (not
numbered). A pair of truncated cones 32 are also press fit into the upper
housing
portion 28. The truncated cones 32, upper housing portion 28 and lower housing
portion 30 provide a guide for receiving and guiding the filling nozzle 22
into the
filler neck 24.
The upper housing portion 28 also extends around a top lip of the
filler neck 24. A cap 34 is removably mounted to the top of the upper housing
portion 28 for providing a protective cover for the filler neck 24 and fuel
tank 26.
The cap 34 is preferably of a simple design which does not seal against the
upper
housing portion 28 but keeps dust, dirt and other impurities from entering the
filler
neck 24 and fuel tank 26. The cap 34 has a cam lock (not shown) or is
otherwise
attached to the upper housing portion 28. As appreciated, the cap 34, housing
portions 28, 30, may be of any suitable design or configuration without
deviating
from the scope of the subject invention.
At least one sealing device is mounted to the housing portions 28, 30
and is moveable between seated and unseated positions for selectively
equalizing
any pressure within the filler neck 24. Specifically, the sealing device
includes a
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vacuum valve 36 for allowing atmospheric air to pass into the fuel tank 26
when the
fuel tank 26 is in a vacuum condition. The sealing device also includes a
pressure
valve 38 for venting the fuel tank 26 when the fuel tank 26 is in a pressure
condition.
As discussed in the background section, during normal operating conditions, a
predetermined pressure is to be maintained within the fuel tank 26 by the
sealing
devices 36, 38. When the pressure within the fuel tank 26 reaches a
predetermined
super-atmospheric level, i.e., a pressure condition, the pressure valve 38
automatically opens to release the pressure. Preferably, the predetermined
super-
atmospheric level is between 15 and 17 kilo Pascal (kPa). In other words, when
the
pressure within the fuel tank 26 reaches lSkPa the pressure valve 38 will
begin to
open. When the pressure reaches l7kPa the pressure valve 38 will be opened
entirely. When the pressure within the fuel tank 26 drops to a predetermined
sub-
atmospheric level, i.e., a vacuum condition, the vacuum valve 36 opens to
similarly
equalize the pressure.
A vent passageway 40 extends around the housing 28, 30 for
providing fluid communicationbetween the sealing devices 36, 38 and the fuel
tank
26. The housing 28, 30 also includes a chamber 42 disposed between the vacuum
36 and pressure 38 valves and in fluid communicationwith the vent passageway
40
for providing fluid communicationbetweenthe fuel tank 26 and the vacuum 36 and
pressure 3 8 valves. Accordingly, the pressure within the fuel tank 26 and
filler neck
24 are directly experienced by the vacuum 36 and pressure 38 valves.
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The refilling assembly 20 is characterized by an actuator 44 pivotally
mounted to the housing 28, 30 and selectively engaging the sealing device 36
for
automatically lifting the sealing device 36 from the seated position to the
unseated
position when the filling nozzle 22 is partially received within the filler
neck 24,
thereby venting any pressurized fluid from the filler neck 24 before the
filling nozzle
22 opens the filler neck 24. The actuator 44 therefore lifts the sealing
device 36,
optionally either the pressure 38 or vacuum 36 valve, regardless of the
pressure
within the fuel tank 26 to ensure a complete release of pressure. The release
of
pressure is preferably vented out to the atmosphere. This complete release of
pressure is a safety measure which combats the deficiencies associated with
the prior
art designs discussed in the background section. As appreciated, the fuel tank
26
may be pressurizedto almost 1 SkPa and the pressure valve 38 will not
automatically
release this pressure. This built-up pressure within the fuel tank 26
necessitates the
need for the subject invention.
Referring also to Figures 4 and 5, the actuator 44 includes a cam 46
selectively engaging one of the sealing devices 36, 38 for lifting the sealing
device
36, 3 8 to the unseated position when the filling nozzle 22 is partially
received within
the filler neck 24.
As appreciated, once the filling nozzle 22 opens the filler neck 24 the
refilling of the fuel may commence. A liquid seal between the filling nozzle
22 and
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the filler pipe 25 is created during the refueling. A mechanical seal (not
shown) may
also be used between the filling nozzle 22 and filler pipe 25 to create this
seal. The
liquid seal prevents any displaced fuel vapors from venting into the
atmosphere.
Preferably, the fuel vapors will vent through an environmentally safe
container such
as a carbon canister (not shown).
The cam 46 is preferably an integral part of the actuator 44. The
sealing device 36, 38 includes a post 48 selectively engaging the cam 46 of
the
actuator 44 for effecting movement of the sealing device 36, 38.
The actuator 44 is preferably a first flap 44 pivotally connected to the
housing 28, 30 for selective engagementwith the filling nozzle 22. The first
flap 44
extends partially into the lower housing portion 30. A second flap 50 is also
pivotally connected to the housing 28, 30 and disposed below the first flap
44. In
other words, the second flap 50 is positioned to engage the filling nozzle 22
after the
filling nozzle 22 engages the first flap 44. A flap gasket 52 is mounted to a
distal
end of the housing 28, 30 and is engaged by the second flap 50 for sealing a
portion
of the housing 28, 30 from the filler neck 24 of the fuel tank 26.
Specifically, the
second flap 50 seals the lower housing portion 30. As shown in Figures 4 and
6, a
pair of springs 54 are mounted between the housing 28, 30 and the second flap
50
for continuously biasing the second flap 50 against the flap gasket 52.
Preferably,
the first flap 44 pivots in a clockwise direction and the second flap 50
pivots in a
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counter-clockwisedirection. The second flap 50 primarily seals the housing 28,
30
from the filler pipe 25 and prevents any fuel vapor from escaping out the
filler neck
24.
During insertion of the filling nozzle 22, the filling nozzle 22 first
engages and pivots the first flap 44. This releases any built up pressure in
the filler
neck 24, filler pipe 25 and fuel tank 26. The filling nozzle 22 then hits the
second
flap 50 which urges the second flap 50 out of engagement with the flap gasket
52.
Since the pressure is released, there is no danger of splashing fuel and/or
fuel vapors
injuring the user. The filling nozzle 22 can now be completely inserted within
the
housing 28, 30 and the refilling of the fuel tank can begin.
In the preferred embodiment of Figures 2 through 6, the actuator 44,
or first flap, engages the vacuum valve 36 when the actuator 44 is pivoted by
the
filling nozzle 22. The vacuum valve 36 includes a vacuum gasket 56 mounted to
the
housing 28, 30 and a sealing portion 58 extending from the post 48 for
selective
engagement with the vacuum gasket 56 to seal the filler neck 24. The vacuum
gasket 56 preferably has an annular configuration with a pair of apertures
(not
numbered). One aperture provides an opening for the post 48 and the other
aperture
extends over a tab 60 which secures the vacuum gasket 5f to the lower housing
portion 30. The sealing portion 58 and post 48 have a substantially T-shaped
configuration when viewed in cross-section.
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The actuator 44 selectively engages the post 48 to lift the sealing
portion 58 from engagement with the vacuum gasket 56 to a position above the
vacuum gasket 56 for venting the filler neck 24, filler pipe 25 and fuel tank
26 before
the filling nozzle 22 opens the filler neck 24. The ventilating of the filler
neck 24
is specifically achieved by opening a fluid passageway between the chamber 42
and
the atmosphere via the unsealing of the vacuum gasket 56.
As also shown in Figure 3, the vacuum valve 36 includes a pair of
vacuum springs 62 engaging the sealing portion 58 for continuously biasing the
sealing portion 58 toward the engagement with the vacuum gasket 56.
Preferably,
the sealing portion 58 has a curved configuration substantially in the shape
of a
banana. As appreciated, the vacuum valve 36 may have any suitable
configuration
so long as the filler neck 24, filler pipe 25 and fuel tank 26 may be
automatically
ventilated before the filling nozzle 22 is completely inserted within the
housing 28,
30. One such variation of the vacuum valve 36 is disclosed in the alternative
embodiment which is discussed in greater detail hereinbelow.
As illustrated in Figure 2, the housing 28, 30 includes an upwardly
proj ecting pressure opening 64 for seating the pressure valve 3 8 and sealing
the filler
neck 24. Specifically, the pressure opening 64 extends from the upper housing
portion 28. The pressure opening 64 is in fluid communicationwith the chamber
42
such that the pressure valve 38 is in direct contact with the pressure exerted
from the
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filler pipe 25.
The pressure valve 38 includes a pressure gasket 66 mounted to a
pressure plate 68. The pressure valve 38 also includes an annular pressure
spring 70
engaging the pressure plate 68 for continuously biasing the pressure gasket 66
against the pressure opening 64 of the housing 28, 30. As discussed above, the
desired pressure which begins to lift the pressure valve 38 is lSkPa, i.e.,
super-
atmospheric pressure. Accordingly, the annular pressure spring 70 must have a
biasing force which equates to holding the pressure gasket 66 against the
pressure
opening 64 up to the lSkPa. Once the pressure within the filler neck 24
achieves
1 SkPa, the pressure plate 68 and gasket 66 will lift upward against the
biasing force
of the pressure spring 70 to open a fluid passageway between the chamber 42
and
the atmosphere. Specifically, there are a number of openings 72 within one of
the
truncated cones 32 to vent the super-atmospheric pressure. As appreciated, the
openings 72 may be holes formed within the cone 32 or gaps formed between the
cones 32 and the lower housing portion 30.
Referring now to Figures 7 through 13, wherein like numerals
increased by 100 indicate like or corresponding parts throughout the several
views,
an alternative embodiment of the fuel refilling assembly is shown. The fuel
refilling
assembly is generally shown at 120 in Figures 7, 8 and 9. As in the preferred
embodiment, the refilling assembly 120 includes a housing having upper 128 and
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lower 130 housing portions mounted within a filler neck 124 of a fuel tank
(not
specifically shown in these figures). The actuator 144 is a first flap 144 and
operates
in substantially the same manner as above. However, the first flap 144 in this
embodiment has a different shaped cam 146 and extends entirely across the
lower
housing portion 130. There is also a second flap 150 with a flap gasket 152
operating in substantially the same manner. Although the second flap 150
pivots
clockwise and has a different spring arrangement. This alternative embodiment
also
has a similar vent passageway 140 and chamber 142 for creating a fluid
passageway
between the filler pipe 125 and the sealing devices. As above, the sealing
devices
include a pressure valve 138 and a vacuum valve 136. The sealing devices 136,
138
also include a post 148 selectively engaging the cam 146 of the actuator 144
for
moving one of the sealing devices 136, 138 to an unseated position. The
primary
difference between the preferred embodiment and this alternative embodiment is
in
the configuration and operation of the pressure 138 and vacuum 136 valves.
As illustrated in Figure 7, the fuel refilling assembly 120 is in a
completely closed condition. Figure 8 shows the refilling assembly 120 in a
partially open condition and Figure 9 shows the refilling assembly 120 in a
fully
open condition. To move the refilling assembly 120 to the partially open
condition,
the filling nozzle 22 is partially inserted into the housing 128, 130 and the
actuator
144 engages the pressure valve 138. Specifically, the first flap 144 pivots
which
engages the cam 146 with the post 148 to lift the pressure valve 138.
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As also shown in Figures 10, 11 and 13, the housing 128, 130
includes an upwardly proj ecting pressure opening 164 for seating the pressure
valve
138 and sealing the filler neck 124 and filler pipe 125. As discussed above,
the post
148 selectively engages the pressure valve 13 8 to lift the pressure valve 13
8 from the
seated position to a position above the pressure opening 164 for venting the
filler
neck 124, filler pipe 125 and fuel tank before the filling nozzle 22 opens the
filler
neck 124. The pressure valve 138 includes a pressure gasket 166 mounted to a
pressure plate 168. The pressure valve 138 also includes an annular pressure
spring
170 engaging the pressure plate 168 for continuously biasing the pressure
gasket 166
against the pressure opening 164 of the housing 128, 130. The components of
the
pressure valve 138, i.e., the pressure gasket 166, pressure plate 168, and
pressure
spring 170, are substantiallythe same as those disclosed in the primary
embodiment.
During normal operating conditions, the pressure valve 138 of this
alternative embodiment operates in a similar fashion as the pressure valve 38
of the
preferred embodiment. In other words, when the pressure within the fuel tank
reaches a predetermined super-atmospheric level, the pressure valve 138
automatically opens to release the pressure. The predetermined super-
atmospheric
level is between lSkPa and l7kPa. The pressure valve 138, however, also
releases
all the pressure within the filler neck 124 and filler pipe 125 as the filling
nozzle 22
is partially inserted into the housing 128, 130. As discussed in the preferred
embodiment, with reference to the vacuum valve 36, this pressure valve 138
vents
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the filler neck 124 and filler pipe 125 by opening a fluid passageway between
the
chamber 142 and the atmosphere via the unsealing of the pressure gasket 166.
As also shown in Figures 10, 1 l and 12, the housing 128, 130 also
includes a downwardly projecting vacuum opening 174 for seating the vacuum
valve
136 and sealing the filler neck 124. The vacuum valve 136 includes a vacuum
gasket 176 mounted to a vacuum plate 178. The vacuum valve 136 also includes
an
annular vacuum spring 180 engaging the vacuum plate 178 for continuously
biasing
the vacuum gasket 176 against the vacuum opening 174 of the housing 128, 130.
The vacuum valve 136 operates in a similar fashion as above such that when the
pressure within the fuel tank drops to a predetermined sub-atmospheric level,
the
vacuum valve 136 opens to equalize the pressure. Specifically, the vacuum
valve
136 opens to create a fluid passageway between the chamber 142 and the
atmosphere.
As best shown in Figures 10 and 11, there are a number of pressure
openings 164 and vacuum openings 174 disposed circumferentiallywithin the
upper
housing portion 128. Preferably, there are four pressure openings 164 and four
vacuum openings 174 disposed in an alternating fashion. In addition, a notch
182
is provided to guide the upward and downward movement of the pressure 164 and
vacuum 174 seals.
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Many modifications and variations of the present invention are
possible in light of the above teachings. It is, therefore, to be understood
that within
the scope of the appended claims the invention may be practiced otherwise than
as
specifically described.
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