Walbro Corporation

Ti Group Automotive Systems Corporation

Mark R Johansen

Lynwood F Crary

John R Forgue

Timothy P Neal

George H Bucci

Daniel A Gilmour

Peter P Kuperus

Matthias Henschel

Martin Stickel

Michael Kloess

Jeffrey M Atwood

David M Ferreira

David A Brady

David M Ferreria

Jason J St Pierre

A cap is formed within the flash of a molded polymeric article. Desirably, the material of the flash, and hence the cap, has the same properties as the molded article. In one embodiment, the molded article is a multi-layer plastic fuel tank having a vapor barrier layer sandwiched between structural and/or adhesive layers and the cap has the same general construction and may be fixed or welded to the fuel tank over an opening through the tank. Advantageously, the cap is formed in the same process used to form the molded article and reduces the scrap or waste material by utilizing a portion of the flash which is removed from the molded article after it is formed. Therefore, the cost and time to produce a molded article and one or more caps is greatly reduced.

Multiple layer polymeric cap and method of making the same

A variable resistor assembly is preferably adapted for use with a fuel level sensor and includes an arcuate resistive area including a plurality of radially oriented and spaced apart conductive contact segments, and further includes a wiper including an arm and at least two contactors carried by the arm, wherein the at least two contactors are arranged on the arm such that the at least two contactors make contact with one of the conductive contact segments before breaking contact with an adjacent one of the conductive contact segments. Preferably, the at least two contactors are laterally offset with respect to one another and/or oriented at an angle with respect to the conductive contact segments.

Fuel level sensor variable resistor assembly

A fuel level measurement device has a fuel level sensor carried by a fuel level float at the distal end of a pivoting float arm of the device which is preferably part of a fuel pump module located inside of a fuel tank preferably for automotive applications. Preferably a sealed arcuate chamber of the float is defined between an electrically conductive cover and a variable electric resistor which preferably is a generally non-conductive ceramic substrate that carries an electrically resistive ink strip. A track exposed in the arcuate chamber has a concave shape that generally faces upward so that a rolling member changes position due to the forces of gravity within the chamber as the float arm pivots generally up and down with changing fuel levels in the tank. The rolling member is electrically conductive and completes the circuit between the electrically conductive cover and the variable resistive ink strip. The sealed chamber provides the pathway for the rolling member and preferably at least in part the buoyancy for the float.

Fuel level measurement device

A fuel system with a fuel tank having at least one opening into an interior of the fuel tank, and an electrically operated vent valve having an inlet communicated with the interior of the fuel tank and an outlet for venting fuel vapor from the fuel tank. The vent valve is movable in response to an electric signal between an open position allowing fuel vapor through the outlet and a closed position to restrict fluid flow through the outlet. A controller is operably communicated with the vent valve to control application of an electric signal to the vent valve and thereby control at least in part the movement of the vent valve between its open and closed positions. In one embodiment the controller is responsive to a fill level in the fuel tank to control the position of the vent valve and thereby the fill level attained within the fuel tank.

Vehicle fuel system

A valve assembly includes a housing having a valve seat defining at least part of a vent passage, a pressure responsive member carried by the housing and defining at least part of a pressure chamber, and a valve carried by the housing and having a closure movable relative to the valve seat between an open position permitting fluid flow through the vent passage and a closed position at least substantially restricting fluid flow through the vent passage. The closure is moved by the pressure responsive member in response to changes in pressure in the pressure chamber. A control passage communicates at one end with a pressure source and at its other end with the pressure chamber and an electrically operated valve is movable from a first position permitting a pressure signal to develop within the pressure chamber and a second position permitting pressure within the pressure chamber to vent.

Valve assembly and refueling sensor

A no-return loop fuel injection system supplies fuel from a fuel pump to an injector fuel rail, through a fuel line. A biased closed pressure control valve communicates with the fuel line and has a valve head preferably of a diaphragm type carrying a fuel side having first and second areas which are segregated and defined by a valve seat when the pressure control valve is closed. An opposite second side of the pressure control valve is exposed to a reference pressure and a closure biasing force. The pressure control valve opens when a hydraulic opening force induced by a fuel pressure exerted upon the first area, plus a fuel pressure exerted upon the second area, is greater than the net reference pressure and closure biasing forces. Preferably, the first area is smaller than the second area, thus manipulating the effects of the fuel pressures exerted upon the first and second areas with respect to opening the valve. When the pressure control valve is open, the system operating pressure exposed to both the first and second areas is sufficient to produce the hydraulic force necessary to keep the valve open. Preferably, the pressure control valve is part of a pressure valve assembly of a fuel pump module located inside a fuel tank. The pressure valve assembly preferably has a flow check valve orientated in a parallel flow configuration to the pressure control valve when the fuel pump is of a variable speed type, or, for systems utilizing constant speed pumps the check valve is replaced with a flow bypass orifice.

No-return loop fuel system

A vapor vent valve for a fuel tank that includes a vapor outlet that connects an interior of the fuel tank with an exterior of the fuel tank. The vent valve also includes a fill cup that has an opening at one end and a sidewall that extends from the open end. A shell defines an interior space and is disposed partially in the fill cup. The shell includes a sidewall that has an opening and an upper edge. A flow passage is defined between the fill cup's sidewall and the shell sidewall to allow fluid which flows into the opening of the fill cup to enter the interior space through the opening in the sidewall of the shell. A float is received in the interior space and is responsive to the level of liquid fuel in the interior space. A closure pivotally carried by the shell is movable to a closed position to prevent fluid flow through the vapor outlet. The closure is also movable to an open position which allows fuel vapor to exit the fuel tank. The closure includes a carrier plate that has an elastomeric layer attached to the carrier plate. The elastomeric layer includes a portion that is attached to the float for actuating the closure to the open and closed positions.

Vapor vent valve

A high flow rate fuel vapor vent and rollover valve assembly with a float valve that provides a progressive closing of a vapor outlet to control the venting of fuel vapors from a fuel tank and the addition of liquid fuel to the tank. The float closes a portion of the vapor outlet in response to liquid fuel at a first level in a vehicle fuel tank. A body completely closes the vapor outlet in response to rollover attitudes of the vehicle. One or more separate baffles are constructed and arranged to prevent the escape of liquid fuel through the vapor outlet.

Vent and rollover valve and fuel pump module

A high flow rate, two stage fuel vapor vent valve assembly utilizing two float valves that provide a progressive closing of a vapor outlet to control the venting of fuel vapors from a fuel tank and the addition of liquid fuel to the tank. A first float closes a portion of the vapor outlet in response to liquid fuel at a first level relative to the valve. A second float closes the remainder of the vapor outlet in response to liquid fuel at a second level higher than the first level. One or more separate baffles are constructed and arranged to prevent the escape of liquid fuel through the vapor outlet.

Vent valve and fuel pump module

A module constructed to be disposed within a fuel tank of the vehicle fuel system carries a vapor vent valve, a fuel pump and other components, such as a fuel lever sender and an overpressure relief valve and outlet. Each of these components may thus be inserted through a single opening into the fuel tank to reduce the number of openings in the fuel tank to thereby reduce the emissions of hazardous hydrocarbon fuel vapors from the fuel tank. Further, the module provides additional protection to the vapor vent valve to prevent sloshing fuel within the fuel tank from entering the vent valve and escaping from the fuel tank and being transferred to the fuel vapor storage canister. The module is constructed such that a portion containing the fuel pump is designed to break away from the rest of the module sealed to the fuel tank, the fuel pump will move away from the vapor vent valve during a vehicle accident instead of crashing into the valve and damaging or destroying it as in prior fuel tank assemblies.

Multi-function fuel pump module

A vehicle on board system for recovering fuel vapors from the fuel tank both during filling of the fuel tank with volatile hydrocarbon liquid fuel and operation of the vehicle engine. A control unit in the fuel tank has a valve assembly actuated by a float to control the flow of fuel vapors from the top of the tank into a receiving canister with activated charcoal for absorbing the fuel vapors which can be purged from the canister by operation of the engine. The valve assembly has a valve seat, a flexible elastomeric closure received on a pivotally mounted carrier plate movable to open and closed positions relative to the seat, and a stripper plate encompassing the seat, overlying the closure and pivotally movable by the float to disengage the closure from the seat to open the valve. Preferably, a pad on the stripper plate bears on only a portion of the flexible closure during initial opening of the valve to thereby decrease the force required to initially open the valve and increase the sensitivity and responseness of the valve assembly. Preferably, to substantially prevent any liquid fuel from passing through the valve assembly while it is open, a depending tube encircles the valve assembly and the float is slidably received in the tube with a relatively close fit to prevent fuel sloshing in the tank which enters the tube from being forced past the float and into the open valve assembly. Preferably, the passage for permitting fuel vapors to flow to the open valve assembly communicates with the tank at a position generally vertically below the valve assembly and preferably an intermediate portion of the passage is disposed generally vertically above the valve assembly and preferably above the fuel tank.

Control valve and system for fuel vapor recovery

An improved filler neck for a fuel inlet of a vehicle fuel tank has a bend communicating with converging and diverging portions which control the flow of fuel through the filler neck to ensure that fuel flows through and downstream of the bend without backing up in the filler neck and actuating an automatic shutoff device of a refueling nozzle received in the filler neck. The filler neck also preferably has a bypass fuel passage through which fuel flows upstream through the filler neck and out to the atmosphere if a predetermined maximum pressure is exceeded within the fuel tank to limit the maximum pressure within the fuel tank and prevent it from being damaged or rupturing. Several angled ribs in the filler neck housing guide the refueling nozzle for proper positioning within the filler neck. Other ribs also provide gaps between the refueling nozzle and the filler neck housing to prevent the refueling nozzle from sealing the filler neck inlet. Slots at the nozzle interface provide a vent area to prevent a vacuum from being generated in the filler neck even when used with a refueling nozzle designed to provide a vapor tight seal at the refueling inlet to prevent liquid fuel from being drawn upstream through the filler neck and thereby prematurely activating the automatic shutoff device of the refueling nozzle.

Fuel tank filler neck with bypass passage

A filler neck of a fuel tank extends from the gas cap to the interior of a fuel tank, and a fill valve insert is positioned adjacent the tank-interior end of the filler neck in a tank/neck coupler construction. The insert carries a flexible valve to close the interior end of the filler neck, and the valve is designed and mounted both to flex open and bodily move downstream to both open and rapidly enlarge the valve opened passageway in response to rapid inflow of fuel to the tank, and to return and revert to a closed position upon cessation of fuel inflow. The fill valve insert is positively positioned and held in the interior of a threaded spout on the fuel tank and is retained and sealed against the filler pipe by a threaded collar screwed onto the threaded spout. In the event the filler neck is pulled loose from its frictional clamp fit in the tank/spout collar by vehicle crash forces, the tank spout will remain closed and sealed by the valve insert remaining retained by the collar in the spout to thereby prevent fuel spillage from the tank.

Fuel tank filler neck check valve

A vehicle on board system for recovering fuel vapors from the fuel tank both during filling of the fuel tank with volatile hydrocarbon liquid fuel and operation of the vehicle engine. A control unit in the fuel tank has a valve assembly actuated by a float to control the flow of fuel vapors from the top of the tank into a receiving canister with activated charcoal for absorbing the fuel vapors which can be purged from the canister by operation of the engine. The valve assembly has a valve seat, a flexible elastomeric closure received on a pivotally mounted carrier plate movable to open and closed positions relative to the seat, and a stripper plate encompassing the seat, overlying the closure and pivotally movable by the float to disengage the closure from the seat to open the valve. Preferably, pads on the stripper plate bear on only a portion of the flexible closure during initial opening of the valve to thereby decrease the force required to initially open the valve and increase the sensitivity and responseness of the valve assembly. Preferably, to substantially prevent any liquid fuel from passing through the valve assembly while it is open, a depending tube encircles the valve assembly and the float is slidably received in the tube with a relatively close fit to prevent fuel sloshing in the tank which enters the tube from being forced past the float and into the open valve assemby.

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Wallingford, CT, United States of America

Mark R Johansen