KR20070021216A - Fuel filler neck assembly and method of fabricating - Google Patents

Abstract

The present invention relates to a fuel filler neck assembly wherein the assembly has an evenly bounded connection (22) between the outer funnel portion (24) and the inner funnel portion (26). Typically the outer funnel portion 24 is formed by sidewalls 36 and offset-expansion cylinders of varying thickness. The inner funnel portion 26 includes a side wall 46 having an internal screw 48 configured to engage a screw of the gas cap. The cage connection 22 is used to couple one end 28 of the outer funnel portion 24 to one end 38 of the inner funnel portion 26. The side wall 36 at one end 28 of the outer funnel portion 24 is folded or bent inwardly to form the curl portion 37 and surrounds the rim 50. The mold assembly 60 is for producing a uniform cage connection 22 between one end 28 of the outer funnel portion 24 and one end 38 of the inner funnel portion 26. Characterized by a method of making an even cage connection 22 between fuel filler neck components.

Description

FUEL FILLER NECK ASSEMBLY AND METHOD OF FABRICATING}

The present invention relates to a fuel filler device of a motor vehicle, in particular a fuel filler neck assembly having an even cage connection between an outer funnel portion and an inner funnel portion, a mold assembly for an equal cage connection and a method of producing an equivalent cage connection.

The fuel filling device delivers fuel by an external fuel source (eg, a gas pump) of a motor vehicle to a fuel storage tank found in a motor vehicle such as a car, truck, boat, airplane, and the like and located in the motor vehicle. The fuel filling device is generally connected to the fuel storage tank by the length of one or more tubes and includes a funnel assembly called a fuel filler neck. The fuel filler neck receives fuel supplied from an external fuel source and the length of one or more tubes supplies fuel to the fuel storage tank. The removable cap (eg gas cap) is secured to the fuel filler neck to seal the fuel filling device after the fuel injection process.

In a typical fuel filling device, the fuel filler neck includes an outer funnel portion and an inner funnel portion. The outer funnel portion is connected to the fuel storage tank by piping. The inner funnel portion typically includes a screw that engages the threaded gas cap and is sized to receive a nozzle from an external fuel source. The inner funnel portion is designed to fit into the outer funnel portion and is usually not fixed or welded to the outer funnel portion. In contrast, individual flanges are often welded to the ends of the outer funnel portion to connect the outer funnel portion to the motor vehicle and to receive the inner funnel portion.

In other existing fuel filling devices, attempts have been made to simplify the manufacture of fuel filler neck assemblies using cage connections, ie the large diameter end of the outer funnel portion is mounted on the large diameter end of the inner funnel portion to join the outer and inner funnel portions. Folded However, because the outer funnel sidewall has a variable thickness by offset-extension fabrication, the edge connection between the outer funnel portion and the inner funnel portion is often uneven, thereby causing the inner funnel portion screw to be misaligned. If the internal funnel screw is not properly aligned, the misalignment of the internal funnel screw is problematic because the threaded gas cap cannot normally be combined with the internal funnel screw.

Summary of the Invention

One aspect of the invention is a fuel filler neck assembly comprising a large diameter end forming a first opening, an opposite small diameter end forming a second opening, and an offset-expansion outer funnel portion having sidewalls between the ends. The side walls form a curled portion at the large diameter end and have a variable thickness. The fuel filler neck assembly also includes an inner funnel portion having a large diameter end defining a first opening, an opposite small diameter end defining a second opening, and a sidewall between the ends. The side wall includes an inner raised surface forming a screw and is folded outward at the large diameter end to form a rim portion. The inner funnel portion is located into the outer funnel portion. The fuel filler neck assembly also includes a hemmed connection between the large diameter end of the outer funnel portion and the large diameter end of the inner funnel portion. The large diameter end of the outer funnel portion is folded inward to the large rim and thereby fits the rim into the curl. The fringe connection is even in that the curl has a consistent height and width.

Another aspect of the present invention is a mold assembly for producing an evenly caged connection between an outer funnel end and an outer funnel end having a variable wall thickness. The mold assembly includes a jaw assembly having a top surface and a recess. The recess includes a sidewall face and a shoulder surface disposed around the opening. The jaw assembly holds the outer and inner funnel ends into the openings. The mold assembly also includes a first tool having a bottom surface. The bottom surface includes a first configuration that is sized to engage the top surface of the jaw assembly and a second indentation having a concave surface and a side wall surface. The second indentation is sized to engage the recess of the jaw assembly and the sidewall surface of the second indentation is sized to engage the sidewall surface of the jaw assembly. The mold assembly also includes a second tool having a bottom surface. The bottom surface includes a first component that is sized to engage the top surface of the jaw assembly, a raised surface extending from the first component and a fillet corner between the first component and the raised surface.

Another aspect of the present invention is a method of making an equivalent cage connection between fuel filler neck components. The method of manufacture comprises a substantially longitudinal straight sidewall and a lateral shoulder portion having a variable sidewall thickness, providing an extended end of an outer funnel having an outer diameter, the outer folded sidewall forming a rim. Providing an inner funnel end, folding the longitudinal straight sidewall of the outer funnel inward to the rim at right angles, sandwiching the rim between the sidewalls of the outer funnel, bending the straight sidewall of the outer funnel downward to the rim, folding And maintaining the outer diameter of the outer funnel end during the bending step.

The features and technical advantages of the invention can be seen from the following description of the preferred embodiments, which together with the claims and the accompanying drawings.

1 is an isometric front view of a fuel filler neck according to one embodiment of the invention,

2 is a cross-sectional view of the fuel filler neck according to an embodiment of the present invention,

3 is a cross sectional view of a fuel filler neck during a manufacturing process in accordance with one embodiment of the present invention;

4 is a cross-sectional view of a fuel filler neck during a manufacturing process in accordance with one embodiment of the present invention;

5 is a cross sectional view of a fuel filler neck during a manufacturing process in accordance with one embodiment of the present invention.

desirable Example  details

With reference to the drawings, in particular FIGS. 1 and 2, one aspect of the invention is a fuel filler neck assembly 20 having an evenly bounded connection 22 between the outer funnel portion 24 and the inner funnel portion 26. .

Typically the outer funnel portion 24 has an extended large diameter end 28 forming a first opening 30, an opposing small diameter end 32 forming a second opening 34, a large diameter end and a small diameter. It is formed by an offset-expansion cylinder comprising side walls 36 between the diameter ends. Typically large diameter end 28 has an expanded diameter relative to the remainder of outer funnel portion 24. In addition, as part of the fuel filler neck assembly 20, the side walls 36 are folded inwardly at the large diameter end 28 to form a curled portion 37. Typically the curls 37 have a consistent height H and width around them to form the inner diameter ID and the outer diameter OD of the large diameter end 28. As the sidewalls are offset-extended, the sidewalls 36 vary in thickness. Typically the outer funnel portion 24 is formed from a thermoplastic material, but can also be made of any material consistent with the use and manufacturing processes disclosed herein. As will be appreciated by those skilled in the art, the outer funnel portion 24 is similar to other outer funnel portions known in the art.

In one embodiment, the inner funnel portion 26 has a large diameter end 38 forming a first opening 40, an opposing small diameter end 42 forming a second opening 44, and a large diameter end. It has sidewalls 46 between the small diameter ends. Sidewall 46 may include an inner raised surface 47 that forms a screw 48 having a helical configuration (not shown) and a length (not shown). Typically the screw 48 is configured to engage the screw of the gas cap. At the large diameter end 38, the side wall 46 is folded outwardly or bent to form a rim portion 50. As described below, the inner funnel portion 26 is disposed within the outer funnel portion 24 and coupled to the outer funnel portion 24. Typically the inner funnel portion 26 is made of the same material as the outer funnel portion 24 but may be made of other materials. Also, as will be appreciated by those skilled in the art, the inner funnel portion 26 is similar to other inner funnel portions known in the art.

The cage connection 22 is used to join the large diameter end 28 of the outer funnel portion 24 and the large diameter end 38 of the inner funnel portion 26. The side wall 36 of the outer funnel portion 24 is folded or bent inwardly to form the curl portion 37 and surrounds the rim 50. The curl portion 37 fits the rim portion 50 to form the cage connecting portion 22. The curl portion 37 forms a gap or space 52 between the curl portion and the rim portion 50. The gap 52 is provided to compensate for the difference in material thickness along the curl 37. At the time of manufacture, the fringe connection 22 is equal in that the curl 37 has a consistent width and height H along its entire length or circumference. In one embodiment, 'H' is at least 1 mm to ensure a satisfactory connection between the outer funnel portion 24 and the inner funnel portion 26. As a result, the outer funnel portion 24, the inner funnel portion 26 and the screw 48 are held in axial alignment by the cage connection 22.

3 to 5, another aspect of the present invention provides an even edge connection 22 between the large diameter end 28 of the outer funnel portion 24 and the large diameter end 38 of the inner funnel portion 26. ) Is a mold assembly (60). The mold assembly 60 is a first tool 64 that initiates the formation of a disk shaped jaw assembly 62, a cage connection 22, to hold the outer and inner funnel portions 24, 26 during the manufacturing process. ) And a second tool 66 for terminating the formation of the cage connection.

As shown in FIG. 3, the disk-shaped jaw assembly 62 includes an upper surface 68 and a recess 70. Recess 70 is typically an annular recess comprising sidewall face 72 and a shoulder surface 74 aligned around opening 76. Top surface 68 may be flat or may include one or more raised surfaces (not shown). The jaw assembly 62 is sized to hold the outer and inner funnel portions 24, 26 into the opening 76 while the cage connection 22 is formed. In one embodiment, the jaw assembly 62 is divided into halves 62a, 62b that can be controllably sealed to hold a particular fuel filler neck assembly and follow it around the assembly during the manufacturing process. The jaw assembly 62 is typically formed of a metal material, ie steel or similar metal material, but can also be manufactured using a rigid thermoplastic material or similar material.

Referring to FIG. 4, the first tool 64 includes a bottom surface 80 having a first component 82 that is sized to engage the top surface 68 of the jaw assembly 62. The lower surface 80 also includes a second indentation 84 having a concave surface 86 and a sidewall surface 88. Typically the concave surface 86 and the side wall surface 88 are joined by a circular or fillet corner 89. In one embodiment, fillet corner 89 has a minimum radius of 0.125 " (0.318 cm). Typically the second indentation 84 is sized to engage the recess 70 of the jaw assembly 62, and the sidewall face 88 is sized to engage the sidewall face 72 of the jaw assembly 62. As will be described below, when the first component 82 contacts the top surface 68, the first tool 64 is folded inward with the large diameter end 28 of the outer funnel end 24 substantially perpendicularly folded. It is configured to lose. Typically the first tool 64 is made of the same or similar material as the jaw assembly 62.

Referring to FIG. 5, the second tool 66 includes a first component 92 that is sized to engage the top surface 68 of the jaw assembly 62, a raised surface 94 extending from the first component, and A bottom surface 90 having a fillet corner 96 between the first component and the raised surface. Typically, the radius of the fillet corner 96 and the height of the raised surface 94 are such that the curled portion 37 is folded over the rim 50 and the rim 50 when the first component 92 contacts the upper surface 68. And thereby thereby terminate the formation of the cage connecting portion 22. The fillet corner 96 maintains the inner diameter ID and the outer diameter OD of the curl 37 at the large diameter end 28 of the outer funnel portion 24 during the manufacturing process. The second tool 66 may be made of the same or similar material as the first tool 64.

In one embodiment, the first component 82 and the concave surface 86 of the first tool 64 and the first component 92 and the raised surface 94 of the second tool 66 are substantially flat. Do. Also, in one particular embodiment, the side wall face 72 of the jaw assembly 62 is at least 2.8 mm, the shoulder face 74 is at least 2 mm, and the opening 76 has a diameter of at least 50.4 mm.

Referring again to FIGS. 3 to 5, another aspect of the present invention is a method of making an equivalent cage connection between fuel filler neck components. First, as shown in FIG. 3, the outer funnel portion 24 has an unfolded extended large diameter end 28, a longitudinal-straight sidewall 36 ′, a lateral shoulder portion 100 and a jaw assembly. It is disposed in 62. As described above with respect to sidewall 36, sidewall 36 'also varies in thickness. Lateral shoulder portion 100 is received on shoulder surface 74. Subsequently, the inner funnel portion 26 is positioned into the outer funnel portion 24 such that the rim 50 is received on the lateral shoulder portion 100. The jaw assembly 62 is then tightened to fit snugly around the outer funnel portion 24.

Next, as shown in FIG. 4, the first tool 64 is moved downwards (as indicated by the arrow) until the first component 82 contacts the top surface 68. When the first tool 64 moves downward, the concave surface 86 causes the side wall 36 'to be folded inward substantially perpendicular to the rim 50, thereby fitting the rim between the side walls. At the same time, sidewall face 72, sidewall face 88 and fillet corner 89 maintain the outer diameter OD of large diameter end 28 when sidewall 36 ′ is folded.

Subsequently, as shown in FIG. 5, the second tool 66 is moved downwards (as indicated by the arrow) until the first component 92 contacts the upper surface 68. When the second tool moves downward, the fillet corner 96 causes the side wall 36 'to bend downward over the rim 50, thereby forming a curl 37 surrounding the rim. When the side wall 36 'is folded by the second tool 66, the side wall surface 72, the side wall surface 88, and the fillet corner 96 have an outer diameter OD and an inner diameter ID of the large diameter end 28. Keep).

The fuel filler neck assembly of the present invention provides a simple mechanical connection between the inner and outer funnel portions. In addition, the fuel filler neck assembly of the present invention includes an evenly capillary connection between the inner funnel portion and the outer funnel portion, thereby reducing the possibility of misalignment of the inner funnel screw and reducing the threaded gas cap and the inner funnel screw Ensures a better fit between.

The mold assembly of the present invention and the method of making the equal cage connection provide a simple method of producing an even cage connection between the outer and inner funnel portions. The mold assembly of the present invention and the method of making the equivalent cage connections allow existing parts to be produced at an internal funnel screw misalignment reduction rate.

Although the present invention has been described and illustrated with respect to its representative embodiments, it will be appreciated that various changes, omissions, and additions described above to those skilled in the art may be made without departing from the spirit of the present invention. Should be understood.

Claims (10)

A fuel filler neck assembly, A large diameter end 28 forming the first opening 30, an opposite small diameter end 32 forming the second opening 34 and a curl 37 at the large diameter end 28 and varying Offset-extended outer funnel portion 24 with sidewalls 36 between the ends having a thickness, A large diameter end 38 forming the first opening 40, an opposing small diameter end 42 forming the second opening 44, and an inner raised surface 47 forming the screw 48; An inner funnel portion 26 positioned within the outer funnel portion 24, with sidewalls 46 between the ends folded outwardly from the large diameter end 38 to form a rim 50; The large diameter end of the outer funnel portion 26 and the large diameter end of the inner funnel portion 26 of the outer funnel portion 24 which are folded inward over the rim portion 50 to fit the rim portion 50 into the curl portion 37. A bridging connection 22 between the 38, Fuel filler neck assembly, characterized in that the cage connection (22) is equal by the curl (37) having a consistent height (H) and width (Ｗ). The method of claim 1, And the outer funnel portion (24) and the screw (48) are axially aligned and held by a cage connection (22). In a mold assembly (60) for producing a uniform cage connection (22) between an outer funnel end and an inner funnel end having a variable wall thickness, A recess 70 having a top face 68 and a side face 72 and a shoulder face 74 disposed around the opening 76 and within the opening 76 the outer funnel end and the inner funnel end. Jaw assembly 62 for maintaining A second indentation 84 having a first component 82 sized to engage the top surface 68 of the jaw assembly 62 and having a concave surface 86 and a sidewall surface 88. And a lower indentation 80, wherein the second indentation 84 is sized to engage with the recess 70 of the jaw assembly 62 and the sidewall surface of the second indentation 84. 88 is a first tool 64 sized to engage the sidewall surface of the jaw assembly 62 and A first component 92 that is sized to engage the upper surface 68 of the jaw assembly 62, a raised surface 94 extending from the first component 92, and the first component 92 And a second tool (66) comprising a bottom surface (90) having a fillet corner (96) between the raised surface (94) and the raised surface (94). The method of claim 3, wherein When the first component 82 of the first tool 64 is in contact with the top surface 68 of the jaw assembly 62, the first tool 64 contacts the outer funnel end 36 ′. Mold assembly, characterized in that folded inward at a right angle. The method according to claim 3 or 4, When the first component 92 of the second tool 66 is in contact with the top surface 68 of the jaw assembly 62, the second tool 66 is connected to the outer funnel end 36 ′. Mold assembly, characterized in that folding downward. The method according to any one of claims 3 to 6, The side wall surfaces 72 and 88 when the first components 82 and 92 of the first and second tools 64 and 66 are in contact with the top surface 68 of the jaw assembly 62; The shoulder face (74) maintains the outer diameter of the outer funnel (24). The method according to any one of claims 3 to 6, The jaw assembly (62) is a mold assembly characterized in that it is an annular assembly comprising a flat top surface (68) and an annular recess (70). The method according to any one of claims 3 to 7, The first component 82 and the concave surface 86 of the first tool 64 are flat, or The first assembly (92) of the lower surface (90) and the raised surface (94) of the second tool (66) are characterized in that the mold assembly is flat. The method according to any one of claims 3 to 8, The side wall surface 72 of the jaw assembly 62 is at least 2.8 mm, The shoulder face 74 of the jaw assembly 62 is at least 6.6 mm, The opening assembly (76) has a diameter of at least 50.4 mm. In a method of manufacturing a uniform cage connection 22 between fuel filler neck components, Providing an extended end of the outer funnel portion 24 including a longitudinal straight sidewall 36 'having a variable sidewall thickness and a lateral-shoulder portion 100, the end having an outer diameter, Providing an end 38 of the inner funnel portion 26 comprising an outwardly folded sidewall forming a rim 50, Fold the longitudinally-straight sidewall 36 'of the outer funnel portion 24 inward onto the rim 50 at a right angle, between the sidewall 36' of the outer funnel portion 24. 50) step, Bending the straight sidewalls 36 'of the outer funnel portion 24 downwardly onto the rim 50; and Maintaining said outer diameter of said end portion (28) of said outer funnel portion (24) during said folding and bending step.

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