Elastomeric seals for automotive fuel systems incorporating graphene

Abstract

A coverless fuel device has an elongate tubular and cylindrical housing open at each end, the housing defining first and second longitudinally spaced apart fluid ports. A first flapper valve is associated with the first fluid port and a second flapper valve is associated with the second fluid port, the flapper valves being movable between open and closed positions and being resiliently urged toward their respective closed positions. The pressure relief valve is at least partially contained within the flapper valve. An elastomeric seal arrangement incorporating a graphene derivative is positioned within the housing proximate the flapper valve for preventing hydrocarbon emissions from the fuel vapor from escaping from the device into the atmosphere.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to USSN 63 / 340,062, filed May 10, 2022. Technical Field

[0003] The present invention generally relates to fuel systems exposed to the effects of hydrocarbon permeation. More specifically, the present invention teaches a graphene-infused elastomeric seal that is incorporated into any vehicle fuel delivery, storage, or recovery system. Background Art

[0004] Related Art Automotive fuel seals are known that can be used to help reduce hydrocarbon permeation of various grades of gasoline within a vehicle fuel system. Stringent government regulations related to increased awareness of climate issues have resulted in calls for increased control of automotive fuel emissions. In the late 1990s, automotive suppliers in the United States were forced to begin implementing ORVR (Onboard Refueling Vapor Recovery) systems to meet EPA requirements to reduce automotive hydrocarbon emissions. The use of low permeation elastomeric seals and materials is a key component of ORVR systems to reduce emissions.

[0005] FKM is one of the most commonly used elastic materials in vehicle fuel systems to help reduce fuel penetration. This material is found in fuel pump threaded ring seals, quick connector O-rings, fill limit vent valves (Fill Limit VentValve) / combination valve seals, inlet check valve seals, and fuel caps or capless seals. All of these components affect and increase the total amount of hydrocarbon emissions from vehicles, which is limited by government regulations. By adding graphene to FKM or other elastomers (such as FVMQ or NBR), the amount of hydrocarbons that penetrate through the material is reduced. FVMQ and NBR are not typically used to reduce penetration, but are often used as secondary seals to help achieve other properties such as low-temperature sealing. When graphene is applied to secondary seals together with primary seals, this only helps to improve the overall permeability of the subassembly.

[0006] More specifically, for seals used in capless refueling systems, there are typically one or two door seals and one or two body or tube seals. In addition, there may be some type of pressure relief seal that is designed to allow fuel vapor pressure to escape from the fuel tank under adverse conditions. Such seals are typically made of FKM to reduce the amount of vapor emissions located within the fuel filler pipe after refueling and even under normal vehicle operating conditions. As will be described with reference to the present invention, the addition of graphene to these seals will reduce the amount of fuel vapor emissions that are exhausted from the upper portion of the fuel filler pipe.

[0007] Graphene is a kind of sp 2 A two-dimensional, planar nanomaterial composed of bonded carbon atoms. Many of the material properties that make graphene so lucrative, such as high tensile strength, high thermal and electrical conductivity, chemical resistance and permeability, stem from the unique bonding structure of planar graphene. However, macro-scale application of graphene in the automotive industry remains a challenge. Summary of the invention

[0008] The present invention describes the use of a graphene derivative elastomer composite system for providing a high quality automotive fuel system seal with improved mechanical and barrier properties. In particular, this includes the use of one or more graphene derivative-incorporating elastomer seals, such as can be integrated into a capless device associated with a fuel filler pipe.

[0009] In non-limiting applications, the capless fuel filling system includes an elongated tubular and cylindrical housing that is open at each end. Typically, the cylindrical housing is constructed of a plastic material to achieve a cheap and durable construction.

[0010] First and second axially spaced fluid ports are formed in the housing, with the first fluid port being located proximate the inlet of the housing and the second fluid port being located proximate the outlet of the housing. The fluid ports are substantially axially aligned with one another and are sized to receive a standard fuel filler nozzle (not shown) therethrough. The design of the fluid ports in the capless arrangement further prevents the insertion of unauthorized hoses (such as for siphoning theft of gas stored in the tank).

[0011] A flapper valve is associated with each fluid port and is movable between an open and closed position. A spring urges each valve toward the closed position. When moving from the closed position to the open position, such as in response to the insertion of a fuel filler tube or nozzle, both flapper valves move away from the housing inlet and toward the housing outlet. In this manner, a fuel filler nozzle inserted into the housing inlet end passes through both the first fluid port and the second fluid port and, in the process, causes the first and second flapper valves to pivot from the open position to the closed position.

[0012] As further depicted, the capless device includes a graphene-derivative-incorporating seal arrangement including a pair of each outer annular body seal, and an inner annular door seal and a pressure relief seal associated with each of the first and second fluid ports.

[0013] Other contemplated applications of the present invention include incorporating the graphene derivative material into an elastomeric seal associated with a quick connector arrangement of a fuel system, the connector arrangement comprising a male connector defining a first body and a female connector defining a second body, the male connector engaging with the female connector to define a fluid communication passage. A seal arrangement incorporated into at least one of the quick connector bodies inhibits hydrocarbon emissions from fuel vapors from escaping the arrangement into the atmosphere. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Reference will now be made to the accompanying drawings, wherein like reference numerals refer to like parts throughout the several views, when read in conjunction with the following detailed description, and wherein:

[0015] Figure 1 is a perspective view of a vehicle uncovered device incorporating an elastomeric seal arrangement incorporating a graphene derivative material in accordance with a non-limiting embodiment of the present invention;

[0016] Figure 2 yes Figure 1 a plan cross-sectional view of the vehicle shown without the cover and depicting the internal arrangement of the body seal, pressure relief seal and door seal;

[0017] Figure 3 is with Figure 2 a further cross-sectional view similarly and additionally depicting an elastomeric seal arrangement for preventing hydrocarbon vapor emissions from escaping to the atmosphere;

[0018] Figure 4 is a front view of a fluid quick connector device incorporating a graphene derivative into an elastomeric seal according to a further embodiment of the present invention;

[0019] Figure 5 is a cross-sectional view of a fluid connector device illustrating a tube having an annular extending protrusion in an intermediate engagement position with a retainer latch; and

[0020] Figure 6 yes Figure 4-5 A further subsequent planar cross-sectional view of a fluid connector device of the present invention is shown and illustrates the tube being installed by a latch and the side of the separate verifier being held open by alignment with an annular bead indicating that the tube is in the installed position. DETAILED DESCRIPTION

[0021] Referring to the accompanying drawings, the present invention discloses a capless fuel device or assembly, such as one that incorporates an elastomeric seal arrangement that incorporates a graphene derivative. Specifically, Figure 1A perspective view of a vehicle uncovered device, generally 10 , incorporating an elastomeric seal arrangement incorporating a graphene derivative is provided in accordance with one non-limiting embodiment of the present invention.

[0022] Figure 2 Further provided Figure 1 A plan cross-sectional view of a vehicle without a cover is shown, and depicts the internal arrangement of the body seal, the pressure relief seal and the door seal, wherein the successive Figure 3 Describes something like Figure 2 and additionally depicts an elastomeric seal arrangement for preventing hydrocarbon vapor emissions from escaping to the atmosphere.

[0023] Referring again to the schematic diagram, when viewed together, an elongated tubular and cylindrical housing 12 is shown, such as having a plastic or polymer structure, not limited to nylon, which is open at each end. In the illustrated embodiment, the housing 12 is incorporated into the fuel filler pipe 14 (see Figure 3 ) to expose it to the presence of hydrocarbon fuel vapors emanating from a connected fuel tank (not shown).

[0024] As further shown, the housing defines first and second longitudinally spaced fluid ports corresponding to the location of each of the first flapper valve 16 and the second flapper valve 18, which are movable between open and closed positions. In a non-limiting configuration, each of the first and second flapper valves further includes first and second valve parts secured together by snap fittings. A pair of springs 20 and 22 are also depicted, which resiliently urge the flapper valves 16 / 18 toward their respective closed positions.

[0025] exist Figure 2-3 Also depicted in each of FIG. 1 are first and second pressure relief valves 24 and 26 corresponding to the first and second flapper valves 16 and 18. As shown, the pressure relief valves are shown contained within the flapper valves.

[0026] The present invention further describes an elastomeric seal arrangement incorporating a graphene derivative material positioned within a housing adjacent to a flapper valve for preventing hydrocarbon emissions from fuel vapor from escaping the device into the atmosphere. As depicted, these include each of a first pressure relief seal 28 and a second pressure relief seal 30 located at the pressure relief valve 24 / 26.

[0027] Also included are first and second elastomeric door seals 32 and 34 disposed correspondingly with the first and second flapper valves 16 and 18. Additional body seals 36 and 38 are disposed at first and second axially spaced locations of the cylindrical housing. The graphene-derivative-incorporated elastomeric seal arrangement operates to block hydrocarbon vapor emissions from being discharged into the atmosphere.

[0028] refer to Figure 4 , a front view is shown at 100 of a fluid coupling according to a further embodiment of the present invention, and some or all of the elastomeric seal components incorporate graphene derivative materials. The coupling has a housing 102 with a female part and an inter-connected insert tube 104. The tube 104 also includes a radially outwardly extending flange 106 (see FIG. 1 ) adjacent its end. Figure 5-6 ), the flange 106 extends around the circumference of the cylindrical tube 104.

[0029] The housing female part 102 incorporates a through hole 108 which communicates the female part with a connected male part 110, the through hole receiving a tube 104 having an annular extending flange 106. Without limitation, the female and male parts 102, 110 of the quick connect housing may be constructed of any suitable material, typically including plastic, and it is also contemplated that another hose or conduit (not shown) is secured to the narrowed diameter male part 110 such that the through hole communicates the mounted tube 104 with the outlet of the male part 110.

[0030] A heat staking operation is used to secure a tubular outer spacer 118 within the housing female part proximate the receiving end of the tube 104 and the annular flange 106. The spacer 118 is provided in combination with the arrangement of seals 120 and 122 and an annular support 124 between the outer spacer 118 and the inward annular shoulder locator 126 to provide pressurized sealing support between the housing female part 102 and the male part 110. As previously described, the material structure of the seals 120 / 122 can incorporate graphene derivative materials for blocking hydrocarbon emissions from fuel vapors to the atmosphere.

[0031] Without limitation, the heat staking operation can be provided according to any number of angular offsets, such as but not limited to placing the heat staking locators at 60 degree offsets (six total), as well as providing any other shape or profile. In any application, the heat staking operation ensures that the outer spacer remains within the body head and avoids axial separation, such as after the tube and flange are disassembled and separated in the manner described later.

[0032] The housing female part 102 further incorporates an insertion end 128 (which is shown in cross-section in the remaining views) having a profile corresponding to each of the latch 130 and the checker 132. The latch and checker are arranged in a stacked arrangement and mounted within the female part 102, which communicates with the insertion direction of the tube 104 through the internal through hole 108, which are further arranged in a stacked arrangement and supported within the end 128 by a mounting slot located at the top (see the internal extended edge profile 134). The insertion end 128 further exhibits opposing side cutout profiles, one of which is formed by Figure 1 The peripheral edge 136 in FIG. 1 is shown as an extended pair of extended sides or legs for accommodating each of the latch 130 and the verifier 132 and causing the latch and verifier to each present a generally "U" shape surrounding the cross-sectional profile of the insertion tube 14 on three sides.

[0033] Not limited to previously Figure 1-3 In the case of any different embodiments described in each of 4-6, the graphene derivative group can again include but is not limited to any one of graphene, monolayer graphene, few-layer graphene, graphene oxide, reduced graphene oxide and functionalized graphene. The loading concentration of the graphene derivative can vary between 0.1-60 weight percent. The sealing material can include but is not limited to any one of fluorinated carbon-based synthetic rubber (FKM), fluorosilane or silicone rubber (FVMQ), thermoplastic vulcanizate (TPV), ethylene propylene diene rubber (EPDM), hydrogenated nitrile rubber (HNBR) or nitrile rubber (NBR).

[0034] Having described the present invention, other and additional preferred embodiments will become apparent to those skilled in the art without departing from the scope of the appended claims. The detailed description and drawings are further understood to support the present disclosure, the scope of which is defined by the claims. Although some best modes and other embodiments for carrying out the claimed teachings have been described in detail, there are various alternative designs and embodiments to implement the disclosure defined in the appended claims.

[0035] The above disclosure is further understood to be not intended to limit the disclosure to the precise form disclosed or to the specific field of use. Therefore, it is contemplated that various alternative embodiments and / or modifications to the disclosure, whether explicitly described or implied herein, are possible in light of the disclosure. Having thus described the embodiments of the disclosure, one of ordinary skill in the art will recognize that changes may be made in form and detail without departing from the scope of the disclosure. Therefore, the disclosure is limited only by the claims.

[0036] In the above description, the present disclosure has been described with reference to specific embodiments. However, those skilled in the art will appreciate that the various embodiments disclosed herein may be modified or otherwise implemented in various other ways without departing from the spirit and scope of the present disclosure. Therefore, the description should be considered illustrative and is intended to teach those skilled in the art how to make and use the various embodiments of the present disclosure. It should be understood that the form of the disclosure shown and described herein will be considered as a representative embodiment. Equivalent elements, materials, processes or steps may replace those represented and described herein. In addition, certain features of the present disclosure may be used independently of the use of other features, all of which will be apparent to those skilled in the art after benefiting from the description of the present disclosure. Expressions used to describe and claim the present disclosure, such as "including", "comprising", "incorporating", "consisting of", "having", "is" are intended to be interpreted in a non-exclusive manner, i.e., allowing for the presence of items, parts or elements that are not explicitly described. Mentioning the singular should also be interpreted as being related to the plural.

[0037] Further, various embodiments disclosed herein should be considered to have illustrative and explanatory meanings, and should never be interpreted as limitations to the present disclosure. All connection references (e.g., attach, adhere, connect, connect, etc.) are only used to help readers understand the present disclosure, and may not cause limitations, particularly the position, direction or use of the system and / or method disclosed herein. Therefore, the connection reference (if present) should be interpreted in a broad sense. In addition, this connection reference does not necessarily infer that two elements are directly connected to each other.

[0038] In addition, all numerical terms, such as, but not limited to, "first", "second", "third", "primary", "secondary", "main" or any other general and / or numerical terms, should also be regarded as identifiers only to help the reader understand the various elements, embodiments, variations and / or modifications of the present disclosure, and may not create any limitations, especially regarding the order or preference of any element, embodiment, variation or modification relative to another element, embodiment, variation and / or modification.

[0039] It will also be understood that one or more of the elements depicted in the drawings / figures may also be implemented in a more separate or integrated manner, or even removed or rendered inoperable in some cases, which is useful depending on the particular application. In addition, unless otherwise specifically stated, any signal shading in the drawings / figures should be considered merely as exemplary and not limiting.

Claims

1. A capless fuel device comprising: an elongated tubular and cylindrical housing open at each end, the housing defining first and second longitudinally spaced fluid ports, a first flapper valve associated with the first fluid port and a second flapper valve associated with the second fluid port, the flapper valves being movable between open and closed positions and being resiliently urged toward their respective closed positions, a pressure relief valve contained within each of said flapper valves; and An elastomeric seal arrangement incorporating a graphene derivative is positioned within the housing proximate the flapper valve for preventing hydrocarbon emissions from fuel vapors from escaping the device into the atmosphere.

2. The device of claim 1, the elastomeric seal further comprising a first pressure relief seal and a second pressure relief seal.

3. The apparatus of claim 1, and further comprising first and second springs urging the first and second flapper valves toward a closed position.

4. The apparatus of claim 1, said elastomeric seal further comprising a door seal surrounding said flapper valve.

5. The apparatus of claim 1, said elastomeric seal further comprising a body seal disposed at first and second axially spaced locations on said cylindrical housing. 6 . The apparatus of claim 1 , each of the first and second flapper valves further comprising a first valve part and a second valve part secured together by a snap fitting.

7. The device according to claim 1, wherein the graphene derivative further comprises at least one selected from the group consisting of single-layer graphene, few-layer graphene, graphene oxide, reduced graphene oxide, and functionalized graphene.

8. The device of claim 1, wherein the elastomeric seal further comprises any one of fluorinated carbon-based synthetic rubber, fluorosilicone rubber, thermoplastic vulcanizate, EPDM rubber, hydrogenated nitrile rubber, or nitrile rubber.

9. A quick connector device for a fuel system, comprising: a male connector defining a first body and a female connector defining a second body, the male connector engaging with the female connector to define a fluid communication passage; An elastomeric seal arrangement incorporated into at least one of the bodies, at least one of the elastomeric seals incorporating graphene, is provided for preventing hydrocarbon emissions from fuel vapors from escaping the device into the atmosphere.

10. The quick connector according to claim 9, wherein the graphene further comprises a graphene derivative comprising at least one selected from the group consisting of single-layer graphene, few-layer graphene, graphene oxide, reduced graphene oxide and functionalized graphene.

11. The quick connector according to claim 9, wherein the elastomeric seal further comprises any one of fluorinated carbon-based synthetic rubber, fluorosilicone rubber, thermoplastic vulcanizate rubber, EPDM rubber, hydrogenated nitrile rubber or nitrile rubber.

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