Capless Refill Adapter for Diesel Exhaust Fluid Systems
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Solution Overview
Problem
Existing fluid refilling systems, such as diesel exhaust fluid systems, face issues with increased length due to threaded surfaces and caps, leading to longer refill times and improper sealing, especially in confined spaces, and magnetic ring placement upstream of flaps that further elongate the system.
Innovation Solution
A refill adapter with a pivotable door sealed by a biasing member, positioned downstream of the magnetic ring, reduces length by eliminating the need for additional caps and optimizing ventilation passages to decrease diameter, allowing easier installation in tight spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a removable cap with threaded surface is used to seal the filler neck, then the filler neck can be sealed, but the overall length of the filler neck increases
Solution Approach 1:
The invention removes the threaded cap component entirely from the system. Instead of using a separate removable cap to seal the filler neck, the design integrates sealing functionality directly into the filler neck structure through a pivotable flap valve that automatically opens and closes, eliminating the need for a threaded sealing cap and thereby reducing overall length.
Solution Approach 2:
The sealing function is merged with the valve function. The pivotable flap serves both as the sealing element and as the flow control valve, combining what were previously separate functions (cap sealing and valve operation) into a single integrated component, thus reducing the number of parts and overall length.
2Reliability
If a removable cap is coupled and decoupled during refilling, then the filler neck can be sealed, but the refilling time increases
Solution Approach 1:
The pivotable flap valve operates automatically based on fluid pressure differential. When the nozzle is inserted and fluid flows in, the flap automatically opens; when refilling completes, the flap automatically closes. This self-actuating mechanism eliminates the need for manual cap removal and installation, significantly reducing refilling time.
Solution Approach 2:
The filler neck is pre-configured with the pivotable flap in a closed position, ready to automatically open upon nozzle insertion. This preliminary setup eliminates the time-consuming manual operation of removing caps during each refilling event.
3Reliability
If a removable cap is used, then the filler neck can be sealed, but the likelihood of improper sealing and accidental loss of cap increases
Solution Approach 1:
The removable cap is completely removed from the system. The pivotable flap is permanently integrated into the filler neck structure, eliminating the risk of accidental cap loss and improper sealing associated with removable caps. The flap's fixed integration ensures consistent, reliable sealing.
Solution Approach 2:
Instead of using a removable cap that requires proper threading and engagement, the design inverts the approach by using a fixed pivotable flap that passively seals through its hinge mechanism. This inversion from removable to fixed design eliminates user error in sealing.
4Extent of automation
If the magnetic ring is positioned upstream of the pivotable flap, then the valve can be actuated, but the overall length of the filler neck increases
Solution Approach 1:
The magnetic ring is repositioned from an upstream location (which would require additional axial length) to a downstream location behind the pivotable flap. This dimensional repositioning allows the magnetic actuation field to reach the nozzle valve through the body of the adapter, reducing the overall axial length of the filler neck while maintaining automated valve actuation capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The adapter efficiently seals the nozzle aperture without additional caps, reduces overall length, and enhances usability in limited spaces by positioning the magnetic ring downstream of the pivotable door and utilizing axial ventilation passages, facilitating smoother fluid flow and vapor ventilation.
Implementation Method 1
a magnetic ring positioned within the body, downstream of the pivotable door between the first end and second end
Implementation Method 2
a pivotable door sealing the aperture and forming an external surface of the adapter
Implementation Method 3
a vent line connection of the filler neck is positioned downstream of the pivotable flap
Data Source
AI summary
Methods and systems are provided for an adapter for a fluid refilling system. In one example, an adapter configured for use with a diesel exhaust fluid (DEF) system may include a first end configured to couple with a DEF refill passage, a second end including an aperture shaped to receive a DEF nozzle, a pivotable door closing the aperture and biased against the aperture by a biasing member, and a magnetic ring positioned within the adapter and downstream of the pivotable door. The pivotable door may be formed of a material permeable to DEF vapors and may include a plurality of vent holes configured to flow vapors from the DEF system to atmosphere.