DEF Tank Magnet Integration for Mis-Filling Prevention
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Solution Overview
Problem
Existing diesel exhaust fluid (DEF) tanks lack effective mis-filling prevention mechanisms, risking the incorrect filling of diesel fuel into DEF tanks, which can lead to inefficient emission reduction and potential damage to vehicles.
Innovation Solution
Integration of a magnet into the DEF reservoir body that interacts with a corresponding magnet on a dedicated DEF fill nozzle, ensuring only the correct fluid is filled by creating a magnetic force to open a valve on the nozzle, thus preventing erroneous filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a separate DEF tank is used with a dispensing nozzle, then the operator can refill the DEF tank periodically, but the operator may inadvertently fill the wrong tank with the wrong type of fluid
Solution Approach 1:
A magnetically actuated valve serves as an intermediary mechanism between the fill nozzle and the DEF tank. The valve is controlled by a magnet on the fill nozzle that only activates when the correct DEF tank is inserted, preventing accidental activation of the wrong tank. This intermediary control mechanism ensures that filling only occurs when the proper tank is connected, resolving the contradiction between ease of refilling and prevention of mis-filling.
Solution Approach 2:
The patent replaces traditional mechanical coupling mechanisms with a magnetic field-based control system. Instead of relying solely on physical connection or manual operation, the system uses magnetic interaction between the fill nozzle and tank to automatically control the filling process. This substitution provides more reliable and precise control, preventing mis-filling while maintaining operational simplicity.
2Reliability
If a magnet is integrated into the reservoir body, then mis-filling prevention cannot be removed or bypassed, but the manufacturing process becomes more complex
Solution Approach 1:
The magnet is merged with the reservoir body through integral molding, combining two separate components into a single unified structure. This merging ensures that the magnet remains permanently attached and cannot be removed or bypassed, maximizing the reliability of mis-filling prevention. The integration is achieved through a molding process that accommodates the magnet within the reservoir body structure.
Solution Approach 2:
The magnet is pre-positioned within the reservoir body during the molding process, ensuring proper alignment and functionality before the reservoir is assembled into the final system. This preliminary placement ensures that the magnetic control mechanism is ready to immediately prevent mis-filling when the fill nozzle is inserted, without requiring additional assembly steps or adjustments.
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 magnetic interaction ensures that only DEF can be introduced into the reservoir, enhancing safety and compliance with the designed system by preventing the filling of diesel fuel into the DEF tank, thereby maintaining the effectiveness of the emission reduction process.
Implementation Method 1
The magnetic interaction between the reservoir and nozzle prevents erroneous filling
Data Source
AI summary
A diesel exhaust fluid (DEF) storage system may include a reservoir body having a magnet integrally formed about an inlet opening of the reservoir body. For example, the magnet may be molding about a perimeter of the inlet opening during a molding process in which the reservoir body is formed. In some examples, the inlet opening defines a lumen extending into an interior of the reservoir body with the magnet being positioned at a location along the lumen opposite an external end face. The position of the magnet may be effective to engage a corresponding magnet on a DEF fill nozzle, allowing DEF to be introduced into the reservoir body. By integrating the magnet into the reservoir body, protection features that prevent erroneous filling of the reservoir body cannot be removed or bypassed.