Fuel Tank Filler Pipe Insert for Nozzle Retention
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Solution Overview
Problem
Refueling systems for diesel trucks face challenges such as fuel surges causing nozzle disengagement and inadequate fuel levels due to improper nozzle fit and orientation, leading to costly spills and inefficient fueling.
Innovation Solution
An insert is coupled to the filler pipe with projections and apertures that securely engage the refueling nozzle, guiding and constraining it to prevent disengagement and ensure efficient fuel delivery, compatible with both low-flow and high-flow diesel nozzles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional filler pipe without support structure is used, then the device complexity is low, but the refueling nozzle may disengage due to fuel surges or operator error causing fuel spills
Solution Approach 1:
The filler pipe is segmented into an outer filler pipe structure and an inner insert component. The insert is a separate piece that can be manufactured independently and then inserted into the filler pipe, allowing for complex retention features without complicating the entire filler pipe assembly.
Solution Approach 2:
The insert acts as an intermediary component between the filler pipe and the refueling nozzle. It provides the retention features (protrusions, grooves, sealing surfaces) that securely hold the nozzle, while the filler pipe itself remains relatively simple in structure.
2Adaptability or versatility
If the filler pipe length is increased to accommodate various nozzle sizes, then the adaptability improves, but the fuel may not fill to the desired level due to inadequate nozzle engagement
Solution Approach 1:
The insert provides localized engagement features at specific positions within the filler pipe. Different sections of the insert have different geometries (protrusions, grooves, sealing surfaces) that accommodate different nozzle types, ensuring proper engagement and fuel level accuracy for each nozzle variant.
Solution Approach 2:
The single insert component serves multiple functions: it retains the nozzle, seals the connection, guides the nozzle into proper orientation, and accommodates different nozzle sizes and types. This multi-functionality is achieved within a compact structure that fits within the existing filler pipe.
3Reliability
If nozzle holding structures are welded on the inner surface of the filler pipe, then the nozzle retention is improved, but the manufacturing time and cost increase
Solution Approach 1:
The retention features are segmented into a separate insert component rather than being welded onto the filler pipe. This allows the insert to be manufactured using cost-effective processes like injection molding or machining, eliminating the need for welding operations and reducing manufacturing complexity.
Solution Approach 2:
The insert appears to be designed as a relatively simple, potentially disposable component that can be manufactured economically. If damaged or lost, the insert can be replaced without replacing the entire filler pipe assembly, reducing maintenance costs.
Data Source
AI summary
Systems are provided for refueling a fuel tank of a motor vehicle via an insert for a filler pipe. In one example, a system may include an insert coupled to an inner circumference of the filler pipe, the insert including a plurality of projections positioned on an inner circumference of the insert. The plurality of projections may include a first projection spanning a first axial length, a second projection spanning a second axial length, and a third projection spanning a third axial length.