Fuel Filler Flap Protective Cap Integration for Refueling Connection
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Solution Overview
Problem
Motor vehicle pressurized container systems face issues with the protective cap of the refueling connection becoming untight due to dust and dirt, leading to potential component damage and interference with the refueling process, as the cap is not always correctly positioned or secured before the fuel filler flap is closed.
Innovation Solution
A closure system design where the fuel filler flap can only be closed with the protective cap correctly positioned on the refueling connection, utilizing a radially sealing protective cap and loss-preventing means to ensure the cap is securely in place, either through a key lock arrangement or by restricting its placement to the refueling compartment, preventing the cap from being disposed outside this area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the protective cap is made removable for easy access, then ease of operation is improved, but reliability deteriorates as the cap may be lost or misplaced
Solution Approach 1:
The fuel filler flap is designed with an integrated protective cap that is pre-positioned and cannot be lost or misplaced. The cap is formed as part of the flap structure itself, eliminating the risk of the cap being removed and lost while maintaining easy access when the flap is opened.
Solution Approach 2:
The protective cap function is merged with the fuel filler flap structure. The cap is formed integrally with the flap, combining two separate components (flap and cap) into one unified structure that performs both functions simultaneously.
2Ease of operation
If the refueling connection is exposed for easy fueling, then ease of operation is improved, but object-affected harmful factors worsen due to dust and dirt contamination
Solution Approach 1:
The protective cap is pre-positioned on the refueling connection in a ready-to-use state. Before refueling begins, the cap is already in place protecting the connection, and the system is designed so the cap must be in position before the fueling process can start.
Solution Approach 2:
The protective cap acts as an intermediary element between the refueling connection and the external environment. It provides a barrier that prevents direct contact between the connection and harmful external factors like dust and dirt during normal vehicle operation.
3Object-affected harmful factors
If a separate protective cap is used, then protection against environmental influences is improved, but device complexity increases due to additional components
Solution Approach 1:
The protective cap function is merged with the fuel filler flap structure. Instead of being a separate removable component, the cap is formed integrally with the flap, reducing the total number of parts while maintaining the protective function.
Solution Approach 2:
The fuel filler flap is designed to serve multiple functions: it acts as both the closure for the fuel tank opening and simultaneously serves as the protective cap for the refueling connection. This multi-functionality eliminates the need for a separate protective cap component.
4Reliability
If the protective cap is made secure to prevent loss, then reliability is improved, but ease of operation deteriorates due to difficulty in removal
Solution Approach 1:
By merging the protective cap with the fuel filler flap, the retention problem is eliminated entirely. The cap cannot be lost because it is part of the flap structure that remains attached to the vehicle body when closed.
Solution Approach 2:
The system is designed so the protective cap is already in its secure position as part of the closed flap structure. When fueling is needed, the entire flap assembly is opened in a single action, providing both removal and access simultaneously without requiring separate cap removal steps.
Data Source
AI summary
A closure system for a pressurized container system for a motor vehicle includes a fuel filler flap and at least one refueling connection. The refueling connection has a non-return valve and a protective cap. The protective cap is designed to be pluggable onto an end of the refueling connection. The fuel filler flap covers a refueling compartment which is set back from the vehicle body. On the side facing the refueling compartment, the fuel filler flap has such a contour that the fuel filler flap can be closed only if the protective cap is fitted on the refueling connection.