Modular Filling Head for Liquid Tank Refueling
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Solution Overview
Problem
The existing filling heads for motor vehicle liquid tanks, particularly those with a one-piece design, are limited to specific geometries, requiring costly and complex injection molding tools for different geometries, and struggle with liquid flow and sealing issues during refueling.
Innovation Solution
A modular filling head design featuring an assembled molded immersion tube body with two parts forming a filler neck and liquid jet, including a sealing element and baffle for air venting and flow control, allowing for different nozzle geometries and improved sealing and filling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a one-piece design of the inlet spout with the socket housing is used, then the structure is simple, but it can only be used for a specific filler neck of a predetermined geometry and requires costly and complex injection molding tools for different geometries
Solution Approach 1:
The filling head is divided into separate modular components: a housing and an immersion tube body that can be assembled together. This segmentation allows the immersion tube body to be changed independently to accommodate different filler neck geometries without replacing the entire filling head or requiring new injection molding tools for the housing portion.
Solution Approach 2:
The housing is designed as a universal component that can accommodate multiple types of immersion tube bodies with different geometries. This multi-functionality allows a single housing design to work with various filler neck configurations, reducing the need for specialized tools for each geometry.
2Productivity
If the liquid reservoir fills quickly, then filling speed is high, but liquid flow may escape and form an air cushion that prevents liquid from flowing into the liquid reservoir
Solution Approach 1:
The air outlet opening is positioned in the first shaped body part to allow air to escape from the liquid reservoir before liquid reaches it. This preliminary air venting action prevents air cushion formation that would block liquid flow, enabling high filling speeds without compromising liquid flow control.
Solution Approach 2:
The opening in the first shaped body part acts as an intermediary pathway for air to exit the liquid reservoir. This mediator function allows the liquid reservoir to fill quickly while maintaining reliable liquid flow by preventing air pocket formation that would disrupt the flow.
3Productivity
If the liquid reservoir is designed to accommodate flowing liquid, then filling efficiency improves, but liquid may escape through the opening
Solution Approach 1:
The opening is positioned in the first shaped body part at a location where air can escape vertically or laterally from the liquid reservoir without liquid reaching it. This spatial arrangement in another dimension allows efficient liquid accumulation while preventing spill-back through strategic positioning.
Solution Approach 2:
The opening is located in a specific local region of the first shaped body part where only air needs to pass through. The local geometry and positioning ensure that this opening serves its air venting function without becoming a pathway for liquid escape, maintaining filling efficiency while preventing harmful spill-back.
Data Source
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AI summary
The head (100) has a cylindrical-shaped compound dip tube shaped body arranged inside the head. A first molding body part forms a filler neck (104) for a filling nozzle (105). A second molding body part i.e. plastic injection molded part, forms a liquid jet of the filling nozzle that is attached at the first molding body. The two molding body parts are utilized for receiving an amount of liquid and forming a housing wall and a liquid reservoir. The second molding body part comprises a circulating gush wall to diminish a liquid flow into the reservoir.