Modular Tank Filler Neck for Capless Conversion
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Solution Overview
Problem
Existing filler neck systems for motor vehicles are not adaptable to non-standardized fuel filling nozzles, making it difficult for manufacturers to switch between capless and capped systems, leading to marketing challenges due to differences in construction and design.
Innovation Solution
A modular filler neck system with a housing and insert that includes a flow aid and head part with interlocking elements, allowing for easy conversion between capless and capped systems by using a flow aid with catches and a head part with detent catches and a sealing element, enabling the system to be adapted to market requirements without modification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a capless filler neck system is used, then the system can be simplified and modernized, but it cannot accommodate non-standardized fuel filling nozzles in certain markets
Solution Approach 1:
The filler neck system is divided into separate modular components: a base filler neck and interchangeable adapter elements. The adapter can be detached and replaced depending on the required cap or capless configuration, allowing the same base structure to serve multiple market requirements without designing entirely different systems.
Solution Approach 2:
The filler neck base structure is designed with universal mounting features and standardized connection points that can accommodate both cap and capless configurations. By using a universal base design with optional adapter elements, the system achieves multi-functionality to serve different market standards and preferences.
2Adaptability or versatility
If a capped filler neck system is used, then compatibility with non-standardized fuel filling nozzles is achieved, but the system construction differs significantly from capless systems creating conversion difficulties
Solution Approach 1:
The system separates the filler neck into a common base structure and distinct adapter components. The adapter contains the cap mechanism when needed, while the base remains identical for both cap and capless versions, reducing construction differences and facilitating easier conversion between system types.
Solution Approach 2:
An adapter element serves as an intermediary component that bridges the base filler neck and the cap mechanism. This intermediary allows the cap functionality to be added or removed without modifying the base structure, enabling easy conversion between capped and capless configurations.
3Adaptability or versatility
If different filler neck systems are designed for different markets, then local requirements are met, but manufacturing costs increase and individual adaptation becomes difficult
Solution Approach 1:
The filler neck is manufactured as segmented modular components with standardized interfaces. The base filler neck is produced in high volume as a universal component, while market-specific adapters are produced separately and assembled through simple attachment processes, reducing overall manufacturing complexity and cost.
Solution Approach 2:
A universal base filler neck design serves multiple market segments, reducing the need to manufacture entirely different base structures for different regions. Only the adapter elements vary by market, simplifying the manufacturing portfolio and enabling individual adaptation through simple component selection rather than complete redesign.
Data Source
AI summary
This disclosure relates to a tank filler neck which comprises a housing, in which at least one flow aid and a head part are arranged. The flow aid and the head part, which may be designed with a screw thread, are connected to form an insert, which by insertion in the housing can be connected thereto, a flap comprising a grounding lug being connectable to the head part.