Urea Tank Filler Neck Insert With Integrated Magnetic Shielding
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Solution Overview
Problem
Existing solutions for preventing incorrect refueling of urea into fuel tanks in diesel-powered vehicles, such as those using ring-shaped permanent magnets, lack detailed descriptions of magnet shielding from aggressive urea-water solutions and require complex assembly processes with additional sealing needs, leading to increased costs and complexity.
Innovation Solution
A simple, quick-to-assemble insert for the urea tank filler neck comprising two plastic components and a pre-magnetized ring-shaped permanent magnet, which is ultrasonically welded for gas-tight and liquid-tight sealing without additional sealing components, allowing for easy installation and reduced costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional sealing components (ring seals) are used to protect the permanent magnet from urea-water solution, then the reliability of magnet protection is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the sealing function into the structural design of the filler neck itself. The filler neck is designed with an integrated sealing geometry that directly contacts and seals around the permanent magnet, eliminating the need for separate ring seals or additional sealing components. This integration maintains reliable protection while simplifying the overall device structure.
2Ease of operation
If the permanent magnet is magnetized before installation, then the ease of assembly is improved, but the manufacturing process requires pre-magnetization capability
Solution Approach 1:
The patent applies preliminary action by magnetizing the permanent magnet before it is installed in the filler neck. The magnet is delivered in a pre-magnetized state, which simplifies the assembly process as no magnetizing device is needed during installation. The design accepts this pre-magnetization requirement as a manageable manufacturing step that enables significant assembly simplification.
3Reliability
If the permanent magnet is shielded from aggressive urea-water solution, then the reliability of the magnet is improved, but the device complexity increases due to additional shielding components
Solution Approach 1:
The patent merges the shielding function into the structural design of the filler neck. The filler neck is designed with an integrated sealing geometry that directly contacts and seals around the permanent magnet, eliminating the need for separate ring seals or additional sealing components. This integration maintains reliable protection while simplifying the overall device structure.
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 solution enables rapid and cost-effective assembly of the insert, ensuring correct refueling by eliminating the need for magnetizing devices and additional seals, while maintaining the integrity of the urea tank filler neck, thus preventing incorrect fueling.
Implementation Method 1
a ring-shaped permanent magnet is used. The permanent magnet is located in a space that is closed off by a cover and a seal
Implementation Method 2
the two plastic components 11 and 12 are welded gas-tight and liquid-tight at their bearing ring surfaces by means of ultrasound
Data Source
Figure 1~2
AI summary
The invention relates to an insert (10) for a filler neck of a urea container in diesel-operated motor vehicles, preferably lorries, wherein two plastic components (11, 12) which preferably engage into one another and receive, between them, a preferably annular component (13) which is composed of magnetic material and is magnetized permanently before the installation, are welded to one another in a gas-tight and liquid-tight manner.