Abstract: An improved an end cap assembly for a fuel pump is provided. The end cap assembly includes first and second brush caps herein that are overmolded onto first and second shunt wires to ensure a fluid-tight seal around the shunt wires without requiring heat staking, sonic welding, or melt flowing the end cap to the shunt wires. The brush caps are cone-shaped and include a snap-fit feature that retains the brush caps in place when the endcap assembly is transported prior to being assembled to a fuel pump body.

Abstract: An improved an end cap assembly for a fuel pump is provided. The end cap assembly includes first and second brush caps herein that are overmolded onto first and second shunt wires to ensure a fluid-tight seal around the shunt wires without requiring heat staking, sonic welding, or melt flowing the end cap to the shunt wires. The brush caps are cone-shaped and include a snap-fit feature that retains the brush caps in place when the endcap assembly is transported prior to being assembled to a fuel pump body.

Abstract: A fuel system includes a fuel pump having an inlet and an outlet. The fuel system also includes a jet pump assembly having a first fuel passage defined by a first tube, the first fuel passage having a first fuel passage inlet and a first fuel passage outlet; and a second fuel passage defined by a second tube and connected to the outlet of the fuel pump, the second fuel passage having an exit orifice which discharges a first flow into the first fuel passage which draws a second flow into the first fuel passage through the first fuel passage inlet such that the first flow and the second flow combine in the first fuel passage and exit the first fuel passage through the first fuel passage outlet. The second fuel passage also has an initial orifice arranged upstream from, and in series with, the exit orifice.

Abstract: A fuel system includes a fuel pump and a jet pump assembly. The jet pump assembly includes a first fuel passage defined by a first tube. The jet pump assembly also includes a second fuel passage which receives pressurized fuel from the fuel pump, the second fuel passage having a primary orifice centered about and extending along a primary orifice axis such that the primary orifice axis is directed into the first fuel passage and such that the primary orifice introduces a first flow of fuel into the first fuel passage. The second fuel passage also has a secondary orifice centered about and extending along a secondary orifice axis which is not coincident with the primary orifice axis and which is directed at an inner surface of the first tube and the secondary orifice introduces a second flow of fuel into the first fuel passage which impinges the inner surface.

Abstract: A fuel system for an internal combustion engine includes an outlet conduit having an internal volume and also having an exterior surface that is exposed to an environment. The fuel system also includes a pressure pulsation damper which includes a pressure pulsation damper wall made of a resilient and compliant polymer material which defines a pressure pulsation damper chamber. The pressure pulsation damper wall extends along, and is centered about, a pressure pulsation damper axis such that the pressure pulsation damper wall circumferentially surrounds the pressure pulsation damper axis, thereby defining the pressure pulsation damper chamber which is circumferentially surrounded by the pressure pulsation damper wall, the pressure pulsation damper wall having an inner wall surface which is in fluid communication with the internal volume of the outlet conduit and also having an outer wall surface which is exposed to the environment.

Abstract: A fuel pressure regulator includes a housing having a housing bore and a housing inlet; a piston located within the housing bore such that the piston and the housing bore define an accumulation chamber and such that the piston moves between a first piston position where the accumulation chamber is minimized in volume and a second piston position where the accumulation chamber is maximized in volume, the piston having a piston bore with a piston inlet and a piston outlet and a valve seat defined therebetween; a piston spring which biases the piston toward the first piston position; a valve closure which moves between a seated position which prevents fluid communication from the piston inlet to the piston outlet and an unseated position which provides fluid communication from the piston inlet to the piston outlet; and a valve closure spring which biases the valve closure toward the seated position.

Abstract: An electrical connection includes a first electrical conductor assembly having a first electrical conductor with a first electrical conductor surface and a second electrical conductor assembly having a second electrical conductor with a second electrical conductor surface which is engaged with the first electrical conductor surface such that the second electrical conductor assembly and the first electrical conductor assembly reciprocate relative to each other along a path. The first electrical conductor surface and the second electrical conductor surface provide electrical communication between the first electrical conductor assembly and the second electrical conductor assembly along the path. The second electrical conductor surface has a first area of gold having a first magnitude of hardness which engages the first electrical conductor surface and also has a second area of gold having a second magnitude of hardness which is greater than the first magnitude of hardness.

Abstract: A fuel pressure regulator includes a housing having a housing bore and a housing inlet; a piston located within the housing bore such that the piston and the housing bore define an accumulation chamber and such that the piston moves between a first piston position where the accumulation chamber is minimized in volume and a second piston position where the accumulation chamber is maximized in volume, the piston having a piston bore with a piston inlet and a piston outlet and a valve seat defined therebetween; a piston spring which biases the piston toward the first piston position; a valve closure which moves between a seated position which prevents fluid communication from the piston inlet to the piston outlet and an unseated position which provides fluid communication from the piston inlet to the piston outlet; and a valve closure spring which biases the valve closure toward the seated position.

Abstract: An electrical connection includes a first electrical conductor assembly having a first electrical conductor with a first electrical conductor surface and a second electrical conductor assembly having a second electrical conductor with a second electrical conductor surface which is engaged with the first electrical conductor surface such that the second electrical conductor assembly and the first electrical conductor assembly reciprocate relative to each other along a path. The first electrical conductor surface and the second electrical conductor surface provide electrical communication between the first electrical conductor assembly and the second electrical conductor assembly along the path. The second electrical conductor surface has a first area of gold having a first magnitude of hardness which engages the first electrical conductor surface and also has a second area of gold having a second magnitude of hardness which is greater than the first magnitude of hardness.

Abstract: A fuel system includes a fuel pump and a jet pump assembly. The jet pump assembly includes a first fuel passage defined by a first tube. The jet pump assembly also includes a second fuel passage which receives pressurized fuel from the fuel pump, the second fuel passage having a primary orifice centered about and extending along a primary orifice axis such that the primary orifice axis is directed into the first fuel passage and such that the primary orifice introduces a first flow of fuel into the first fuel passage. The second fuel passage also has a secondary orifice centered about and extending along a secondary orifice axis which is not coincident with the primary orifice axis and which is directed at an inner surface of the first tube and the secondary orifice introduces a second flow of fuel into the first fuel passage which impinges the inner surface.

Abstract: A fuel pressure regulator includes a housing defining a fuel inlet and a fuel outlet; a valve seat located between the fuel inlet and the fuel outlet, the valve seat being centered about a valve seat axis; a valve member centered about a valve member axis, the valve member being moveable between 1) a closed position where the valve member engages the valve seat to prevent fuel flow from the fuel inlet to the fuel outlet and 2) an open position where the valve member is disengaged from the valve seat to permit fuel flow from the fuel inlet to the fuel outlet; and a grounding member grounded to the housing which engages the valve member to cause the valve member axis to tip relative to the valve seat axis when the valve member moves from the closed position to the open position.

Abstract: A fuel pressure regulator includes a housing defining a fuel inlet and a fuel outlet; a valve seat located between the fuel inlet and the fuel outlet, the valve seat being centered about a valve seat axis; a valve member centered about a valve member axis, the valve member being moveable between 1) a closed position where the valve member engages the valve seat to prevent fuel flow from the fuel inlet to the fuel outlet and 2) an open position where the valve member is disengaged from the valve seat to permit fuel flow from the fuel inlet to the fuel outlet; and a grounding member grounded to the housing which engages the valve member to cause the valve member axis to tip relative to the valve seat axis when the valve member moves from the closed position to the open position.

Abstract: A fluid level sensor for generating a warning upon, e.g., low fuel conditions in a vehicle gas tank. A vacuum conduit is disposed in the tank. The vacuum conduit has first and second vacuum openings and an actuation opening into which the fuel pump can pump fluid through a Venturi conduit to induce a vacuum. A first conduit extends from the first vacuum opening to a vacuum sensor outside the tank and a second conduit extends from the second vacuum opening. The second conduit extends down into the tank and terminates in an open end. When fluid in the tank drops below the opening the vacuum sensor senses a change in vacuum in the tank, triggering a low level alarm.

Abstract: A fuel level sensor includes a wiper support with metal wiper contacts. A rotatable shaft holds the wiper support and a seal assembly is provided in which the wiper support is disposed. The seal assembly includes a frame and a cover that are sealed together along respective peripheries with the wiper support being sandwiched therebetween. The shaft extends into and through an opening formed in the cover and is rotatable therein with a holder covering an end of the shaft and sealing the opening in cooperation with the cover. The frame is formed with a diaphragm above the wiper shaft that is deflectable to facilitate assembly and allow the sensor to compensate for pressure changes in a fluid tank in which the sensor can be disposed.

Abstract: A fuel module for a vehicle has a module housing in fluid communication with a fuel tank of the vehicle and supporting a fuel pump. A pressure regulator is in the module housing and the regulator receives fuel from the pump. An orifice is disposed in a fluid path between the pump and the intake of the regulator.

Abstract: A fuel module for a vehicle has a module housing in fluid communication with a fuel tank of the vehicle and supporting a fuel pump. A pressure regulator is in the module housing and the regulator receives fuel from the pump. An orifice is disposed in a fluid path between the pump and the intake of the regulator.

Abstract: A fluid level sensor for generating a warning upon, e.g., low fuel conditions in a vehicle gas tank. A vacuum conduit is disposed in the tank. The vacuum conduit has first and second vacuum openings and an actuation opening into which the fuel pump can pump fluid through a Venturi conduit to induce a vacuum. A first conduit extends from the first vacuum opening to a vacuum sensor outside the tank and a second conduit extends from the second vacuum opening. The second conduit extends down into the tank and terminates in an open end. When fluid in the tank drops below the opening the vacuum sensor senses a change in vacuum in the tank, triggering a low level alarm.