Abstract: A vapor handling system is provided to control fuel vapor in a vehicle fuel system to prevent the fuel vapor from escaping to the atmosphere during filling of the vehicle fuel tank. An on-board vacuum-actuated system is included for preventing overfilling of the tank by automatically triggering shut-off of fuel flow from a fuel-dispensing nozzle when the fuel tank is full. A control valve system is also included for protecting the canister from exposure to liquid fuel during an overfill condition which may be caused by a malfunction of a fuel-dispensing nozzle.

Abstract: A flow-metering valve assembly is provided for vehicle fuel tanks. The assembly includes a valve housing having an interior wall configured to define a chamber having an inlet and an exhaust outlet. The interior wall provides a first flow-metering surface situated in close proximity to the outlet. A spring-biased pressure-relief element is situated in the chamber and includes a valve member having an inner surface confronting the inlet and an upstanding skirt attached to the valve member. The skirt has a distal portion extending in an outward direction toward the outlet means to provide a second flow-metering surface. The first and second surfaces cooperate to define a variable flow-metering orifice therebetween.

Abstract: A system is provided for activating a sensor during an initial stage of a vehicle refueling activity. The system includes a fuel tank filler neck having a mouth and a fuel cap having a closure rotatably engaging the filler neck for closing the mouth. A sensor is positioned in close proximity to the filler neck. The fuel cap further includes a seal between the closure and the filler neck, an outer shell providing a hand grip, a hub, and an actuator member movable between an inactive position and a sensor-activating position. The hub interconnects the closure and the outer shell for applying a torque to the closure after a predetermined amount of movement of the shell relative to the filler neck so that a lost motion connection is established between the closure and the shell. The lost motion of the hub acts to move the actuator member to its sensor-activating position before rotating the closure relative to the filler neck in an amount sufficient to break the seal.

Abstract: An apparatus is provided for controlling discharge of fuel vapor from the fuel tank having a filler neck during refueling. The apparatus includes a passage for conducting fuel vapor between the fuel tank and a distal portion of the filler neck and a valve for selectively blocking flow of fuel vapor through the conducting means. The valve is operable between a flow-blocking position and a flow-delivery position. A spring yieldably biases the blocking means away from its flow-blocking position to a flow-delivery position. An assembly defining a venting control chamber in communication with the valve is provided for using liquid fuel in the fuel tank to develop a pressure head in the venting control chamber having a magnitude in excess of a predetermined threshold level to exert a closing force on the valve in opposition to the spring so that the valve is moved to its flow-blocking position, thereby preventing discharge of pressurized fuel vapor in the tank to the filler neck through the passage.

Abstract: A filler neck is provided for receiving a filler cap including a closure member having an axially outer portion, a threaded axially middle portion, and an axially inner portion. The filler neck includes a generally cylindrical tube having an axially outer portion, a threaded axially middle portion for receiving the threaded axially middle portion of the closure member, and a reduced-diameter axially inner portion. The reduced-diameter axially inner portion is positioned for receiving the axially inner portion of the closure member in a closely spaced relation to prevent radial movement of the axially inner portion of the closure member.

Abstract: A fuel cap for use in a vehicle fuel system filler neck is provided. The fuel cap includes a closure for closing the filler neck and a pressure relief valve that is movable between a filler neck-venting position and a non-venting position. A roll-over control assembly is provided for selectively utilizing liquid fuel and fuel vapor in the filler neck to exert a closing force on the pressure relief valve so that the pressure relief valve is moved to its non-venting position to block discharge of liquid fuel to the atmosphere through the pressure relief valve during vehicle rollover. The roll-over control assembly cooperates with the pressure relief valve to define a venting control chamber for containing fuel and a fuel vapor in a predetermined region to permit the fuel and fuel vapor to exert the closing force on the pressure relief valve. A passageway is provided for establishing communication of fuel and fuel vapor in the filler neck with the venting control chamber.

Abstract: A fuel cap is provided with a vent system for lowering the actuation pressure of its internal pressure-relief valve in response to rotation of the fuel cap relative to the filler neck in a cap-removal direction. The vent system provides an operative connection between the cap handle and a pressure-relief valve in the cap. The vent system includes a spring for applying a closure-inducing force urging the pressure-relief valve against its valve seat to close a vent aperture in the cap, and a control system for regulating the magnitude of the closure-inducing force in response to rotation of the handle in a cap-removal direction. Use of the control system to lower the magnitude of the closure-inducing force permits the pressure-relief valve to move away from the valve seat to a venting position upon exposure to excessive fuel vapor pressure in the filler neck so that a fuel vapor-venting outlet through the cap is established during a removal of the fuel cap from the filler neck.

Abstract: A vapor recovery system is provided for recovering fuel vapors discharged from a fuel tank having a vent tube and a separate filler neck during refueling. The vapor recovery system includes a partition dividing the filler neck into an outer chamber communicable with the atmosphere and an inner chamber in fluid communication with the fuel tank. The partition includes an aperture for sealingly admitting a fuel dispensing nozzle into the inner chamber without coupling the inner and outer chambers in fluid communication during refueling. A fuel cap may sealingly engage the filler neck to close the mouth of the filler neck. A refueling sensing system is provided for actuating a flow valve during an initial stage of each refueling activity to permit flow of fuel vapor to the canister. Upon removal of the fuel cap, fuel vapor discharged from the fuel tank is conducted automatically to the canister for processing therein instead of being discharged directly into the atmosphere.

Abstract: A fuel cap is provided for closing the threaded filler neck of a fuel tank. The cap includes a housing having threads for engaging the filler neck, a seal for sealingly engaging said filler neck upon rotation of the housing in a first direction, and a handle for rotating the housing relative to the filler neck. The cap further includes a hub for providing a lost-motion driving connection between the handle and the housing. The lost motion of the hub acts to permit a predetermined amount of relative movement of the handle and the filler neck before the housing can be rotated relative to the filler neck sufficiently to break the seal.

Abstract: A fuel vapor recovery system of a motor vehicle is disclosed including a valve. The valve is situated between a fuel tank and a conduit leading from the fuel tank to a canister. The valve includes a chamber having a first opening to the fuel tank and a second opening to the conduit. The valve also includes a ball for closing the first opening, the ball having a mass selected to effect a first closing pressure on the first opening when the vehicle is stationary. The size of the ball is selected relative to the chamber to permit movement within the chamber to effect a second closing pressure less than the first closing pressure when the vehicle is subjected to vibration. The first closing pressure is selected to produce a predetermined head pressure in the fuel tank during introduction of fuel into the fuel tank which effectively blocks the introduction of fuel in excess of a predetermined maximum fuel capacity, thereby preventing overfilling of the fuel tank.

Abstract: A flow-metering valve assembly is provided for vehicle fuel tanks. The assembly includes a valve housing having an interior wall configured to define a chamber having an inlet and an exhaust outlet. The interior wall provides a first flow-metering surface situated in close proximity to the outlet. A spring-biased pressure-relief element is situated in the chamber and includes a valve member having an inner surface confronting the inlet and an upstanding skirt attached to the valve member. The skirt has a distal portion extending in an outward direction toward the outlet means to provide a second flow-metering surface. The first and second surfaces cooperate to define a variable flow-metering orifice therebetween.

Abstract: A cap for closing the filler neck of a vehicle fuel tank is provided. The cap includes a valve body having an upper opening and movable between a normal lower position and an upper position. The valve body includes a ball disposed therein to seal the upper opening when the cap and filler neck are rolled over to a substantially inverted position and vent openings in the side wall that are located somewhat above the level of the ball when the cap and filler neck are substantially upright. When the valve body is in the normal lower position, fuel vapor is allowed to vent to the atmosphere through the vent openings and upper opening in the valve body. If the ball is upwardly and seals the upper opening prematurely, the fuel vapor will form the valve body to the upper position to allow the fuel vapor to continue to vent to the atmosphere around the valve body.

Abstract: A roll-over valve is provided for use in a vehicle fuel system having an outlet for discharging fuel vapor. The roll-over valve includes a hollow valve member that terminates in a distal tip. A roll-over ball is provided for moving the distal tip from an outlet-opening position to an outlet-closing position in response to tilting of the hollow valve member during vehicle rollover conditions. Weighted members in the form of weighted balls are disposed within the hollow valve member to counteract the lifting force that may be imposed upon the hollow valve member by the formation of a low pressure area over the distal tip due to high flow rates of vapor over the tip. The weighted balls aid in preventing the valve member from being urged upwardly to prematurely seal the outlet. The hollow valve member is formed to include a sealed chamber so that a buoyant force is created when fuel enters the valve.

Abstract: An apparatus is provided for determining the quantity of fuel in a fuel tank having a contoured interior wall. The apparatus includes a buoyant member for floating on the top surface of fuel in the fuel tank, a conductor supported on the buoyant member to float therewith, and a pattern of resistance in electrical contact with the floating conductor. The pattern of resistance is selected to correspond to the contour of the interior wall. Thus, the resistance pattern is coded to represent the volume profile of the fuel tank. A voltage is applied across the conductor and the pattern of resistance. The floating conductor and the pattern of resistance cooperate to provide a value of resistance corresponding to the depth of fuel in the fuel tank at the measurement location. An indicator interprets that value of resistance to determine the instantaneous quantity of fuel in the fuel tank.

Abstract: A fuel cap having a pressure-vacuum valve assembly for sealing a vehicle fuel tank is provided. The cap has a normally closed vent to vent the fuel tank, with a first valve member to open the vent when the pressure within the tank reaches a predetermined superatmospheric level. The cap also has a second valve member to open the vent when the pressure within the tank reaches a predetermined subatmospheric level. The cap includes a roll-over valve disposed above the first and second valve members to close the vent when the vehicle and cap are rolled over to a substantially inverted orientation to prevent fuel from spilling out of the cap.

Abstract: A flow-metering valve assembly is provided for vehicle fuel tanks. The assembly includes a valve housing having an interior wall configured to define a chamber having an inlet and an exhaust outlet. The interior wall provides a first flow-metering surface situated in close proximity to the outlet. A spring-biased pressure-relief element is situated in the chamber and includes a valve member having an inner surface confronting the inlet and an upstanding skirt attached to the valve member. The skirt has a distal portion extending in an outward direction toward the outlet means to provide a second flow-metering surface. The first and second surfaces cooperate to define a variable flow-metering orifice therebetween.

Abstract: A vapor recovery system is provided for recovering fuel vapors discharged from a fuel tank having a vent tube and a separate filler neck during refueling. The vapor recovery system includes a partition dividing the filler neck into an outer chamber communicable with the atmosphere and an inner chamber in fluid communication with the fuel tank. The partition includes an aperture for sealingly admitting a fuel dispensing nozzle into the inner chamber without coupling the inner and outer chambers in fluid communication during refueling. A fuel cap may sealingly engage the filler neck to close the mouth of the filler neck. A refueling sensing system is provided for actuating a flow valve during an initial stage of each refueling activity to permit flow of fuel vapor to the canister. Upon removal of the fuel cap, fuel vapor discharged from the fuel tank is conducted automatically to the canister for processing therein instead of being discharged directly into the atmosphere.

Abstract: A system is provided for recovering fuel vapors discharged from a vehicle fuel system during refueling. The vehicle fuel system including a fuel tank having a filler neck and a separate outlet. The system includes a venting module mounted in the outlet and configured to divide the outlet into separate first and second fuel vapor flow ports. Pressurized fuel vapor in the fuel tank is exhaustable therefrom through at least one of the first and second ports. The venting module includes a first chamber inside the first tank and a second chamber outside the fuel tank. A vapor delivery system conducts fuel vapor from the first and second ports to a fuel vapor treatment site. A roll-over valve assembly in the first chamber selectively blocks the flow of fuel vapors through the first fuel vapor flow port during vehicle rollover or the like.

Abstract: A fuel sender unit is provided for delivering fuel from a conventional fuel tank that may have a resilient bottom wall of the type that deflects under a fuel load. The fuel sender unit includes a support fixture mounted on the fuel tank, a sending unit within the fuel tank for pumping fuel in the fuel tank toward a point of use outside the fuel tank, and an extension apparatus for coupling the sending means to the support fixture for relative movement therebetween. The extension apparatus includes a plurality of fluid-conducting telescoping guide tube assemblies. The sending unit includes a pump and a reservoir cup for accumulating an auxiliary supply of fuel within the fuel tank to maintain a substantially uninterrupted supply of fuel to the pump. The sending unit is lowerable to a variety of depths within the fuel tank to reach and pump fuel accumulating in various regions along the bottom fuel tank wall notwithstanding sagging deformation of said bottom wall.

Abstract: A roll-over valve is provided for use in a vehicle fuel system having an outlet for discharging fuel vapor. The roll-over valve includes a hollow valve member that terminates in a distal tip and includes a side wall. The distal tip is formed to include a top aperture and the side wall is formed to include at least one side aperture. The top aperture and side aperture cooperate to prevent the formation of a low pressure area that might otherwise be formed over the distal tip to prevent the hollow valve member from prematurely sealing the outlet. A roll-over ball is provided for moving the distal tip from an outlet-opening position to an outlet-closing position in response to tilting of the hollow valve member during vehicle roll-over conditions. A ball is provided in the hollow valve member for closing the top aperture during a selected first range of tilting positions of the hollow valve member.