FUEL TRANSDUCER MODULE PROTECTIVE COVER

Abstract

A fuel sending unit protective cover assembly is disclosed, for protecting the fuel transducer module mounted to a fuel tank. The protective cover is associated with a locking ring. The locking ring engages the E-ring permanently secured to a fuel tank, by rotational engagement of the locking ring with one or more tabs protruding from the E-ring. The cover body with a plurality of descending legs is configured to engage ascending legs on the E-ring. The cover body is configured to permit installation and removal of the protective cover from the fuel tank without removal or disconnection of fluid conduits and electrical wiring.

Description

FIELD OF THE INVENTION

The present invention relates in general to a device for securing and protecting a fuel transducer module in relation to a fuel tank.

BACKGROUND

A fuel transducer module is a common element in a fuel storage vessel, such as a fuel tank utilized in a vehicle. A fuel tank is a vessel having at least one filler opening and at least one outlet. Because the fuel tank is often mounted deep within the structure of a vehicle, and hence, not readily accessible or visible to the operator, a fuel level sensing unit or transducer is typically installed in the tank to transmit, electrically or mechanically, an indication of the quantity of fuel remaining in the tank.

Because each opening in the fuel tank presents the opportunity for spillage or leakage, it is desirable to minimize the number of openings therein, and accordingly, fuel tank designs may utilize a unified transducer module which includes conduits for fuel and fuel vapors. The module fits over or within an opening in the tank, and is secured to the tank by appropriate seals to prevent leakage.

In a typical mounting installation for a fuel transducer module, a “hard point” or anchor is permanently affixed to the tank. Typical of such attachment points is an imbedded or encapsulated ring, commonly referred to as an “E-ring” which may be molded into a plastic tank or welded to a metal tank. Such an E-ring typically surrounds a circular opening in the tank, and the fuel transducer module is engaged therewith. To hold the fuel transducer module in position on the tank in relation to the E-ring, a locking ring is provided which engages the E-ring and typically captures a flange on the fuel transducer module between the locking ring and the surface of the fuel tank. Typical of such installations is a fuel-sending unit and locking ring as described in U.S. Pat. No. 5,207,463, issued to Seizert, et al., and described in U.S. Patent Application Publication 2004/0021271, to Tratnik.

A typical fuel transducer module presents one or more electrical connectors, usually in the form of an electrical union comprised of a socket and a plurality of conductors disposed in each. The transducer module also typically contains one or more fuel conduits or vents which communicate with the interior of the fuel tank.

In recent years, vehicle crashworthiness standards have evolved which include regulations and engineering specifications designed to reduce the likelihood of fire or explosion in the event of a vehicular accident. In particular, a great deal of attention has been paid to fuel tank design, with due consideration to the positioning of the fuel tanks in vehicles, and the reduction of risk of damage to the fuel tank and its components in a collision.

Because elements of the fuel transducer protrude outward from the surface of the fuel tank, it is desirable that those components be protected from impact during a collision. As a result, guards have been developed to surround the fuel transducer module, thereby offering a measure of protection against damage to the components of the module during a collision.

Existing guards utilize either a stamped or drawn construction. These guards have a plurality of openings which allow electrical wiring and tubing to be connected from the vehicle in which the fuel tank is mounted to the fuel transducer module. The guards are typically mounted to the fuel tank or locking ring using threaded fasteners, such as studs.

The design of currently known guards, however, presents certain practical limitations during fuel tank assembly and repair operations. Attachment of a guard utilizing threaded fasteners is time-consuming, and the manufacture of locking rings containing threaded fasteners is expensive. Additionally, currently known guards require the removal of the electrical connectors, fuel and vent lines from the transducer during the assembly or repair process.

It is desirable, therefore, to provide a fuel-sending unit protective cover which can be easily attached to and removed from the fuel tank without the need for fasteners or tools, which is simple to manufacture and affordable, and which simplifies vehicle assembly and repair by being installable and removable without disturbing the electrical, fluid and vent connections between a vehicle and its installed fuel tank.

It is an object of the present invention, to provide a protective guard to surround a fuel transducer module, and to protect said module against damage from external forces.

It is further an object of the present invention to provide a guard which is easily formed from a single piece of material.

It is a further object of the present invention to provide a guard which is easily and securely attached to a fuel tank and fuel transducer mounting ring without the need for fasteners, such as nuts, bolts or studs, and which can be affixed to a fuel tank without the use of numerous tools.

It is a further object of the present invention to provide a guard for a fuel transducer module which is easily installed and removed from a fuel tank, while allowing the fuel transducer module to remain in place, and without requiring disconnection of conduits or electrical wiring harnesses from the transducer.

SUMMARY

A fuel-sending unit protective cover is provided for protecting a fuel transducer module mounted to a fuel tank. The protective cover is associated with a locking ring. The locking ring engages the E-ring permanently secured to a fuel tank, by rotational engagement of the locking ring with one or more tabs protruding from the E-ring. A plurality of slots is provided on the locking ring to engage the tabs of the E-ring, and a fuel transducer module is captured between the surface of the fuel tank and the E-ring.

A cover body with a plurality of descending legs is configured to engage ascending legs on the E-ring. The distal ends of the descending legs are provided with feet, which, in turn, engage spring clips mounted to the ascending legs of the locking ring. The body of the cover is provided with a socket for engagement with an installation and removal tool.

The feet of the cover engage detents in the spring clips preventing unintentional rotation of the cover in relation to the E-ring. The cover and its associated legs are configured so that the legs do not interfere with the fuel transducer module when the cover is installed or removed.

BRIEF DESCRIPTION OF THE DRAWINGS

The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:

FIG. 1 is a perspective view of a fuel transducer module associated with a locking ring, as taught in the prior art.

FIG. 2 is a side view of the present invention in engagement with a locking ring, as positioned on a fuel tank.

FIG. 3 is a perspective view of the surface of a fuel tank to which is attached a conventional E-ring.

FIG. 4 is a perspective view of the present invention in partial engagement with the locking ring of the present invention.

FIG. 5 is a perspective view of the protective cover and locking ring of the present invention in substantial engagement.

FIG. 5A is a detailed view of a first portion of the locking ring engaged with the protective cover.

FIG. 5B is a detailed view of a second portion of the locking ring engaged with the protective cover.

DETAILED DESCRIPTION

The environment in which the invention operates is depicted generally at FIG. 1. A fuel tank 12, typically constructed of either metal or plastic, is formed in the configuration of a generally closed vessel having a top, bottom, and sides. As depicted in FIG. 1, an attachment area 14 it is designated on one surface of the fuel tank 12 (usually a top surface) onto which a fuel transducer module 20 will be mounted. Typically, this area 14 of the fuel tank 12 is substantially flat and smooth. An opening is formed in the fuel tank 12 to accommodate portions of the fuel transducer module 20 including associated conduits 22 and fuel-level measuring elements (not shown). The transducer module 20 is also typically equipped with an electrical union 24 in the form of a socket equipped with a plurality of electrical conductors, designed to engage with a mating electrical plug (not shown). The transducer module 20 contains multiple conduits 22 for transmission of fuel, air and fuel vapors to and from the interior of the fuel tank 12. All of the conduits 22 and electrical unions 24 are mounted to a unitary body, and the entire transducer module 20 is typically pre-manufactured and appropriately configured for the particular fuel tank installation of the type common to motor vehicles. It will be appreciated that fuel transducer modules 20 of this type are designed to be fully pre-assembled prior to installation on the fuel tank 12.

The fuel transducer module 20 body is typically cylindrical, having the necessary strength and thickness to provide sufficient mechanical support to the conduits 22 and electrical union 24 mounted to the upper surface of the module 20, as well as to the conduits 22 and transducer elements mounted to and through the bottom of the transducer module 20.

With further reference now to FIG. 1, FIG. 2 and FIG. 3, the placement of the fuel transducer module 20 in relation to the fuel tank 12 will be best understood. To facilitate attachment, the fuel tank 12 is provided with an attached or embedded ring 40, commonly referred to as an E-ring, and typically manufactured of metal appropriately formed and stamped. The E-ring 40 has an annular body 44, and protruding therefrom at a plurality of locations around the circumference of the E-ring 40 is a series of tabs 46. Each tab 46 has an upwardly extending ascender 48, and a horizontal extension 50 which extends inwardly toward the center of the E-ring 40 substantially parallel to the upper surface of fuel tank 12. Although FIG. 2 and FIG. 3 depict an E-ring 40 of the type generally embedded within a molded plastic tank, it will be appreciated that E-ring 40 can be mounted to the upper surface of the tank 12 as well. For attachment of E-rings 40 to metal tanks, it is known to utilize fasteners or welding to secure the E-ring 40 to the tank 12, where it functions in substantially the same fashion as an E-ring 40 which is embedded in a molded plastic tank 12. The E-ring 40 so configured and attached creates the basic point of attachment for the fuel transducer module 20, when used in conjunction with an appropriate locking ring.

A locking ring 60 of the type utilized in the present invention is depicted in FIGS. 2, 4, 5 and in detail in FIGS. 5A and 5B. The locking ring 60 comprises an annular body having a central aperture 64. The outer circumference of the central aperture 64 is turned upward, creating a lip 66. The lip 66 is provided with a plurality of plateaus 67 and ramp sections 65 which extend upward from the annular body portion at a height above the height of the remaining circumferential lip 66. Also extending upward from the circumferential lip 66 is a plurality of feet 70a-c, each comprising an ascender 68, a toe portion 72, a heel portion 71 and a slot 74. The plurality of slots 74 associated with said plurality of ascenders 68 are open in the same circumferential orientation as shown in FIG. 4, to allow insertion of a cover element which will be described in detail herein.

The body of the locking ring 60 is further provided with a plurality of arcurate openings 80, each said arcurate opening 80 having a wide portion 82 and a narrow portion 84. The width of the wide portion 82 of each said arcurate opening 80 corresponds to the width of the tab extension 50 of the E-ring tab 46, so that the locking ring 60 may fit over the tab extensions 50 when the locking ring 60 wide portion 82 of the arcurate opening 80 is aligned with the tab extension 50 of the E-ring tabs 46. As depicted in FIG. 2, once the locking ring 60 has been placed over the E-ring tabs 46, it will rest substantially on the upper surface of the transducer 20 and of the fuel tank 12. In this embodiment, a gasket 38, preferably in the form of an O-ring, is placed between the annular body of the locking ring 60 and the upper surface of the fuel tank 12, so as to be positioned between the bottom of the fuel transducer module 20 and the upper surface of the fuel tank 12, thereby creating a fluid-tight seal between said fuel transducer module 20 and said fuel tank 12.

The fuel transducer module 20 body is formed with an annular lip 29 having a diameter larger than the diameter of the central aperture 64 of the locking ring 60. Accordingly, placement of the locking ring 60 over the module 20, and over the E-ring tabs 46 establishes the initial position for securing the fuel transducer module 20 to the upper surface of the fuel tank 12. In this configuration, the locking ring 60 is ready for rotation in the direction R.

From FIGS. 2, 3 and 4, it will be appreciated that the annular body of the locking ring 60, adjacent to the narrow portion 84 of the arcurate openings 80, is provided with a plurality of protrusions 86. As the locking ring is rotated in direction R, the ascenders 48 of the tabs 46 of the E-ring 40 pass into the narrow portion 84 of the arcurate openings 80 of the locking ring, and at the same time tab extensions 50 engage the protrusions 86 of the locking ring 60. The height of the ascenders 48 of the tabs 46 of the E-ring 40 is selected to result in engagement between the tab extensions 50 of the E-ring 40 with the protrusions 86 adjacent the arcurate openings 80 of the locking ring 60. This engagement urges the locking ring 60 downward, toward the E-ring 40, with the annular lip 29 of the fuel transducer module 20 captured under the annular body 62 of the locking ring 60, and simultaneously compressing the gasket 38 between the annular lip of the fuel transducer module and the upper surface of the tank 12. Detents 52 formed in the tab extensions 50 of the E-ring 40 frictionally engage the protrusions 86 adjacent to the narrow portions 84 of the arcurate openings 80, preventing counter-rotation of the locking ring 60 in relation to the E-ring 40.

To facilitate the rotational engagement above described, the locking ring 60 is provided with a plurality of cutouts 76 around its circumference which are designed to engage with a cooperative installation tool (not shown). This tool is provided with a plurality of engaging fingers and a central socket of the type adapted to engage a square drive ratcheting wrench. By placement of the fingers of the tool in the cutouts 76 of the locking ring 60, and by application of torque in the direction R, the locking ring 60 can be rotated conveniently into the locked configuration, after which the tool may be removed.

At this stage in the installation process, the transducer module 20 is secured to the mounting surface of the fuel tank 12 by the locking ring 60 and its engagement with the E-ring 40. With reference now to FIGS. 2, 4, 5, 5A and 5B, securement of the protective cover 100 of the present invention will be fully understood. The protective cover 100 comprises a formed element having a body 102 and a plurality of legs 104, each of said legs 104 having formed therein a foot 106. In plan view, it will be appreciated that the legs 104 of the cover 100 are oriented as follows: two of the legs 104 are positioned substantially in diametric opposition, with a third leg 104 positioned approximately at an angle of approximately 60° (ø₁) to a first one of the legs 104, and at an angle of approximately 120° (ø₂) to a second one of said first legs 104. This configuration leaves a substantially semi-circular opening (ø₃) unimpeded, thereby allowing installation of the cover 100 even though the fuel transducer module 20 and its conduit and wiring already in place and connected. The cover 100 with its associated body 102 and legs 104, provides protection to the fuel transducer module 20 in the event of a catastrophic impact to the fuel tank area surrounding the module. Each leg 104 of the cover is formed at its proximal end as a portion of the body 102, and is bent substantially normal to the body 102, thereby creating a descending leg 104 element to engage the locking ring 60. At the distal end of each leg 104 is formed a foot 106 having a heel 108 and a guide 110 designed to engage the locking ring 60 in a manner to be described. Ridges 87 are formed in feet 106 to engage spring elements 79a-c as herein described.

Each foot 70a-c of the locking ring 60 has a heel 71, a toe 72 and a slot 74. Affixed between the heel 71 and the toe 72 are clips 77a-c, utilizing fasteners 69, such as rivets. The clips 77a-c are formed of a resilient material, such as spring steel. The clips 77a-c each have a spring element 79a-c formed therein. One end of each spring element 79a-c is provided with a V-shaped detent 75. Impressed within one surface of the V-shaped detent 75c is an impression 88. This impression engages a gap 78 formed in foot 106. At the distal end of each spring clip 77a-c an upward turned tang 73 is provided to allow engagement of a tool to lift the spring element 79a, if necessary for removal of the cover.

Complimentary to the locking ring feet 70a-c are cover element feet 106, each of which is provided with a ridge 87 and a guide 110. The guide 110 is oriented downwardly, and is configured to engage the outer circumference of the lip 66 of the locking ring 60. The guides 110, collectively, therefore, serve to guide and position the cover into juxtaposition with the locking ring 60. Each foot 106 has a ridge 87 formed therein. As shown in FIG. 5A, at least one of the foot 106 associated with at least one leg 104 of the cover 100 is provided with a gap 89 formed in ridge 87. This gap 89 engages the impression 88 formed in the spring element 79a of the clip 77a, effectively locking the spring element 79 into the upturned portion of the ridge 87.

To install the cover 100 in relation to the locking ring 60, the cover 100 is placed on the locking ring 60 so that the undersides of the feet 106 rest on the upturned lip 66 of the annular body of the locking ring 60, with the feet 106 of the cover adjacent to the feet 70 of the locking ring 60. The cover is then rotated in direction R, bringing the feet 106 of the cover into the slots 74 of the locking ring feet 70. This rotation also brings the feet 106 of the cover into engagement with the spring elements 79 of the clips 77. Further rotation of the cover 100 in direction R brings the detents 75 of the spring elements 79 into engagement with ridges 87 on the cover feet 106. Simultaneously, the guides 110 of the cover feet 106 serve to guide and position the cover 102 into alignment with the lip 66 of the locking ring 60. Once fully engaged, the detent of the spring elements 79 locks the cover 100 into the desired positional relationship with the locking ring 60.

In one embodiment, the upper section of the protective cover is provided with a socket 120 configured to engage a typical square drive ratchet-type wrench to allow the cover 100 to be rotated into locked relationship with the locking ring 60 by providing the necessary mechanical advantage to impart the necessary torque to the cover 100.

By virtue of the angular relationship of the legs of the cover 100, the cover 100 can be installed on and removed from the locking ring 60 without the necessity of disconnecting any of the electrical or fluid connections associated with the fuel transducer module 20.

The foregoing description of the preferred embodiment according to the present invention are provided for the purposes of illustration only, and not for purposes of limitation, the invention being defined by the claims:

Claims

1. In a fuel tank equipped with an embedded mounting ring for securing a transducer to said tank, a fuel transducer module protective cover assembly comprising:

a locking ring removably engageable with said mounting ring, said locking ring comprising a plurality of slots oriented in a common circumferential direction in relation to the circumference of said ring;

a plurality of spring clips adjacent to said slots; and

a cover element comprising a body portion and a plurality of legs dependent from said body portion, each of said legs having a foot element dependent therefrom, whereby one of each said foot elements is engageable with one of each said slots, and whereby said cover element and said locking ring are secured in engagement by said spring clips.

2. The invention of claim 1, wherein said plurality of legs further comprises a first leg, a second leg and a third leg, said first and said second legs being substantially diametrically opposed on said body and said third leg disposed on said body between said first and said second legs.

3. The invention of claim 2, wherein said body further comprises a socket whereby an engaging tool is removably attachable to said cover element.

4. The invention of claim 1, wherein at least one of said foot elements comprises a ridge, wherein said at least one of said spring clips comprises a detent, and wherein said ridge engages said detent when said cover element is engaged with said locking ring.

5. A cover for attachment to an annular fuel transducer locking ring having a first circumference, said cover comprising a substantially circular body and a substantially cylindrical side wall having a second circumference and a substantially circular lower edge, further comprising at least one opening formed in at least one section of said side wall, said opening extending through said edge.

6. The invention of claim 5, further comprising attachment means for removably securing said cover to said locking ring.

7. The invention of claim 6, wherein said attachment means are spring clips engaging said lower edge and said locking ring circumference.