Description:
FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
[See section 10, Rule 13]

FUEL FILLER APPARATUS OF VEHICLE

HERO MOTOCORP LIMITED, an Indian Company at: The Grand Plaza, Plot No.2, Nelson Mandela Road, Vasant Kunj- Phase -II, New Delhi, India, 110 070

THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED.

FIELD OF THE INVENTION:
[001] The present invention relates to a fuel filler apparatus of a vehicle, and more particularly to a fuel filler structure of the fuel filler apparatus.

BACKGROUND OF THE INVENTION:
[002] Generally, in two-wheeled vehicles, fuel is filled into a fuel tank through a fuel filler apparatus. The fuel filler apparatus includes a fuel filler structure and a fuel tank cap. The fuel filler apparatus is generally fixed to the opening of the fuel tank and in particular, the fuel filler structure is welded to the opening of the fuel tank. The fuel tank cap is adapted to be fitted and locked onto the fuel filler structure such that it restricts access to the fuel filler structure.

[003] The fuel filler structure generally comprises an annular structure comprising a bottom wall, a peripheral wall extending perpendicularly in a first direction from the bottom wall, a first aperture located at about a middle portion of the bottom wall, and at least a second aperture located between the first aperture and the peripheral wall. The fuel filler structure further comprises a first annular body joined to the bottom wall such that the first annular body extends perpendicularly in a second direction from the bottom wall and surrounds the first aperture. The fuel filler structure further comprises a pipe element extending along the second direction from the bottom wall such that the pipe element surrounds the second aperture. The second aperture and the pipe element provide a draining functionality i.e. it allows water and/or spill over fuel (which may be get collected on the annular structure) to be drained out of the fuel tank.

[004] The annular structure may further comprise one or more provisions that may be used while welding the fuel filler structure to the opening of the fuel tank. The first annular body may further comprise a stopper structure for restrict ingress of a fuel filler gun during the process of filling fuel into the fuel tank. The annular structure may further comprise additional components which are well known to a person skilled in the art and similarly, the fuel tank cap may comprise one or more components which are well known to a person skilled in the art.

[005] During the process of making the fuel tank, firstly the fuel filler structure is formed i.e. the pipe element and the first annular body is welded to the bottom surface of the annular structure. Thereafter, the fuel filler structure (and more particularly, a top edge of the peripheral wall of the filler structure) is welded to the opening of the fuel tank. Thereafter, the fuel cap may be coupled to the fuel filler structure (in case the fuel cap is hinged with respect to the fuel filler structure). To enhance a speed and a quality of the fuel tank, it is preferable to weld the fuel filler structure to the opening of the fuel tank using a robotic welding machine. However, while using a robotic welding machine, a height of a top edge of the peripheral wall of the annular structure forming part of the filler structure should be at a uniform to avoid any defect after the welding process.

[006] However, it has been observed that in many instances, despite taking an annular structure having uniform height of the top edge of the peripheral wall, the fuel filler structure formed therefrom (i.e. after welding the pipe element and the first annular body to the bottom surface of the annular structure) fails to have uniform height of the top edge of the peripheral wall. When a fuel filler structure having non-uniform uniform height of the top edge of the peripheral wall is used form welding, a quality of welding is substantially degraded and hence, the fuel tank has many associated disadvantages. Thus, there exists a need to overcome the aforesaid disadvantage.

SUMMARY OF THE INVENTION:
[007] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[008] Accordingly, the present invention provides a fuel filler apparatus of a fuel tank of a vehicle comprising a fuel filler structure located in an opening of the fuel tank, and a fuel tank cap adapted to be fitted and locked onto the fuel filler structure. In an embodiment of the invention, the fuel filler structure comprising an annular structure comprising a bottom wall, a peripheral wall extending perpendicularly in a first direction from the bottom wall, a first aperture located at about a middle portion of the bottom wall, and at least a second aperture located between the first aperture and the peripheral wall. The fuel filler structure further comprises a first annular body joined to the bottom wall such that the first annular body extends perpendicularly in a second direction from the bottom wall and surrounds the first aperture. The fuel filler structure further comprises a pipe element extending along the second direction from the bottom wall. The fuel filler structure further comprises a second annular body joined to the bottom wall such that the second annular body extends perpendicularly in the second direction from the bottom wall. In an embodiment of the invention, the second annular body couples the pipe element to the bottom wall such that the pipe element provides a fluid flow path from the second aperture.

[009] In an embodiment of the invention, the bottom wall comprises a groove surrounding the first aperture, the groove adapted to receive a proximal tip of the first annular body.

[0010] In another embodiment of the invention, the fuel filler structure further comprises a set of brackets for coupling the first annular body to the bottom wall of the annular structure.

[0011] In yet another embodiment of the invention, the pipe element comprises a drain pipe and the second aperture comprises a drain aperture.

[0012] In still another embodiment of the invention, the second annular body being coupled to the bottom wall vide projection welding.

[0013] The invention furthermore provides a method for making a fuel filler apparatus, said method comprising providing an annular structure comprising a bottom wall, a peripheral wall extending perpendicularly in a first direction from the bottom wall, a first aperture located at about a middle portion of the bottom wall, and at least a second aperture located between the first aperture and the peripheral wall. The method further comprises joining a first annular body and a second annular body to the bottom wall, the first annular body extending perpendicularly in a second direction from the bottom wall and surrounds the first aperture, the second annular body extends perpendicularly in the second direction from the bottom wall and surrounds the second aperture. The method further comprises joining a pipe element to the second annular body such that the pipe element extends along the second direction from the bottom wall provides a fluid flow path from the second aperture.

[0014] In an embodiment of the invention, the step of joining the first annular body to the bottom wall comprises providing a set of brackets on an external peripheral wall of the first annular body, and joining the set of brackets to the bottom wall of the annular structure.

[0015] In another embodiment of the invention, the step of joining the set of brackets to the bottom wall of the annular structure comprises spot welding the set of brackets to the bottom wall of the annular structure.

[0016] In yet another embodiment of the invention, the step of joining the second annular body to the bottom wall comprises projection welding the second annular body to the bottom wall.

[0017] In still another embodiment of the invention, the step of joining the pipe element to the second annular body comprises brazing welding the pipe element to the second annular body.

[0018] An advantage of the invention is that the fuel filler structure has a uniform height of the top edge of the peripheral wall. Another advantage of the invention is that the fuel filler arrangement has a higher level of dimensional accuracy.

[0019] Yet another advantage of the invention is that the fuel filler structure can be accurately welded to the opening of the fuel tank using a robotic welding machine.

[0020] Still another advantage of the invention is that spaces formed between the opening of the fuel tank and the fuel filler structure due to inaccuracy in the welding of the fuel filler structure to the opening of the fuel tank is reduced.

[0021] A further advantage of the invention is that the fuel tank is less susceptible to development of cracks due to inaccuracy in the welding of the fuel filler structure to the opening of the fuel tank.

[0022] A furthermore advantage of the invention is that the fuel tank is less susceptible to premature failures.

[0023] To further clarify the advantages and features of the invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.

BRIEF DESCRIPTION OF THE FIGURES:
[0024] In order that the invention may be readily understood and put into practical effect, reference will now be made to exemplary embodiments as illustrated with reference to the accompanying drawings, where like reference numerals refer to identical or functionally similar elements throughout the separate views. The figures together with a detailed description below, are incorporated in and form part of the specification, and serve to further illustrate the embodiments and explain various principles and advantages, in accordance with the present invention where:

[0025] Figure 1 illustrates a side view of the vehicle in accordance with an embodiment of the invention;

[0026] Figure 2 illustrates a semi-transparent view of the fuel tank in accordance with an embodiment of the invention;

[0027] Figure 3 illustrates a partial cross sectional view of fuel tank in accordance with an embodiment of the invention;

[0028] Figure 4 illustrates a perspective view of the fuel filler structure in accordance with an embodiment of the invention;

[0029] Figure 5 illustrates an exploded view of the fuel filler structure in accordance with an embodiment of the invention; and

[0030] Figure 6 illustrates a flow chart of a process involved in making the fuel filler structure in accordance with an embodiment of the invention.

[0031] It may be noted that to the extent possible, like reference numerals have been used to represent like elements in the drawings. Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have been necessarily been drawn to scale. For example, the dimensions of some of the elements in the drawings may be exaggerated relative to other elements to help to improve understanding of aspects of the present invention. Furthermore, one or more elements may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

Detailed Description of the Invention:
[0032] For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.

[0033] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are explanatory of the invention and are not intended to be restrictive thereof.

[0034] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.

[0035] Reference throughout this specification to “an aspect”, “another aspect” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrase “in an embodiment”, “in another embodiment”, and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

[0036] The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that one or more devices or sub-systems or elements or structures or components proceeded by "comprises... a" does not, without more constraints, preclude the existence of other devices or other sub-systems or other elements or other structures or other components or additional devices or additional sub-systems or additional elements or additional structures or additional components.

[0037] As used herein, and unless the context dictates otherwise, the terms "coupled to", “connected to”, “operably connected to”, and “operatively connected to” are intended to include both direct connection / coupling (in which two elements that are coupled / connected to each other contact each other) and indirect coupling / connection (in which at least one additional element is located between the two elements). Therefore, the terms "coupled to" and "coupled with" are used synonymously. Similarly, the terms “connected to” and “connected with” are used synonymously.

[0038] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one ordinary skilled in the art to which this invention belongs. The device, methods, and examples provided herein are illustrative only and not intended to be limiting.

[0039] The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as being essential to the practice of the invention.

[0040] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.

[0041] Embodiments of the present invention will be described below in detail with reference to the accompanying drawings.

[0042] The terms “front / forward”, “rear / rearward / back / backward”, “up / upper / top”, “down / lower / lower ward / downward, bottom”, “left / leftward”, “right / rightward” used therein represents the directions as seen from a vehicle driver sitting astride.

[0043] While the present invention is illustrated in the context of a vehicle, however, cover and aspects and features thereof can be used with other types of vehicles as well. The terms “vehicle”, “two wheeled vehicle” and “motorcycle” have been interchangeably used throughout the description. The term “vehicle” comprises vehicles such as motorcycles, scooters, bicycles, mopeds, scooter type vehicles, All-Terrain Vehicles (ATV) and the like.

[0044] Referring to Figure 1 there is illustrated a vehicle (10). The vehicle (10) comprises, inter-alia, a front fork (12), a head pipe (14), a front fender (16), a front ground engaging member (18), a rear ground engaging member (20), a headlight (22), a steering handle bar (24), a power unit (26), a rear fender (28), a tail light (30), a seat (32), an exhaust pipe (34), a rear cushion (36), a body frame (38), and a fuel tank (40). The head pipe (14) rotatably supports the steering handle bar (24) and the steering handle bar (24) is configured to be rotated by the rider to steer the vehicle (10). The front ground engaging member (18) is operatively connected to the steering handle bar (24) via the front fork (12). The front ground engaging member (18) is in front portion of the vehicle (10) and is at least partially covered by the front fender (16) while the rear ground engaging member (20) is in rear portion of the vehicle (10) and is at least partly covered by the rear fender (28). The headlight (22) is disposed above the front ground engaging member (18) while the tail light (30) is disposed above the rear ground engaging member (20). In an embodiment of the invention, the fuel tank (40) is disposed between the steering handle bar (24) and the seat (32). The seat (32) provides seating for a rider and a passenger of the vehicle (10). In an embodiment of the invention, the power unit (26) is mounted to the body frame (38) and is disposed below the fuel tank (40). The exhaust pipe (34) is connected to the power unit (26). The power unit (26) in an embodiment of the invention comprises an internal combustion engine adapted to receive fuel as stored in the fuel tank (40), burn the fuel within to a generate a driving power. The driving power thus generated by the power unit (26) is then transferred to at least one of the front ground engaging member and the rear ground engaging member (20) using a suitable power transfer mechanism (42). The exhaust pipe (34) processes the exhaust air as produced by the power unit (26) before dispensing it to the environment. The rear ground engaging member (20) is rotatably supported by the body frame (38) and is coupled to the body frame (38) via a swing arm (44) and the rear cushion (36). The body frame (38) also supports the power unit (26), the seat (32) and the fuel tank (40). It may be noted that the vehicle (10) may include other parts which may not be relevant for explaining the present invention and hence not shown and described.

[0045] Now referring to Figure 2 there is illustrated a partial transparent view of the fuel tank (40) and Figure 3 there is illustrated a partial sectional view of the tank (40), in an embodiment of the invention. The fuel tank (40) comprises an opening (42) which allows a fuel to be filled into the fuel tank (40). The opening (42) of the fuel tank (40) is closed by a fuel filler apparatus (100). In an embodiment of the invention, the fuel filler apparatus (100) comprises fuel filler structure (102) and a fuel tank cap (104). The fuel tank cap (104) is adapted to be fitted and locked on to the filler structure (102). As best shown in Figure 3, in an embodiment of the invention the fuel filler structure (102) is located within the opening (42) provided in the fuel tank (40). In particular, the fuel filler structure (102) is welded within the opening (42) of the fuel tank (40).

[0046] Now referring to Figure 4 there is illustrated a perspective view of the fuel filler structure (102) and referring to Figure 5 there is illustrated an exploded view of the fuel filler structure (102). In an embodiment of the invention, the fuel filler structure (102) comprises an annular structure (106) comprising a bottom wall (108), a peripheral wall (110) extending perpendicularly in a first direction from the bottom wall (108), a first aperture (112) located at about a middle portion (114) of the bottom wall (108), and at least a second aperture (116) located between the first aperture (112) and the peripheral wall (110). The fuel filler structure (102) further comprises a first annular body (118) joined to the bottom wall (108) such that the first annular body (118) extends perpendicularly in a second direction from the bottom wall (108) and surrounds the first aperture (112). The fuel filler structure (102) further comprises a pipe element (120) extending along the second direction from the bottom wall (108). The fuel filler structure (102) furthermore comprises a second annular body (122) joined to the bottom wall (108) such that the second annular body (122) extends perpendicularly in the second direction from the bottom wall (108). The second annular body (122) functions to couple the pipe element (120) to the bottom wall (108) such that the pipe element (120) provides a fluid flow path from the second aperture (116).

[0047] Now referring particularly to Figure 5, in an embodiment of the invention, the bottom wall (106) comprises a groove (124) surrounding the first aperture (112). The groove (124) is adapted to receive a proximal tip (126) of the first annular body (118). Also, the fuel filler structure (102) comprises at least one bracket (128) coupling the first annular body (118) to the bottom wall (108) of the annular structure (106). These specific aspects of the invention are helpful during the process of making the fuel filler structure (102), which has been described later.

[0048] In an embodiment of the invention, the pipe element (120) comprises a drain pipe. The second aperture (116) comprises a drain aperture. Thus, the second aperture (116), the second annular body (122) and the pipe element (120) provide a draining functionality i.e. it allows water and/or spill over fuel (which may be get collected on the annular structure (106)) to be drained out of the fuel tank (40).

[0049] In an embodiment of the invention the fuel filler structure (102) and more particularly, the bottom wall (108) of the annular structure (106) may further comprise one or more provisions (132) (best visible in Figure 5) that may be used while welding the fuel filler structure (102) to the opening (42) of the fuel tank (40). The first annular body (118) may further comprise a stopper structure (134) (best visible in Figure 4) for restricting ingress of a fuel filler gun during the process of filling fuel into the fuel tank. The fuel filler structure (102) may further comprise additional components which are well known to a person skilled in the art. For instance, the fuel filler structure (102) and more particularly, the annular structure (106) may further comprise a locking mechanism (not visible) which assists in locking of the fuel tank cap (104). Additionally, the fuel filler structure (102) may comprise at least one breather hole (not visible). Similarly, the fuel tank cap (104) may comprise one or more components which are well known to a person skilled in the art.

[0050] Now referring to Figure 6, there is illustrated a method (S100) for making the fuel filler apparatus (100) as described in detail in Figure 2, Figure 3, Figure 4, and Figure 5, in accordance with an embodiment of the invention. In particular, the method (S100) of making the fuel filler apparatus (100) comprises providing (S1) an annular structure (106) comprising a bottom wall (108), a peripheral wall (110) extending perpendicularly in a first direction from the bottom wall (108), a first aperture (112) located at about a middle portion (114) of the bottom wall (108), and at least a second aperture (116) located between the first aperture (112) and the peripheral wall (110). The method (S100) further comprises joining (S2) a first annular body (118) and a second annular body (122) to the bottom wall (108), the first annular body (118) extending perpendicularly in a second direction from the bottom wall (108) and surrounding the first aperture (112), the second annular body (122) extending perpendicularly in the second direction from the bottom wall (108) and surrounding the second aperture (116). The method (S100) further comprises joining (S3) a pipe element (120) to the second annular body (122) to form the fuel filler structure (102), the pipe element (120) extending along the second direction from the bottom wall (108) providing a fluid flow path from the second aperture (116). The method (S100) further comprises providing a fuel tank cap (104) adapted to be fitted and locked onto the fuel filler structure (102) to form the fuel filler apparatus (100).

[0051] In particular, the step of joining (S2) the first annular body (118) to the bottom wall (108) comprises providing (S21) at least one bracket (128) on an external peripheral wall of the first annular body (118), and joining (S22) the at least one bracket (128) to the bottom wall (108) of the annular structure (106). By way of a non-limiting example, the step of joining (S22) the at least one bracket (128) to the bottom wall (108) of the annular structure (106) comprises spot welding the at least one bracket (128) to the bottom wall (108) of the annular structure (106).

[0052] By way of a non-limiting example, the step of joining (S2) the second annular body (122) to the bottom wall (108) comprises projection welding (S23) the second annular body (122) to the bottom wall (108). By way of another non-limiting example the step of joining (S3) the pipe element (120) to the second annular body (122) comprises brazing process (S31) the pipe element (120) to the second annular body (122). In an embodiment of the invention, the brazing process includes gas welding and Metal Inert Gas (MIG) welding.

[0053] It may be noted that the fuel filler apparatus (100) as described above may be used for making the fuel tank (40). While making the fuel tank (40), the fuel filler apparatus (100) and more particularly, the fuel filler structure (102) is located in the opening (42) of the fuel tank (40) and a top edge (130) of the fuel filler structure (102) and more particularly, the top edge (130) of the peripheral wall (110) of the annular structure (106) is continuously welded to the opening (42) of the fuel tank (40). By way of a non-limiting example, a robotic welding machine may be used for continuously welding the top edge (130) of peripheral wall (110) of the annular structure (106) to the opening (42) of the fuel tank (40).

[0054] It has been observed that by providing the second annular body (122) for coupling the pipe element (120) to the bottom wall (108) of the annular structure (106), a top edge (130) of the peripheral wall (110) is at a uniform height, as measured from the bottom wall (108). The phrase “uniform height” is intended to refer to a difference between in (a) a height of an uppermost most point of the top edge (130) of the peripheral wall (110) and (b) a height of a bottommost point of the top edge (130) of the peripheral wall (110) (both heights being measured from the bottom wall (108)), as provided in the following formula.

Difference in height = (height of an uppermost most point of the top edge of the peripheral wall) – (height of a bottommost point of the top edge of the peripheral wall)

[0055] In a preferred aspect of the invention, the difference between in (a) a height of an uppermost most point of the top edge (130) of the peripheral wall (110) and (b) a height of a bottommost point of the top edge (130) of the peripheral wall (110) is less than or equal to about 0.50 mm. In a more preferred aspect of the invention, the difference between in (a) a height of an uppermost most point of the top edge (130) of the peripheral wall (110) and (b) a height of a bottommost point of the top edge (130) of the peripheral wall (110) is less than or equal to about 0.35 mm. In a more preferred aspect of the invention, the difference between in (a) a height of an uppermost most point of the top edge (130) of the peripheral wall (110) and (b) a height of a bottommost point of the top edge (130) of the peripheral wall (110) is less than or equal to about 0.25 mm.

[0056] Without wishing to be tied to any particular hypothesis, is believed that the deformation of the top edge (130) of the peripheral wall (110) is due to thermal stress experienced by the annular structure (106), in particular, the thermal shock experienced by the annular structure during (a) coupling of the first annular body (118) to the annular structure (106), (b) coupling of the second annular body (120) to the annular structure (106).

[0057] Without wishing to be tied to any particular hypothesis, it is believed that when the pipe element (120) is coupled to the bottom wall (108) of the annular structure (106) vide the second annular body (122), the bottom wall (108) and the peripheral wall (110) experiences substantial low amount of thermal shock, which contributes to attaining a top edge (130) of the peripheral wall (110) having uniform height.

[0058] The above observation is quiet surprising for the reason that it is believed that a thermal shock experienced by the annular structure (106) when coupling the first annular body (118) to the annular structure (106) is higher than a thermal shock experienced by the annular structure (106) when coupling the second annular body (120) to the annular structure (106). Despite the above, coupling the pipe element (120) to the bottom wall (108) of the annular structure (106) vide the second annular body (122) contributes significantly to attaining a top edge (130) of the peripheral wall (110) having uniform height.

[0059] Additionally, use of the second annular body (122) for coupling the pipe element (120) to the bottom wall (108) of the annular structure (106) allows for implementation of a coupling technique which generates less thermal stress, which is not otherwise possible. In particular, use of the second annular body (122) for coupling the pipe element (120) to the bottom wall (108) of the annular structure (106) allows for using the projection welding (S23) for coupling the second annular body (122) to the bottom wall (108) while allowing use of brazing welding for coupling the pipe element (120) to the second annular body (122). This allows for a substantial reduction in the thermal shock experienced by the annular structure (106) and hence, significantly contributes to attaining a top edge (130) of the peripheral wall (110) having uniform height.

[0060] Additionally, using at least one bracket (128) for coupling the first annular body (118) to the bottom wall (108) of the annular structure (106) allows for implementation of a coupling technique which generates less thermal stress, which is not otherwise possible. In particular, use of at least one bracket (128) for coupling the first annular body (118) to the bottom wall (108) of the annular structure (106) allows for brazing welding the at least one bracket (128) with the first annular body (118) while allowing for spot welding the at least one bracket (128) to the annular structure (106). This also contributes to a reduction in the thermal shock experienced by the annular structure (106) and hence, contributes to attaining a top edge (130) of the peripheral wall (110) having uniform height.

[0061] Thus, an advantage of the invention is that the fuel filler structure (102) has a uniform height of the top edge (130) of the peripheral wall (110). Another advantage of the invention is that the fuel filler arrangement (102) has a higher level of dimensional accuracy.

[0062] By ensuring that the top edge (130) of the peripheral wall (110) is at a uniform height, the fuel filler structure (102) can be more effectively welded to the opening (42) of the fuel tank (40) using a robotic welding machine. Yet another advantage of the invention is that the fuel filler structure (102) can be accurately welded to the opening (42) of the fuel tank (40) using a robotic welding machine.

[0063] Still another advantage of the invention is that spaces formed between the opening (42) of the fuel tank (40) and the fuel filler structure (102) due to inaccuracy in the welding of the fuel filler structure (102) to the opening (42) of the fuel tank (40) is reduced.

[0064] A further advantage of the invention is that the fuel tank (40) is less susceptible to development of cracks due to inaccuracy in the welding of the fuel filler structure (102) to the opening (42) of the fuel tank (40). A furthermore advantage of the invention is that the fuel tank (40) is less development of susceptible premature failures.

[0065] A further advantage of the invention is that a total weight of the fuel structure (102) as well as the fuel filler apparatus (100) is not substantially increased. A furthermore advantage of the invention is that a cost of the fuel filler arrangement (100) and a cost of the vehicle (10) is not substantially increased. In fact, since the rejection rate of the fuel filler apparatus (100) due to dimensional in-accuracies and rejection rate of the fuel tank (40) due to development of cracks and other reasons, is substantially reduced, a substantial cost benefit achieved by implementation of the invention.

[0066] While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended. As would be apparent to a person in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.

[0067] The figures and the forgoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, orders of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts necessarily need to be performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples.
, Claims:WE CLAIM:

1. A fuel filler apparatus (100) of a fuel tank (40) of a vehicle (10) comprising a fuel filler structure (102) located in an opening (42) of the fuel tank (40), and a fuel tank cap (104) adapted to be fitted and locked onto the fuel filler structure (102), the fuel filler structure (102) comprising:
an annular structure (106) comprising a bottom wall (108), a peripheral wall (110) extending perpendicularly in a first direction from the bottom wall (108), a first aperture (112) located at about a middle portion (114) of the bottom wall (108), and at least a second aperture (116) located between the first aperture (112) and the peripheral wall (110);
a first annular body (118) joined to the bottom wall (108) such that the first annular body (118) extends perpendicularly in a second direction from the bottom wall (108) and surrounds the first aperture (112);
a pipe element (120) extending along the second direction from the bottom wall (108); and
a second annular body (122) joined to the bottom wall (108) such that the second annular body (122) extends perpendicularly in the second direction from the bottom wall (108), the second annular body (122) coupling the pipe element (120) to the bottom wall (108) such that the pipe element (120) provides a fluid flow path from the second aperture (116).

2. The fuel filler apparatus (100) as claimed in claim 1, wherein the bottom wall (106) comprises a groove (124) surrounding the first aperture (112), the groove (124) adapted to receive a proximal tip (126) of the first annular body (118).

3. The fuel filler apparatus (100) as claimed in claim 1, comprising at least one bracket (128) coupling the first annular body (118) to the bottom wall (108) of the annular structure (106).

4. The fuel filler apparatus (100) as claimed in claim 1, wherein:
the pipe element (120) comprises a drain pipe;
the second aperture (116) comprises a drain aperture;
and a top edge (130) of the peripheral wall (110) being at a uniform height, as measured from the bottom wall (108).

5. The fuel filler apparatus (100) as claimed in claim 1, wherein the second annular body (122) being coupled to the bottom wall (108) vide projection welding.

6. A method (S100) for making a fuel filler apparatus (100) of a fuel tank (40) of a vehicle (10) comprising a fuel filler structure (102) located in an opening (42) of the fuel tank (42), and a fuel tank cap (104) adapted to be fitted and locked onto the fuel filler structure (102), said method comprising:
providing (S1) an annular structure (106) comprising a bottom wall (108), a peripheral wall (110) extending perpendicularly in a first direction from the bottom wall (108), a first aperture (112) located at about a middle portion (114) of the bottom wall (108), and at least a second aperture (116) located between the first aperture (112) and the peripheral wall (110);
joining (S2) a first annular body (118) and a second annular body (122) to the bottom wall (108), the first annular body (118) extending perpendicularly in a second direction from the bottom wall (108) and surrounds the first aperture (112), the second annular body (122) extends perpendicularly in the second direction from the bottom wall (108) and surrounds the second aperture (116);
joining (S3) a pipe element (120) to the second annular body (122) to form the fuel filler structure (102), the pipe element (120) extending along the second direction from the bottom wall (108) providing a fluid flow path from the second aperture (116); and
providing (S4) a fuel tank cap (104) adapted to be fitted and locked onto the fuel filler structure (102).

7. The method as claimed in claim 6, wherein the step of joining (S2) the first annular body (118) to the bottom wall (108) comprises:
providing (S21) at least one bracket (128) on an external peripheral wall of the first annular body (118), and
joining (S22) the at least one bracket (128) to the bottom wall (108) of the annular structure (106).

8. The method as claimed in claim 7, wherein the step of joining (S22) the at least one bracket (128) to the bottom wall (108) of the annular structure (106) comprises spot welding the at least one bracket (128) to the bottom wall (108) of the annular structure (106).

9. The method as claimed in claim 6, wherein the step of joining (S2) the second annular body (122) to the bottom wall (108) comprises projection welding (S23) the second annular body (122) to the bottom wall (108), and the step of joining (S3) the pipe element (120) to the second annular body (122) comprises brazing welding (S31) the pipe element (120) to the second annular body (122).

10. A vehicle (10), comprising:
a front ground engaging member (18);
a rear ground engaging member (20);
a power unit (26) adapted to receive fuel as stored in a fuel tank (40), burn the fuel within to a generate a driving power, and transfer the driving power to at least one of the front ground engaging member (18) and the rear ground engaging member (20);
the fuel tank (40) comprising a fuel filler structure (102) located in an opening (42) of the fuel tank (40), and a fuel tank cap (104) adapted to be fitted and locked onto the fuel filler structure (102), the fuel filler structure (102) comprising:
an annular structure (106) comprising a bottom wall (108), a peripheral wall (110) extending perpendicularly in a first direction from the bottom wall (108), a first aperture (112) located at about a middle portion (114) of the bottom wall (108), and at least a second aperture (116) located between the first aperture (112) and the peripheral wall (110);
a first annular body (118) joined to the bottom wall (108) such that the first annular body (118) extends perpendicularly in a second direction from the bottom wall (108) and surrounds the first aperture (112);
a pipe element (120) extending along the second direction from the bottom wall (108); and
a second annular body (122) joined to the bottom wall (108) such that the second annular body (122) extends perpendicularly in the second direction from the bottom wall (108), the second annular body (122) coupling the pipe element (120) to the bottom wall (108) such that the pipe element (120) provides a fluid flow path from the second aperture (116).