DESC:INLET PROTECTION SYSTEM FOR FUEL CONTAINERS IN GASEOUS FUEL VEHICLES AND METHOD THEREOF

FIELD OF DISCLOSURE
The present disclosure generally relates to a system designed to prevent dust, dirt, or other contaminants from entering a fuel system, more particularly to a device for preventing dust, dirt, or other contaminants to enter in gaseous fuel vehicles through a fuel inlet of the vehicles.

BACKGROUND OF THE INVENTION
Gaseous fuel vehicles, especially CNG and LPG variants, are highly preferred these days and currently in high demand. It provides cleaner-burning fuel compared to traditional gasoline or diesel. It is more cost-effective than gasoline or diesel on an energy-equivalent basis. This can lead to significant fuel cost savings for both consumers and businesses operating large fleets of commercial vehicles. Further, the gaseous fuel vehicles typically meet stringent emission standards, making them compliant with automotive regulations and hence environment friendly.
Despite having several advantages of using gaseous fuel vehicles, the entry of dust, dirt, or other contaminants into the fuel system of gaseous vehicles can have several negative effects on the vehicle's performance and components. Particulate matter such as dust and dirt can lead to clogging of fuel filters, injectors, and other components within the fuel system. This can restrict the flow of fuel and result in diminished engine performance. Contaminants in the fuel can interfere with the combustion process, leading to incomplete or inefficient burning of fuel. This can result in reduced fuel efficiency, lower power output, and increased emissions.
Moreover, the ingress of fine particles into the fuel system can pose significant risks to the fuel injectors, potentially causing damage to their delicate components. Such damage can compromise the injectors' precision and disrupt the spray pattern, leading to inconsistent fuel distribution. As a result, this imbalance in fuel delivery can adversely affect engine performance, resulting in reduced efficiency, increased emissions, and potential long-term damage to engine components.
Contaminants, especially if they contain corrosive elements, can contribute to the corrosion of fuel system components. Corrosion can weaken the structural integrity of parts, leading to leaks and potential safety hazards. Solid particles entering the fuel system may damage the fuel pump by causing wear on its components. This can result in decreased pump efficiency, leading to fuel delivery problems and potential engine stalling. Further, the contaminants can disrupt the proper mixing of air and fuel in the combustion chamber, leading to an imbalanced air-fuel mixture. This can result in erratic engine performance, increased emissions, and difficulty in maintaining optimal fuel-air ratios.
To mitigate these issues, it's crucial to use protective caps on fuel inlets when the filling unit is not in use for refilling. Conventional dust caps have several infirmities. Certain alloys such as brass or metals such as iron may be used to construct the dust caps, on the other hand other materials are not suitable due to reaction with gas. Nevertheless, the conventional dust cap can corrode over time, especially in harsh environmental conditions or if exposed to certain chemicals. These alloys are costly and heavy as well, which may be unsuitable for ease of operation. Over time, brass tends to develop a patina, which is a thin layer forming on the surface due to oxidation. Some users may find the changing appearance of brass undesirable, and maintaining a polished appearance might require additional effort. Brass has relatively high thermal conductivity.
In extremely cold or hot environments, the dust cap may transfer heat or cold more effectively than other materials, potentially affecting the temperature of the fuel inlet and user inconvenience. Further, brass dust caps may require more intricate machining processes compared to simpler materials. This complexity can increase manufacturing costs and lead times.
Furthermore, iron and brass dust caps are susceptible to corrosion, which compromises the integrity of the dust cap and its ability to effectively seal the fuel inlet. The dust caps are susceptible to leaks. Sometimes due to faults in the valve system of the fuel inlets, gas may start leaking. The conventional dust caps are incapable of preventing the leakage, as it has no sealing provision for stopping the leakage of gas. There may be attempts to use other materials like plastic in place of brass, but then there may be various manufacturing defects like warpage, shrinkage, blowholes. Also, during the operation, the dust caps may deform and are difficult to manufacture.
Due to the above-mentioned reasons, the existing dust caps are not suitable for usage. Hence, there is an urgent need to provide an efficient dust cap which overcomes all the above-mentioned problems.

OBJECT OF THE INVENTION
An object of the present invention is to provide an ingress protection mechanism for preventing the entry of dust, dirt, debris, and other contaminants into a fueling system.
Another object of the present invention is to ensure safety of the vehicle’s occupant by keeping the connections and openings of the gaseous fuel system sealed when not in use, preventing any potential leaks or pressure losses.
Yet another object of the present invention is to contribute to environmental protection by preventing the release of gaseous fuel due to leaks or system failures.
Yet another object of the present invention is to prolong the life of valves, fittings, and other sensitive parts by preventing the entry of particles that could cause abrasion or corrosion.
Yet another object of the present invention is to provide efficient and trouble-free fueling of CNG vehicles, without causing delays and malfunctions during the fueling process.
Yet another object of the present invention is to provide a plug via complying with regulatory standards and safety guidelines.
Yet another object of the present invention is to provide a plug having a material, which is free from problems like high cost, manufacturing defects, bulky weight, operational inconvenience etc.

SUMMARY OF THE INVENTION
An inlet protection system for fuel containers in gaseous fuel vehicles in accordance with the present invention is provided. The inlet protection system for a fueling port, in gaseous fuel vehicle comprising: an inlet protection system for a fuel container, in a gaseous fuel vehicle comprising: a fill valve for entry of gaseous fuel inside the fuel container; a plug inserted into the fill valve for preventing entry of contaminants and preventing release of gaseous fuel from the fuel container; wherein, the plug is made of plastic material including nylon, polymers.
In an embodiment of the present disclosure, the plug has at least one end and an aperture provided at the at least one end. The at least one end of the plug is tapered. The aperture provides an inner cavity inside the plug.
In an embodiment of the present disclosure, the inner cavity is having a diameter in the range of 4.0 mm to 5.0 mm and extending axially along the length of the plug having length of 50 mm to 60 mm, providing rigidity and strength to the plug.
In an embodiment of the present disclosure, the plug comprises provision for accommodating at least one sealing ring for closing the fill valve to prevent gas contamination and preventing leakage of the gaseous fuel.
In an embodiment of the present disclosure, the plug comprises of plurality of sections axially positioned one behind the other.
In an embodiment of the present disclosure, the first section of the plug is tapered at the at least one end at an angle of 25 to 40 degrees towards the aperture to collect contaminants in the inner cavity of the plug.
In an embodiment of the present disclosure, the second section of the plug having a length of 45 mm to 60 mm comprising two sealing portions accommodating two sealing rings at two locations spaced at distances apart for preventing the release of gaseous fuel when the plug is inserted into the fill valve.
In an embodiment of the present disclosure, the third section of the plug comprises a grip portion having a length of 6 mm to 10 mm and a through hole.
In an embodiment of the present disclosure, the plastic material comprises blend of polyamide 66 (PA66) and 50% glass fiber (GF) reinforcement.
In an embodiment of the present disclosure, the plug actuates a micro-switch. Further, the micro-switch is configured to detect the presence or absence of the plug within the fill valve.
A method for inlet protection for a fuel container, in a gaseous fuel vehicle in accordance with the present disclosure is provided. The method comprising the following steps: positioning a fill valve in the fuel container for entry of gaseous fuel. The method further comprises inserting a plug into the fill valve for preventing entry of contaminants and preventing release of gaseous fuel from the fuel container; wherein, the plug is formed by a method including the step of injecting a molten plastic material into a mold cavity and cooling the mold to solidify the plastic material.
In an embodiment of the present disclosure, the method comprises forming an unitary body with an outer surface and an inner cavity initiating from a tapered end of the outer surface.
The foregoing paragraphs have been provided by way of general introduction and are not intended to limit the scope of the following claims. The described embodiments, together with further advantages, will be best understood by reference to the following detailed description taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS:
The above and other objects, features, and advantages of the present disclosure will be more apparent from the detailed description taken in conjunction with the accompanying drawings. One or more embodiments of the present invention are now described, by way of examples only with reference to the accompanied drawings wherein like reference numerals represent like elements.
FIG.1 illustrates a gaseous fuel filling arrangement in a gaseous vehicle in accordance with the present disclosure;
FIG. 2 illustrates an enlarged view of a plug assembly provided on a fill valve assembly in accordance with the present disclosure;
FIG. 3A illustrates a three-dimensional view of the plug in accordance with the present disclosure;
FIG. 3B and 3C illustrate sealing provisions in the plug in accordance with the present disclosure;
FIG. 4 illustrates cross sectional view of the plug in accordance with the present disclosure; and
FIG. 5 illustrates cross sectional view of the plug in operational state with the micro-switch in accordance with the present disclosure.

LIST OF REFERENCE NUMERALS:
100 –Plug
101 – Grip Portion
102 – Inner Cavity
103 – Tapered End
104 – Micro Switch
105 – Filling Unit
110 – First O-Ring
115 – Second O-Ring
120 - Hole
125 – Cylinder
130 – Cylinder Valve
135 - Solenoid
140 – High Pressure Regulator
145 – Attachment String
150 – Fill Valve
155 – First Section
160 – Second Section
165 – Third Section

DETAILED DESCRIPTION
Embodiments of the present disclosure are best understood by reference to the figures and description set forth herein. All the aspects of the embodiments described herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit and scope thereof, and the embodiments herein include all such modifications.
As used herein, the term ‘exemplary’ or ‘illustrative’ means ‘serving as an example, instance, or illustration.’ Any implementation described herein as exemplary or illustrative is not necessarily to be construed as advantageous and/or preferred over other embodiments. Unless the context requires otherwise, throughout the description and the claims, the word ‘comprise’ and variations thereof, such as ‘comprises’ and ‘comprising’ are to be construed in an open, inclusive sense, i.e., as ‘including, but not limited to.’
FIG.1 refers to an embodiment of the present invention with reference to a gaseous fuel filling arrangement in a vehicle. The gaseous fuel filling process may employ exemplary fuels like CNG (compressed natural gas), although other gaseous fuels such as Liquefied petroleum gas (LPG), liquefied natural gas (LNG) may be used, begins at the vehicle's fill valve (150). The fill valve (150) is of NZS (New Zealand standard) filing unit. The fill valve (150) is connected to a storage cylinder (125) and is where a fueling nozzle (not shown) of the fueling gun is attached. There is a cylinder valve (130), which is used to control the release of gas from the cylinder (125) providing a regulated gas supply when needed. Once the cylinder (125) has been filled, the fill valve (150) is closed, and the cylinder valve (130) remains sealed until the gas is required. When opened, the cylinder valve (130) allows gas to flow out, often through a pressure regulator, to ensure a controlled and safe release. A solenoid (135) in the filling valve (150) is used to automate and precisely control the gas. It may be an electromagnetic actuator that opens or closes the fill valve (150) based on an electrical signal, making the filling process more efficient, safe, and reliable. A high-pressure regulator (140) in a CNG (Compressed Natural Gas) cylinder (125) plays a critical role in reducing the high-pressure gas stored in the cylinder (125) to a safe and usable level for vehicle operation. The fill valve (150) is open to atmosphere and as the vehicle is transported from one place to another, there is a tendency that dust, contaminants and water are collected at the fill valve (150), and as the nozzle is connected for filling operation, there is a tendency that there may be hindrance to refueling operation of the cylinder (125). As depicted in FIG.1 and with reference to FIG. 2 where an enlarged view of the plug (100) is shown, the plug (100) is inserted in the fill valve (150), which seals and prevents any dust or other contaminants to reach the fueling channel. In conditions, when fuel filling needs to be done the plug (100) is removed from its position in order to insert the nozzle in the fill valve (150).
Referring to FIG.3A, 3B, 3C, and 4, the plug (100) has been described in detail in the following paragraphs. The plug (100) comprises a hollow body having an outer surface, an aperture providing an inner cavity (102) to a substantial portion inside the plug (100). The plug (100) comprises plurality of sections axially positioned one behind the other, number may vary based on design and requirements. The first section (155) is open to external atmosphere tapered (103) at an angle of 25 to 40 degrees preferably 37 degrees towards the inner cavity (102) to collect contaminants in the inner cavity (102) of the plug (100). The second section (160) of the plug (100) having a length of 45 mm to 60 mm preferably 49 mm, preferably comprising two sealing rings at two locations spaced at different distances for preventing the entry of contaminants into the fueling port system and preventing the release of gaseous fuel due to leaks or system failures when the plug (100) is inserted into the port. The sealing is facilitated preferably with the help of O rings (110,115), although other sealing components may be used. O-rings are circular elastomeric seals commonly made of materials like rubber or silicone. When placed in a groove or recess on the dust plug or the mating surface, they create a tight seal. This helps prevent the entry of dust, dirt, moisture, and other contaminants into the protected area, such as the CNG fill valve (150). These O-rings (110, 115) are made up of materials that are resistant to natural gas and the operating conditions of the system. O-rings further contribute to a proper seal while still allowing for the easy removal and reinsertion of the dust plug. This ensures that the protective barrier can be maintained without compromising the accessibility of the fill valve (150) when needed.
In a preferred embodiment, the O-rings (110, 115) are strategically placed at two locations in order to prevent outflow of gas from the upper portion and the lower portions of the plug (100). There is a non-return valve, (NRV) (not shown) proximate to the fill valve (150) which is a check valve that prevents backflow of gas during the filling (105) process. In case of a fault in the non-return valve (NRV), the NRV can stop working and hence, the gas will start leaking. The plug (100) will stop the leakage as it consists of the O rings (110,115) for sealing the gas. Faults in the NRV may arise due to spring rusting or spring getting stuck in the body or screw loosening, of the filling unit (105) due to wear or cut in some case. These failure modes will cause leakage through the NRV and gas will escape/leak to atmosphere. Plastic plug (100) will seal this gas and avoid further leakage.
The third section (165) of the plug (100) comprises a grip portion (101) having a length of 6 mm to 10 mm preferably 8 mm and a through hole (120) for engagement with an attaching means for theft prevention. The attaching means preferably refers to a string although other attachment means (145) may also be used, as shown in Figure 2 as well. The grip portion (101) of a plug (100) allows a person to grasp, hold, and manipulate the dust plug easily. This design feature is practical for the installation and removal of the plug (100), especially in situations where it needs to be accessed frequently or where manual dexterity is essential. Further, the grip portion (101) being made of a plastic material is resistant to heat as it possesses lower thermal conductivity especially when the fill valve (150) is placed inside the engine compartment and therefore transmit heat to the metal/alloy dust plugs as well. This may lead to user inconvenience, therefore in the present invention, a combination of different plastic materials is incorporated to withstand such heat and provide operational convenience.
According to FIG. 4, a cross-sectional view of the plug (100) is depicted. The plug (100) comprises the hollow body having the outer surface, and the inner cavity (102). The at least one end of the plug (100) is tapered (103) and the inner cavity (102) is provided at the tapered (103) end to collect contaminants in the inner cavity (102) of the plug (100).
The inner cavity (102) of the plug (100) provided at the tapered end (103) comprising an inlet of diameter range of 4.0 mm to 5.0 mm preferably 4.5 mm. As the tapered end (103) is exposed to the external environment during vehicle running conditions, it attracts a lot of dust and contaminants at the external surface, hence, in the present embodiment, the external surface area has been reduced in order to effectively reduce contamination on surface and further gradual tapering enables that the dust collected at the exterior surface falls on the inner cavity (102) and hence, there is no contamination of the fill valve (150).
The plug (100) comprises of a unitary plastic body with an outer surface and an inner cavity (102) for sealing and protecting fueling ports in vehicular fueling systems. The plastic plug (100) is ridden with various manufacturing defects like warpage. Warpage is the deformation that can occur in injection molded parts when different parts of the part shrink unevenly. Further, there may be encumbrances of shrinkage, where contraction of a plastic molded component as it begins to cool after the injection process. The conventional molded plug may also face issues of blow holes defect, which may take the form of bubble shaped cavities beneath the surface of the molding.
Thus, in the present invention, the inner cavity (102) of the plug (100) extends axially along the length of the plug (100) having length of 50 mm to 60 mm preferably 55 mm, providing rigidity and strength to the plug (100). This ensures better flow of materials, avoiding defects of warpage, shrinkage, blow holes, also the hollow plug caters to weight reduction. There is also good control on dimensions and tolerances due to uniform wall thickness. The inlet aperture across the length of the plug (100) ensures efficient air ventilation, which is good for cyclic thermal effect, and effectively dissipates heat.
According to an embodiment of the invention, the plastic body of the plug comprises blend of polyamide 66 (PA66) and 50% glass fiber (GF) reinforcement, although other materials such as Polyethylene, Polypropylene, Polyvinyl Chloride, Polyethylene Terephthalate, Polystyrene, Polyurethane, Thermoplastic Elastomers, Polyethylene Chlorinates, Nitrile Rubber and other plastic family members may be considered. It's important to note that the choice of material for the dust plug depends on the specific requirements of the application, including the environmental conditions it will be exposed to, the desired level of protection, and any industry standards or regulations that must be met. The invention may also incorporate blends or modified versions of these materials to achieve specific performance characteristics in dust plugs. The choice of material helps in reduction of weight, reduces cost, and provides longevity to the plug (100).
Referring to FIG. 5, which depicts cross sectional view of the plug (100) in operational state with the micro-switch (104). The operation of a micro-switch (104) in the dust plug of the vehicles is typically associated with safety and control functions during the fueling process. The micro-switches (104) are small, sensitive electrical switches that are activated by mechanical force. The micro-switch (104) is positioned in such a way that it is activated or deactivated based on the presence or absence of the dust plug. The tapered (103) section enables operation of a micro-switch (104), when the dust plug is inserted. When the dust plug (100) is inserted into the fill valve (150), it triggers the micro-switch (104). The micro-switch (104) serves as a safety interlock mechanism. It ensures that the vehicle can only start when the dust plug is properly inserted into the fill valve (150). This information can be valuable for maintenance and troubleshooting.
Hence, the present invention is advantageous over the conventional dust caps in terms of catering to a plastic plug (100), which negates any dust or contaminant deposition on the external surface by reducing the surface area of the external surface, further this ensures that the vehicle is in operation only when the dust plug is in proper position providing sealing protection both to the contaminants and also to the gaseous outflow in case of valve failure. The plastic plug (100) further has less interference with plastic micro-switch (104) as there is no metal/ alloy contact reducing wear and tear of micro-switch (104) and enhanced longevity of the same. The present invention complies with regulatory standards and safety guidelines
Although the present disclosure has been described in terms of certain preferred embodiments, various features of separate embodiments can be combined to form additional embodiments not expressly described. Moreover, other embodiments apparent to those of ordinary skill in the art after reading this disclosure are also within the scope of this invention. Furthermore, not all the features, aspects and advantages are necessarily required to practice the present disclosure. Thus, while the above detailed description has shown, described, and pointed out novel features of the invention as applied to various embodiments, it will be understood that various omissions, substitutions, and changes in the form and details of the apparatus or process illustrated may be made by those of ordinary skill in the technology without departing from the spirit of the invention. The inventions may be embodied in other specific forms not explicitly described herein. The embodiments described above are to be considered in all respects as illustrative only and not restrictive in any manner.
,CLAIMS:We Claim:

1. An inlet protection system for fuel container (125), in gaseous fuel vehicle, the system comprising:
a fill valve (150) for entry of gaseous fuel inside the fuel container (125); and
a plug (100) inserted into the fill valve (150) for preventing entry of contaminants and preventing release of gaseous fuel from the fuel container (125), wherein, the plug (100) is made up of Plastic material selected from the group of materials comprising nylon or polymer.

2. The system as claimed in claim 1, wherein the plug (100) has at least one end (103) and an aperture provided at the at least one end (103).

3. The system as claimed in claim 2, wherein the at least one end (103) of the plug (100) is tapered.

4. The system as claimed in claim 2, wherein the aperture provides an inner cavity (102) inside the plug (100).

5. The system as claimed in claim 4, wherein the inner cavity (102) is having a diameter in the range of 4.0 mm to 5.0 mm and extending axially along the length of the plug (100) having a length of 50 mm to 60 mm, providing rigidity and strength to the plug (100).

6. The system as claimed in claim 1, wherein the plug (100) comprises provision for accommodating at least one sealing ring for closing the fill valve (150) to prevent gas contamination and preventing leakage of gaseous fuel.

7. The system as claimed in claim 1, wherein the plug (100) comprises of plurality of sections (155, 160, 165) axially positioned one behind the other.

8. The system as claimed in claim 7, wherein the first section (155) of the plug (100) is tapered (103) at the end at an angle of 25 to 40 degrees towards the aperture to collect contaminants in the inner cavity (102) of the plug (100).

9. The system as claimed in claim 7, wherein the second section (160) of the plug (100) having a length of 45 mm to 60 mm comprising two sealing portions (110,115) accommodating two sealing rings at two locations spaced at distances apart for preventing the release of gaseous fuel when the plug (100) is inserted into the fill valve (150).

10. The system as claimed in claim 7, wherein the third section (165) of the plug (100) comprises of a grip portion (101) having a length of 6 mm to 10 mm and a through hole (120).

11. The system as claimed in claim 1, wherein the plastic material comprises of blend of polyamide 66 (PA66) and 50% glass fiber (GF) reinforcement.

12. The system as claimed in claim 1, wherein the plug (100) actuates a micro-switch (104), the micro-switch (104) is configured to detect the presence or absence of the plug (100) within the fill valve (150).

13. A method for inlet protection for fuel container (125), in gaseous fuel vehicles, the method comprising:
positioning a fill valve (150) in the fuel container (125) for entry of gaseous fuel;
inserting a plug (100) into the fill valve (150) for preventing entry of contaminants and preventing release of the gaseous fuel from the fuel container (125), wherein, the plug (100) is formed by a method including the steps:
injecting a molten plastic material into a mold cavity; and
cooling the mold to solidify the plastic material.

14. The method as claimed in claim 13, wherein the method of forming the plug comprises step of forming an inner cavity (102) within the plug using mold cavity wherein the inner cavity initiating from a tapered end (103) of an outer surface of the plug.