[001] The present invention relates to a cap assembly, more specifically relates to a fuel tank cap assembly.
BACKGROUND
[002] Fuel tanks are used to store flammable fluids safely. Automobiles are powered by fuels and hence, are provided with fuel tanks for storage of fuel. A fuel tank is provided with an opening and/or port (also referred as ‘neck’) at its upper surface so that fuel can be refilled in the fuel tank. The opening/port of the fuel tank is covered by a fuel tank cap.
[003] Fuel tank cap is a crucial component of a fuel tank. The fuel tank cap helps to eliminate release of fumes and/or gas vapours from the fuel tank into the atmosphere by providing a tight seal at the opening/port. Further, the fuel tank cap prevents water, dirt, debris from entering the fuel tank thereby, eliminating any chance of contamination of the fuel.
[004] However, conventional fuel tank caps do not provide the necessary security to prevent fuel theft from the caps due to inefficient locking mechanisms provided with the caps. In addition to the above, the conventional caps provide fewer key combinations, which further enhances the problem of security of the caps. Moreover, the conventional caps have a reduced surface area and diameter which reduces the gripping area for the user to open/close the cap. Further, reduced diameter and surface area may impact the coupling of various components of the cap.
[005] Therefore, there exists a need for an improved fuel tank cap that overcomes the limitations of the existing caps.
SUMMARY
[006] The present invention relates to a fuel tank cap configured to be mounted over a fuel tank. The fuel tank cap includes a cover having a pre-defined outer diameter to enhance gripping of a fuel tank cap. The fuel tank cap further includes a barrel coupled to the cover and a lock bar. The barrel includes a first end and a second end. The first end has a key insertion area while the second end includes a protrusion. The barrel further includes a plurality of slots disposed between the first end and the second end. At least one of the plurality of slots configured to receive a key plate. The lock bar includes an upper cavity structured to receive the protrusion. The upper cavity includes a first wall and a second receiving portion. At least one of the plurality of slots are equipped to interchangeably receive key plates to result in a pre-defined number of key combinations thereby minimizing thefts and enhancing security of the fuel tank.
[007] The protrusion is slidably coupled to the upper cavity of the lock bar. On rotation of a key, the protrusion of the barrel is configured to slide within the upper cavity and be seated within the second receiving portion to produce a ratchet sound thereby facilitating locking of the cap on a filler neck.
[008] The foregoing features and other features as well as the advantages of the invention will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures.
BREIF DESCRIPTION OF DRAWINGS
[009] The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the apportioned drawings. For the purpose of illustrating the present disclosure, exemplary, constructions of the disclosure are shown in the drawings. However, the disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale.
[010] Fig.1 illustrates an exploded view of a fuel tank cap 100 in accordance with an embodiment of the present invention.
[011] Fig. 1a illustrates a cross-sectional view of a fuel tank cap 100 in accordance with an embodiment of the present invention.
[012] Fig. 1b illustrates a top view of a cover 10 in accordance with an embodiment of the present invention.
[013] Fig. 2a illustrates a front view of a lock bar 50 in accordance with an embodiment of the present invention.
[014] Fig. 2b illustrates an isometric view of the lock bar 50 in accordance with an embodiment of the present invention.
[015] Fig. 3 illustrates a flow chart depicting a method of locking the cap 100 on a filler neck in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF DRAWINGS
[016] Prior to describing the invention in detail, definitions of certain words or phrases used throughout this patent document will be defined: the terms "include" and "comprise", as well as derivatives thereof, mean inclusion without limitation; the term "or" is inclusive, meaning and/or; the phrases "coupled with" and "associated therewith", as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have a property of, or the like; Definitions of certain words and phrases are provided throughout this patent document, and those of ordinary skill in the art will understand that such definitions apply in many, if not most, instances to prior as well as future uses of such defined words and phrases.
[017] Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment, but mean “one or more but not all embodiments” unless expressly specified otherwise. The terms “including,” “comprising,” “having,” and variations thereof mean “including but not limited to” unless expressly specified otherwise. An enumerated listing of items does not imply that any or all of the items are mutually exclusive and/or mutually inclusive, unless expressly specified otherwise. The terms “a,” “an,” and “the” also refer to “one or more” unless expressly specified otherwise.
[018] Although the operations of exemplary embodiments of the disclosed method may be described in a particular, sequential order for convenient presentation, it should be understood that the disclosed embodiments can encompass an order of operations other than the particular, sequential order disclosed. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Further, descriptions and disclosures provided in association with one particular embodiment are not limited to that embodiment, and may be applied to any embodiment disclosed herein. Moreover, for the sake of simplicity, the attached figures may not show the various ways in which the disclosed system, method, and apparatus can be used in combination with other systems, methods, and apparatuses.
[019] Furthermore, the described features, advantages, and characteristics of the embodiments may be combined in any suitable manner. One skilled in the relevant art will recognize that the embodiments may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments. These features and advantages of the embodiments will become more fully apparent from the following description and apportioned claims, or may be learned by the practice of embodiments as set forth hereinafter.
[020] In accordance with the present disclosure, a fuel tank cap (or cap) is disclosed. The cap may be mounted over a fuel tank provided with automobiles. The automobiles may include light commercial vehicles (LCVs), for example, pickup trucks, minibuses, three-wheeler vehicles, etc.
[021] The fuel tank cap of the present invention includes a plurality of components such as one or more of, a cover, a stator, a barrel, a lock bar, a ring, a sealing member, a contact plate, a resilient member, a case body, etc. The aforesaid components are coupled together to facilitate effective locking/unlocking of the cap over a filler neck of the fuel tank of the automobile.
[022] The cover of the cap has a larger outer diameter ranging from 60mm to 65mm. The larger diameter of the cap provides enhanced surface area for gripping the cap and also improves mating of other components (described in below paragraphs) of the cap with the cover.
[023] The barrel of the present invention is provided with a plurality of slots for receiving corresponding key plates. The key plates may be structured to be placed in the slots interchangeably resulting in a plurality of key combinations. The cap of the present invention provides significantly more key combinations as compared to conventional caps. The cap of the present invention provides more than a thousand key combinations leading to enhanced safety of the fuel tank.
[024] The lock bar of the cap includes at least one cavity of a predefined shape configured to be coupled with the barrel to facilitate locking/unlocking of the cap. The lock bar is housed within the stator in such a way that the barrel slides inside the cavity of the lock bar upon rotation of the cover to facilitate the locking of the cap. The locking of the cap may be indicated by a ratchet sound. Such locking/unlocking of the cap mediated by the lock bar and barrel results in
[025] Further owing to the sealing member, the cap of the present invention provides minimum sealing compression which complies with the BS-6 norms.
[026] Now moving specifically to drawings, Fig.1 illustrates an exploded view of a fuel tank cap 100 (or a fuel tank cap assembly 100 or a cap 100). As evident, the cap 100 includes a cover 10, a case 20, a stator 30, a barrel 40, a lock bar 50, a valve 60, etc.
[027] The cover 10 may be made of a durable material such as but not limited to plastic, zinc, aluminium, nylon, etc. In an embodiment, the cover 10 is made of nylon 6 with 15% glass fiber. The cover 10 may be resistant to wear and tear.
[028] The cover 10 may include a pre-defined shape including without limitation, circular, oval, rectangular, etc. In an embodiment, the cover 10 is circular. The cover 10 may have a predefined outer diameter ranging from 60mm to 65mm (which is larger than conventional covers). In an embodiment, the cover 10 has a diameter of 60mm. The larger outer diameter of the cover 10 helps in providing enhanced grip to the user and also facilitates mating of other components (described in below paragraphs) of the cap 100 with the cover 10.
[029] The cover 10 may include a top surface 11, as depicted in Fig. 1a. The top surface 11 of the cover 10 may be provided with a rotatable closure means 11a as shown in FIGs. 1 and 1a. The closure means 11a may include without limitation, a lid, a cap, a flap, etc. In an embodiment, the closure means 11a is in the form of a flap. The closure means 11a is provided to cover a key insertion area (not shown) of the cap 100 thereby preventing the exposure of the key insertion area to dust, debris, water, and/or other harsh conditions which may impact the performance of the cap 100.
[030] The closure means 11a may be made of same and/or different material as that of the cover 10. In an embodiment, the closure means 11a is made of the same material as the cover 10.
[031] The closure means 11a may include a pre-defined shape and dimensions that are sufficient to completely cover the key insertion area. In an embodiment, the closure means 11a is oblong shaped.
[032] The closure means 11a may be coupled on to the top surface 11 in such a way that closure means 11a temporarily covers the key insertion area of the cap 100 and the key insertion area may be easily uncovered by the user anytime. In an embodiment, the closure means 11a may be rotatably attached to the top surface 11 of the cover 10. The closure means 11a may be attached by means of a spring, a torsion spring, etc. In an embodiment, the closure means 11a is attached by means of spring.
[033] The closure means 11a may be capable of rotating in a clockwise and/or anti-clockwise direction. In an embodiment, the closure means 11a rotates in a clockwise direction. The closure means 11a may be rotated to expose the key insertion area of the cap 100 as and when required by the user. In an embodiment, the closure means 11a is rotated manually.
[034] Further, the top surface 11 may include a stopper 11b. The stopper 11b may be an integral part of the cover 10 or may be attached to the cover 10 externally via an attachment means. The stopper 11b may be placed adjacent to the closure means 11a. The stopper 11b is provided to restrict unwanted/accidental rotation of the closure means 11a, thereby significantly reducing damages to the closure means 11a and/or also, limiting the exposure of key insertion area to harsh conditions.
[035] The stopper 11b may be provided in any shape such as but not limited to a circular shape, a triangular shape, etc. In an embodiment, the stopper 11b is triangular shaped.
[036] The cover 10 may be a moulded structure and has a plurality of internally formed cavities to secure the case 20. The case 20 may be permanently or removably attached to the cover 10. In an embodiment, the case 20 is permanently attached with the cover 10.
[037] The case 20 may be attached with the cover 10 by means of a ring 23 and a sealant 25 (as depicted in FIGs. 1 and 1b). The ring 23 may include a plurality of indents 23a. In an embodiment, the ring 23 includes three indents 23a. The plurality of indents 23a may be inserted inside the plurality of cavities of the cover 10 in order to engage the case 20 with the cover 10.
[038] The ring 23 may be made of, without limitation plastic, zinc, aluminium, nylon, etc. In an embodiment, the ring 23 is made of nylon 6 with 30% glass fiber.
[039] The ring 23 may have a predefined diameter ranging from 95.0mm to 95.5mm. In an embodiment, the diameter of the ring 23 is 95.3mm. The case 20 may be a cylindrical structure having a length ranging from 40.20mm to 41.20mm. In an embodiment, the length of the case 20 is 40.7mm.
[040] The case 20 may include a plurality of threads 21 on its outer surface. The plurality of threads 21 may be provided to engage with the neck of the fuel tank as described below. The plurality of threads 21 may have a predefined pitch ranging from 6.1mm to 6.9mm. In an embodiment, the thread 21 has a pitch of 6.5mm. The case 20 may alternately include any other mechanism to engage with the fuel tank.
[041] Further, the cover 10 along with the case 20 may be used to house a plurality of other components of the cap 100, such as but not limited to the stator 30, the barrel 40, the lock bar 50, the valve 60, etc. The aforesaid components are functionally coupled in a predefined manner in order to facilitate locking/unlocking of the cap 100.
[042] The stator 30 (as shown in Fig.1) of the cap 100 may be made of a durable material including but not limited to plastic material, zinc, aluminium or its alloy, etc. In an embodiment, the stator 30 is made of nylon 6 with 50% glass fiber. The stator 30 acts as a protective cover for other components provided within the stator 30 (described below). The stator 30 also provides structural integrity to the cap 100. The stator 30 provides a space for receiving a key when the user inserts the key into the cap 100 through the key insertion area for locking/unlocking the cap 100 on the neck.
[043] The stator 30 may have a predefined shape and dimension. In an embodiment, the stator 30 is a hollow cylinder. The stator 30 may be a moulded hollow cylinder having a plurality of predefined cavities to accommodate other components. The stator 30 may have a length ranging from 40.2mm to 41.0mm. The stator 30 may have a diameter ranging from 22.0mm to 22.6mm. In an embodiment, the length and diameter of the stator 30 are 33mm and 34mm, respectively.
[044] The stator 30 may be used to house the barrel 40 of the cap 100 and hence, the barrel 40 is coupled to the cover 10 via the stator 30. It is to be noted that the shape and dimensions of the stator 30 may be varied as per the shape and dimensions of the barrel 40.
[045] The barrel 40 may be a cylindrical structure used to lock and/or unlock the cap 100 with the help of the key. The barrel 40 may include two ends opposite to each other, for example, a first end 40a and a second end 40b. The distance between the first end 40a and the second end 40b may define the length of the barrel 40. The length of the barrel 40 may be in a range of 33.80mm to 34.4mm. In an embodiment, the length of the barrel 40 is 34.1mm. The first end 40a may be disposed towards the cover 10. The barrel 40 may include the key insertion area towards the first end 40a.
[046] The barrel 40 may include a plurality of slots 40c disposed between the first end 40a and the second end 40b. The said slots 40c may include a predefined shape and pre-defined dimensions. In an embodiment, the slots 40c are rectangular in shape and are linearly disposed in a column as shown in FIG. 1b.
[047] At least one of the slots 40c is structured to interchangeably receive a corresponding key plate 40c1. The key plates 40c1 may be similar or different from each other. In an embodiment, all key plates 40c1 are different. At a given time, each of the slots 40c may receive a corresponding key plate 40c1. Alternately, some of the slots 40c may receive the key plate 40c1 while the others may be empty. The different combinations (mating) of the key plates 40c1 and the slots 40c may result in different key combinations. The mating between the one or more slots 40c and the corresponding key plate(s) 40c1 may be performed at the time of assembly of the cap 100.
[048] In an embodiment, the cap 100 of the present invention is manufactured with a pre-defined combination out of more than a thousand key combinations. In an exemplary embodiment, there are eight number of slots 40c that help in creating thousand to three thousand key combinations. Hence, as there are more than thousand key combinations, the chances of a key for a cap 100 being able to lock/unlock another cap 100 is significantly minimized thereby leading to enhanced safety of the fuel tank. The possibility of having the said key combinations increases the security of the cap 100 by minimizing thefts.
[049] In an embodiment, the second end 40b of the barrel 40 includes a protrusion 40b1 (as depicted in Fig.1b). The protrusion 40b1 of the barrel 40 may engage with the lock bar 50 to facilitate locking/unlocking of the cap 100, as explained below. The predefined shape of the protrusion 40b1 may include a rectangular shape, a square shape, etc. In an embodiment, the protrusion 40b1 is shaped in a rectangular shape.
[050] The lock bar 50 may include a pre-defined structure as shown in FIGs. 2a and 2b. In an embodiment, the lock bar 50 may be rectangular shaped block having a top surface 50a and a bottom surface 50b. The top surface 50a may be provided with an upper cavity 51. Likewise, the bottom surface 50b may be provided with a lower cavity 53.
[051] The upper cavity 51 may have a shape such as but not limited to a U shape, a rectangular shape, etc. In an embodiment, the upper cavity 51 is L- shaped. The shape of the upper cavity 51 may be defined by a first wall 51a and the second wall 51b. The first wall 51a and the second wall 51b may have similar or different heights ‘H’. In an embodiment, the first wall 51a and the second wall 51b have a similar height ‘H’. The first wall 51a and the second wall 51b may have a height ‘H’ in a range of 3.5 mm to 4.0 mm. In an embodiment, the height of the first wall 51a and the second wall 51b is 3.6 mm and 3.8 mm respectively. Further, the first wall 51a and the second wall 51b may have similar or different widths ‘W’. In an embodiment, the first wall 51a and the second wall 51b have different widths ‘W’ as depicted in Fig. 2b. The second wall 51b may be shorter than the first wall 51a. The width ‘W’ of the first wall 51a may be in a range of 7.0 mm to 8.0 mm, and width ‘W’ of the second wall 51b may be in a range of 4.0 mm to 5.0 mm. In an embodiment, the width ‘W’ of the first wall 51a is 7.0 mm, and the width ‘W’ of the second wall 51b is 4.0 mm.
[052] The shorter width of the second wall 51b results in the formation of a second receiving portion 51c which is used to receive the protrusion 40b1 of the barrel 40 (described below in detail). The second receiving portion 51c is structured and dimensioned based upon the dimensions of the protrusion 40b1. Such complimentary structure and dimensions of the second receiving portion 51c and the protrusion 40b1 eliminates any chances of slippage of the barrel 40 when the protrusion 40b1 slides within the upper cavity 51.
[053] The lower cavity 53 of the lock bar 50 may be provided with a first resilient member 53a. The first resilient member 53a may aid in locking and unlocking of the cap 100.
[054] The lock bar 50 may be disposed inside a cavity (not shown) of the stator 30. The lock bar 50 may be disposed in such a way that the protrusion 40b1 of the barrel 40 is slidable within the upper cavity 51 of the lock bar 50 in order to lock/unlock the cap 100 as depicted in Fig.3. The protrusion 40b1 may be slidable from the first wall 51a of the upper cavity 51 till the second wall 51b of the upper cavity 51.
[055] The first resilient member 53a helps in movement of the protrusion 40b1 of the barrel 40 within the upper cavity 51 of the lock bar 50 thereby facilitating locking/unlocking of the cap 100 as described in detail below.
[056] Further, the cap 100 includes a valve 60 used to maintain adequate gaseous pressure inside the cap 100. The valve 60 may be housed inside the case 20 as depicted in Fig.1b. The valve 60 may be fixed inside the case 20 with the help of a plate 61 and a second resilient member 63. The plate 61 may be made of without limitation, plastic, stainless steel. In an embodiment, the plate 61 is made of stainless steel. The plate 61 may have a diameter ranging from 23.3mm to 23.8mm. In an embodiment, the plate 61 has a diameter of 23.5mm.
[057] The plate 61 of the valve 60 may lift up with the help of the second resilient member 63 in order to release excess air to the atmosphere in case of positive pressure within the fuel tank and to intake air into the fuel tank in case of negative pressure.
[058] The method of locking the cap 100 over the filler neck of the fuel tank is explained below, as depicted in Fig.3. The cap 100 may include at least two operational states i.e. a locked state and an unlocked state. The locked state corresponds to the state in which the protrusion 40b1 of the barrel 40 is seated within the second receiving portion 51c of the lock bar 50. The unlocked state corresponds to the state in which the protrusion 40b1 of the barrel 40 is in contact with the first wall 51a of the lock bar 50.
[059] The cap 100 is initially detached from the filler neck of the fuel tank and is in locked state. In order to fix the cap 100 on the filler neck, the cap 100 is first unlocked with the help of key at step 301. In this step, the closure means 11a present on the cover 10 is rotated i.e. moved downwards in a clockwise direction to expose the key insertion area on the cover 10.
[060] At step 303, a key is inserted in the key insertion area and rotated at an angle of 90° in the clockwise direction. The said rotation of the key unlocks the cap 100.
[061] At step 305, the cap 100 is adequately placed on the filler neck such that the threads 21 of the case 20 mate with the filler neck. Once the cap 100 is properly placed over the filler neck, the case 20 is rotated in a clockwise direction, a predefined number of times until a sufficient amount of torque is applied such that the case 20 cannot over tighten on the filler neck. The predefined number of times may be in a range of 3 to 5. In an embodiment, the case 20 is rotated three times.
[062] At this stage on rotation of the key, the protrusion 40b1 of the barrel 40 slides within the upper cavity 51, reaches the second wall 51b and is seated within the second receiving portion 51c over the lock bar 50. Optionally, the seating of the protrusion 40b1 may produce a ratchet sound. The ratchet sound is an indicator of locking of the cap 100 on the filler neck. Once the cap 100 is sufficiently tightened over the filler neck, the cover 10 can be rotated freely in any direction.
[063] At step 307, the key may be rotated at an angle of 90° in the anti-clockwise direction in order to be removed from the cap 100.
[064] Likewise for unlocking the cap 100, the closure means 11a present on the cover 10 is rotated i.e. moved downwards in a clockwise direction to expose the key insertion area on the cover 10. The key is inserted in the key insertion area and rotated at an angle of 90° in the clockwise direction. Such rotation causes the protrusion 40b1 to slide within the upper cavity 51 and come in contact with the first wall 51a. The cap 100 is then rotated in an anticlockwise direction and subsequently removed from the filler neck.
[065] The above-described preferred embodiments of the present invention is not intended to limit the present invention, any modification within the spirit and principles of the present invention, made by the equivalent replacement, improvement, etc., should be included in the protection of the present invention within the range.
[066] The scope of the invention is only limited by the appended patent claims. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings of the present invention is/are used.

WE CLAIM

1. A fuel tank cap (100) configured to be mounted over a fuel tank, the fuel tank cap (100) comprising:
• a cover (10) having a pre-defined outer diameter to enhance gripping of a fuel tank cap (100);
• a barrel (40) coupled to the cover (10), the barrel (40) having a first end (40a) and a second end (40b), the first end (40a) including a key insertion area, the second end (40b) having a protrusion (40b1), the barrel (40) further including a plurality of slots (40c) disposed between the first end (40a) and the second end (40b); and
• a lock bar (50) having an upper cavity (51) structured to receive the protrusion (40b1), the upper cavity (51) having a first wall (51a) and a second receiving portion (51c),
wherein at least one of the plurality of slots (40c) is equipped to interchangeably receive a key plate (40c1) to result in a pre-defined number of key combinations thereby minimizing thefts and enhancing security of a fuel tank;
wherein on rotation of a key, the protrusion (40b1) of the barrel (40) is configured to slide within the upper cavity (51) and be seated within the second receiving portion (51c) thereby facilitating locking of the fuel tank cap (100) on a filler neck.
2. The fuel tank cap (100) as claimed in claim 1, wherein the protrusion (40b1) of the barrel (40) is configured to slide within the upper cavity (51) and be seated within the second receiving portion (51c) to produce a ratchet sound on rotation of the key.
3. The fuel tank cap (100) as claimed in claim 1, wherein the fuel tank cap (100) includes a case (20) having a plurality of threads (21) to engage with the filler neck.
4. The fuel tank cap (100) as claimed in claim 1, wherein the key insertion area is covered by a rotatable closure means (11a).
5. The fuel tank cap (100) as claimed in claim 4, wherein the closure means (11a) is provided with a stopper (11b) for preventing unwanted/accidental rotation of the closure means (11a).
6. The fuel tank cap (100) as claimed in claim 1 wherein the pre-defined outer diameter ranges from 60mm to 65mm.
7. The fuel tank cap (100) as claimed in claim 1 wherein the lock bar (50) includes a lower cavity (53) having a first resilient member (53a) for facilitating locking/unlocking of the fuel tank cap (100).
8. The fuel tank cap (100) as claimed in claim 1 wherein the case (20) is attached with the cover (10) by means of a ring (23) and a sealant (25).
9. The fuel tank cap (100) as claimed in claim 1 wherein the fuel tank cap (100) includes a valve (60) to release excess air to the atmosphere in case of positive pressure within the fuel tank and intake air into the fuel tank in case of negative pressure.
10. The fuel tank cap (100) as claimed in claim 1 wherein the barrel (40) and the lock bar (50) are disposed inside a stator (30). ,