FIELD OF INVENTION
The present invention relates to n fuel tank assembly for vchiclcs and more
particularly to a hermetic fuel tank assembly for ethanol fuel vehicles such as motor
cycles, scooters, moped, scooty, and the like.
BACKGROUND OF THE INVENTION
The statements this section merely provide ba~k~round'informatiroenla ted
to the present disclosure and inay not cullstit-ute prior art(s).
Generally, the automotive vehicles.are equipped with a fuel level sensor in a
fuel tank to sense or indicate the level of the fuel remaining in the fuel tank.
Examples of such fuel level sensors include the subject matters disclosed in 250933,
262944, 256778, and the like. Typically, the fuel level sensors are known for
sensingldetecting the level of stored fuel in a fuel tank of a vehicle. The fuel 'level
sensors typically coinprises of a.float and its arm in a fuel tank which includes a
variable impedance element whose impedance varies in proportion to the fuel level in
the fuel tank. This impedance is read by a coil-type fuel gauge mounted in a vehicle
information display instrument positioned in fiont of a rider'sldriver's seat of the
vehicle. Thus, a signal corresponding to the level of the fuel as sensed by the fuel
level sensor can be transmitted to the gauge to informthe level of the fuel remaining
in the fuel tank. Further, .the purely mechanical fuel .level sensor includes the float, a
spiral strip of metal, and the fuel gauge. In operation, the float 'moves according to the
fuel level in a vertical direction along the spiral strip of metal, which is attached to 'an
indication needle of the fuel gauge. As the fuel level rises and lowers, the float'causes
the strip of metal to turn, thus moving the indication needle of the fuel gauge and
informing the rider about the current fuel level, preferably by indicating the same in
the information display instrument device of the vehicles.
Conventionally, the fuel level sensors are provided with an arm having a
buoyant member i.e. the float at the end of the arm. The arm is pivotally mounted to a
frame assembly via a housing that accommodates a carrier that carry plurality of
movable contact members on a ceramic resistor card. The ceramic resistor card
includes multiple traces that typically extend out like the spokes of a wheel in an arc
that is approximately of 85 degrees. Thus, as the level of the fuel changes, the float
#moves up and down and causes the arm to which it is attached to change its angle and
therefore move the contact along the arc shaped conductive traces of the ceramic
resistor card, which subsequently sends a signal to the fuel level indicator. These
ceramic based fuel level sensors are open and exposed to the fuel in the fuel tank.
Usually, these fuel level sensors employ silver (Ag) based conductive inks (Ag, Pd,
Pt) and high contents silver contacts (Paliney6, Ag/Ni). These materials function in
fuels that contain moderate sulfur level or may be in a bio fuel such as ethanol based
fuel (mainly used in automobiles in US and Brazil) that subsequently results in thin
lacquer contamination or a complete deterioration of the fuel level sensors. In other
words, these silver based fuel level sensors produce opens or a shift in resistance
when exposed to such extremely reactive fuel. These existing fuel level sensors, when
subjected to such ethanol based fuel, demands a regular servicing, maintenance and
thus replacement resulting in enhanced overall cost of the fuel level sensors.
Moreover, considering the advantages of the bio fuel on the individual and the
environment, there must be an improved fuel unit assembly suitable to the
requirements of the modem vehicles in India and abroad as well.
Various attempts have been made to replace the conventional fuel unit
assembly to meet the necessities of the present fuel unit assembly in all kinds of
vehicles. However, the concepts could not be commercially accepted due to some
drawbacks such as absence of non-degradable components, failure in achieving a
shielded structure for -the fuel unit assembly, extensive cost with respect to the
.manufacturing of a suitable fuel unit assembly, and the like.
Hence, there is an urgent need for an improved fuel unit assembly that can
provide a reliable sealing mechanism for the fuel unit assembly that is dimensionally
stable when exposed to the harsh contents available in the ethanol based fuel, -thus
subsequently limiting the exposure of fuel level sensors to the liquid surroundings
that consequently reduces the particulate contamination, sulfination, dendric growth,
and the like. Therefore, we need an advanced fuel unit assembly without losing the
basic requirements of reliability, safety, less cost, customers' satisfaction and the like.
BRIEF SUMMARY AND OBJECTIVES OF THE INVENTION
The present subject matter relates to a hermetic fuel unit assembly for ethanol
fuel vehicles that includes a top plate suspended from the top inside of a fuel tank to
hold a fuel unit assembly, a central lower annular arm extending down fiom the
center of the top plate, a bracket snap-fitted to the extending arm of the top plate, and
a U-shaped housing operably connected to the bracket by. fasteners. The U-shaped
housing is provided with a base wall and atleast four side walls extending generally
perpendicular to the base wall to create an enclosed compartment. The enclosed
compartment according to the present subject matter includes a thin film resistor
disposed in the enclosed compartment of the U-shaped housing, a wiper placed above
the thin filrn resistor in the enclosed compartment for movement along an arc shaped
conductive trace carved on the thin filrn resistor. The present subject matter further
discloses that the U-shaped housing is hermetically shielded by a first cover by
ultrasonic welding., The first cover is provided with an aperture extending there
through the first cover wherein the aperture is covered by a second carrier projected
to receive a float arm with a float floating in the ethanol fuel in the fuel tank. The
structure is uniquely provided with a second cover covering the second carrier
providing the path for guiding the movement of float arm in the ethanol fuel in the
fuel tank. The hermetic fuel tank assembly for ethanol fuel vehicles according to the
present subject matter advantageously facilitates a completely shielded fuel unit
assembly that can be implemented in ethanol fuel or a fuel comprising gasoline and
ethanol wherein the,percentage of ethanol ranges fiom 25% to 100%.
An object of the present subject matter is to provide the vehicle with the fuel
tank, an engine mounted ahead of a rider's seat, brake lights, tail lights, and other
necessary components of the vehicle.
An object of the present subject matter is to provide the fuel tank with a fuel
supply port formed on the upper surface of the fuel tank.
An object of the present subject matter is to close the fuel supply port by a cap
unit.
An object of the present subject matter is to provide the fuel unit assembly
with sensors/detectors for sensingldetecting the level of stored fuel in a fuel tank of a
vehicle.
An object of the present subject matter is to provide the top plate with atleast
four spaced aperture to receive fasteners for connecting the top plate to the inside top
of the fuel tank.
An object of the present subject matter is to fasten the structures with screws,
snaps, rivets, buttons, zippers, and the like.
Another object of the present subject matter is to structure the lower surface
of the top plate with a knife edge surface that engages a flat rubber gasket to securely
seal the opening of the fuel tank.
Another object of the present subject matter is to configure the top plate with
atleast two bee-hive shaped structures to receive a plurality . of terminals.
Another object of the present subject matter is to provide the fuel unit with
rubber insulation in order to protect the terminal from shortening out.
Another object of the present subject matter is to rivet the wiper with metallic
contacts to move on the thin film resistor for sensing the resistance value
corresponding to the level of the fuel remaining in the fuel tank of the vehicle.
, . Another object of the present subject matter is to hermetically seal the first
cover and the U-shaped housing by ultrasonic welding.
Yet another object of the present subject matter is to fix an elastomeric seal in
the aperture wherein the seal is tightly gripped on a first carrier implanted on the thin
film resistor.
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Another object of the present subject matter is to provide the second carrier
that covers the aperture.
Another object of the present subject matter is to connect the first cover and
the U-shaped housing in a completely shielded environment.
Yet anothcr~objcct of thc prcscnt subject matter is to apply the fuel wit
assembly in ethanol fuel vehicles as well as other kind of fuel vehicles.
Yet another object of the present subject matter is to manufacture the Ushaped
housing, the first cover, the second cover, the carriers, the top plate, and the
fasteners with plastic.
Yet another objective of the present invention is to provide an easy, compict,
less costly and advanced hermetic fuel unit assembly for ethanol fuel vehicles.
BRIEF DESCRIPTION OF DRAWINGS
The summary narrated above and the following detailed description of the
invention can be understood with the drawings appended to this claim. The
illustrations provide' the 'details of the invention. However, it should be understood
that the invention is not limited to the arrangements shown. In the drawings: .
FIG. 1 show a perspective view of an ethanol fuel vehicles in an embodiment of the
present subject matter..
FIG. 2 shows a 'perspective view of a fuel tank of the ethanol fuel vehicles in an
embodiment of the present subject matter.
FIG. 3 shows a front perspective view of a shielded fuel tank unit assembly for the
ethanol fuel vehicles in an embodiment of the present subject matter.
FIG. 4 shows a rear perspective view of a shielded fuel tank unit assembly for the I
ethanol fuel vehicles in an embodiment of the present subject matter.
,
FIG. 5A shows a perspective view of a U-shaped housing in the shielded fuel tank
unit assembly for the ethanol fuel vehicles in an embodiment of the present subject
matter.
FIG. 5B shows a perspective view of a first cover in the shielded fuel tank unit
assembly for the ethanol fuel vehicles in an embodiment of the present subject matter.
FIG. 5C shows a perspective view of a compartment inside the U-shaped housing in
the shielded fuel tank unit assembly for the ethanol fuel vehicles in an embodiment of
the present subject matter.
FIG. 5D shows a perspective view of a closed shielded fuel tank unit assembly for
the ethanol fuel vehicles in an embodiment of the present subject matter.
i
FIG. 5E shows a perspective view of a closed U-shaped housing in the shielded fuel
tank unit assembly for the ethanol fuel vehicles in an embodiment of the present
subject matter.
DETAILED DESCRIPTION OF THE INVENTION
The embodiments of the present subject matter are described in detail with
reference to the accompanying drawings. However, the present subject matter is not
- limited to these embodiments which are only provided to explain more clearly the
present subject matter to the ordinarily skilled in the art of the' present disclosure. In
the accompanying drawings, like reference alphabets and .numerals are used to
indicate like components.
The present invention relates to a fuel tank assembly for vehicles and more
particularly to a hermetic fuel tank assembly for ethanol fuel 'vehicles such as motor
cycles, scooters, 'moped, scooty, and the like. The following description is merely
exemplary in nature and is not intended to limit the present disclosure, application, or .
uses. The present invention will hereinafter be described in detail below as applied to
. *
a motor cycle 100. However, the, principles of the present invention are also
applicable to other vehicles 100 such as three wheelers, four wheelers, and the like.
Upward, lower, front and rear directions (see the directions indicated by the arrows in
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PIG. 1) will be described with respect to directions as seated by the rider on the
motorcycle 100.
FIG. 1 illustrates a two wheeler 100 that may include a fuel tank 102 and an
engine mounted ahead of a rider's' seat 104, a frame 106 and two relatively large sized
wheels 108 on which the frame 106 rides. The structure is necessarily provided with a
pair of left and right front fork members rotatably supported by a head pipe 110 on
the front end of the vehicle frame. The steering of the two wheelers 100 is possible
via a front wheel which is mounted on the front fork member whereas the 'rear wheel
(drive wheel) is at the rear end. FIG. 1 shows a handlebar 112 secured to an upper
portion of the front fork member, and the front and rear portion of the handle bar 112
is covered with a handle cover which is further divided into forward and'backward
portions. The two wheeler 100 are also provided with various lights mounted
externally on the vehicle to indicate certain information about the vehicle to other
drivers and pedestrians. These lights mainly include brake lights and tail lights
besides indicator light bulbs which are provided to indicate the driving direction of
the two wheelers. The two wheeler 100 is further provided with the intelligent vehicle
information display instrument 114 (as shown in FIG. 2 later) (also known as a
speedometer) located between the handle bars 112 of the two wheeler 100. The
vehicle information display instrument 114 may be viewable by the rider of the motor
cycle 100 when the rider is seated on the seat 104 and operating the vehicle 100. The
vehicle information display instrument 114 may be disposed generally in front of the
rider so that the rider can inspect or view a variety of information that form part of
the vehicle information display instrument 114, which information may indicate .an
operating condition or conditions of the vehicle. The vehicle information display
instrument 114 may be provided with audio/visual warning indicators comprising
information such as speed, the fuel level, telephone, bluetooth, rpm of the engine, tell'
tale symbols, turn signal indicator, hazard warning indicator and 1 or other indicators.
FIG. 1 further shows a headlight 116 provided, as an attachment to the top middle of
the handlebar of the motor cycle, to light the road ahead.
*
In an embodiment of the present subject matter, FIG. 2 discloses a
perspective view of the fuel tank 102 provided with a fuel supply port 118 formed on
the upper surface of the fuel tank 102. The fuel supply port 118 may be closed by a
cap unit (not shown) which is basically a cap to seal the fuel tank 102. The cap unit
can arbitrarily be opened and closed because its hinge portion is rotatably supported
through a hinge pin. In an embodiment of the present subject matter, the locking unit
incorporates a lock bar which is capable of moving/retracting sideward by means of.
an ignition key. The fuel tank 102 is further provided with a fucl pump (not shown)
mounted either externally to the fuel tank 102 or in the lowest portion of the inner
bottom surface of the fuel tank. The fuel pump and its function is not within the scope
of the present subject matter. In an embodiment of the present subject matter, the fuel
tank 102 is also provided with a fuel unit assembly for sensingldetecting the level of
stored fuel in a fuel tank of a vehicle. The fuel unit assembly may vary in
configuration, as discussed later, depending on the configuration of the fuel tank 102
and also on the basis of inserting the fuel level sensors into the fuel tank 102. The
present subject matter will hereinafter be described in detail below as applied to one
of the types of fuel unit assembly i.e. an adjustable lever type fuel unit assembly.
However, the principles of the present invention are also applicable to a second type
of fuel unit assembly i.e. a simple lever type fuel unit assembly.
In an embodiment of the present subject matter, FIG. 3 illustrates a
perspective view of a hermetic fuel unit assembly 200 (hereinafter may be referred as
fuel unit assembly) for ethanol fuel vehicles. In an embodiment of the present subject
matter, the herhetic fuel unit assembly 200 is structured of a top plate 202 suspended
f i o i the top inside of the fuel tank 102 to hold the fuel unit assembly 200. The top .,
plate 202, which is squarely shaped in configuration, is provided with atleast four
orderly spaced apertures 204 to receive fasteners (not shown) for connecting the top
plate 202 to the inside top of the fuel tank 102 in a preferred embodiment of the
present subject matter. The shape of the top plate 202 is not restricted within the '
scope of the present subject matter. In an embodiment of the present subject matter,
top plate 202 and the fasteners are preferably made of plastic in order to avoid the
I
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possibilities of reactions or hazards in ethanol fuel. The fasteners may include,
however not restricted to, screws, snaps, rivets, buttons, zippers, mushroom fasteners,
and the like. In an embodiment of the present subject matter, the lower surface of the
top plate. 202 is provided with a knife-edge surface that engages a flat rubber gasket
206 to securely seal the opening of the fuel tank 102. The top plate 202 is structured
with a snap-fit arrangement on the lateral sides of a central lower annular arm 208
extending down from the center of the top plate 202 in an embodiment of the present
subjcct mattcr. This cxtcnding arm 208 is designed to receive the snap fit of the upper
end of a plastic bracket 210 in a preferred embodiment of the present subject matter.
In an alternative embodiment (which is not shown), the bracket 210 may either be
threaded with the top plate 202 or press fitted with an appropriate locking adhesive.
The top plate 202 is further provided with atleast two integral beehive shaped
structures 212 to receive a plurality of terminals 214. The terminals 214 are
rectangularly shaped and are made of conductive material. In an embodiment of the
present subject matter, the fuel' unit assembly 200 may be provided with rubber
insulation or plastic insulation in order to protect the terminal 214 from shorte'ning
out. In an exemplary embodiment of the present subject matter, the top plate 202 is
operably connected to a U-shaded housing 216 via the bracket 210 by fasteners as
discussed hereinafter k t h reference to FIG. 4.
FIG. 4 illustrates a perspective view of the U-shaped shielded housing 216
provided with a base wall 218. and atleast four 'side walls 220 extending generally i
I perpendicular to the base wall 218 to create an enclosed compartment 222, in an I
I
embodiment of the fuel unit assembly 200 in accordance with the present subject
matter. The enclosed compartment 222 in the U-shaped shielded housing 216
I
disposes a thin film resistor 224 (also known as TFR) (as shown in FIG. 5A) and
operatively holded by atleast a clamp 226, in an embodiment of the present subject I
matter. The U-shaped shielded housing 216 further includes a wiper 228 placed
above the thin film resistor 224 in the compartment 222 for movement along an arc
shaped conductive trace carved on the thin film resistor 224, in an exemplary
embodiment of the present subject matter. The wiper 228 is riveted with metallic 1
contacts to move on the thin film resistor 224 for sensing the resistance value
corresponding to the instant fuel level in the fuel tank 102, as discussed later. In a
preferred embodiment of the present subject matter, the Wshaped shielded housing
216 is hermetically concealed by a first cover 230 to completely enclose the
'compartment 222 of the U-shaped 'shielded housing 216 as shown in FIG 5B. In gn
embodiment of the present subject matter, the U-shaped shielded homing 216 and the
first cover 230 are made of fuel resistant plastic, such as 'but not restricted to, acetyl
polymer. In m embodiment of thc prcscnt subject matter, the U-shaped shielded
housing 216 is connected to the first cover 230 by ultrasonic. welding. However,
various other processes such as laser welding, spin welding, heat plate joining,
vibration welding, and the like may be utilized to connect the U-shaped shielded
housing 216 and the first cover 230. In an exemplary embodiment, the first cover 230
is provided with an aperture 232 extending there-through the first cover 230. The
aperture 232 discloses an elastomeric rubber seal 234 tightly gripped on a first carrier
236 implanted on the thin film resistor 224, as shown in FIG 5C. In another
embodiment, the aperture 232 is covered by a second carrier 238 (please refer FIG.
SD) designed to receive a float arm 240 with a float 242 (shown in FIG. 3) floating in .
the ethanol fuel in the 'fuel tank 102. Further, the assembly as shown in FIG. 5D is
overlaid with a second cover 244 snap fitted (please refer FIG. 5E) (on a t l k t two
opposite sides) with the U-shaped housing 216 and the first cover 230 respectively, in
an embodiment of the present subject matter. The second cover 238 may also be
connected to the U-shaped housing 216 and the first cover 230 by other means such
as fasteners, and the like. Hence, the first cover 230 is connected to the U-shaped
shielded housing 216 such that the compartment 222 containing the thin film resistor,
wiper, and the like is completely shielded from the liquid environment. In other.
words, the first cover and the U-shaped housing 216 are permanently attached
assuring a throughout life of the fuel unit assembly 200.
During operation, the hermetic fuel unit assembly 200 is operationally
connected to the fuel tank 102, as discussed above. The ethanol fuel in the fuel tank
102 cause the float 242 to rise to the top thereof once the fuel tank 102 is filled with
the ethanol fuel. As the fuel level increases or decreases in the fuel tank 102, the float
242 is raised or lowered to rotate the wiper 228 relative to the thin film resistor 224
via the float arm 240 floating in the ethanol fuel. The rotation of wiper 228, and thus
metallic contacts move to different positions thereof to vary or provide a different
pre-determined resistance to indicate the level of the ethanol fuel remaining in the
fuel tank 102 and thus informing the rider about the current fuel level, preferably by
indicating the same in the information display instrument device 114 in the vehicles.
In an cmbodimcnt of thc prcscnt subjcct mattcr, thc thin film resistor 224 is stationed
below the terminals 214 that may be soldered for a permanently assembly. These
terminals 214 may be sealed by a sealing material such as but not restricted to araldite,
epoxy, and the like. In another embodiment of the present subject matter, the
terminals 214 may be covered with a rubber sealing in order to protect them from any
breakage, failure, or liquid. In this manner, the compartment containing the thin film
resistor, wiper, metallic contacts, terminals, and the like are permanently sealed to
ensure a substantially, and preferably entirely liquid free (ethanol fuel fi-ee)
environment within the compartment of the fuel tank assembly in accordance with the
present subject matter.
The hermetic fuel tank.*sembly for ethanol fuel vehicles according to the
present subject matter advantageously facilitates a completely shielded fuel unit
assembly that can be implemented in ethanol fuel or a fuel comprising gasoline and
ethanol wherein the percentage of ethanol ranges from 25% to 100%. The
arrangement according to the present subject matter discloses ' a liquid free
environment resulting in a secured surrounding conditions, esp for silver (Ag) based
conductive inks (Ag, Pd, Pt) and high contents silver contacts (Paliney6, Ag/Ni)
required for thin film resistors. Further, the presence of elastomeric seal and the
second cover guarantees a robust construction of the shielded fuel unit assembly that
can be implemented in any kind of fuels such as gasoline fuel or biofuel. Furthermore,
such he1 unit assembly remarkably exhibits a dimensional stability when exposed to
harsh chemicals present in the ethanol fuel or any other variety of fuels. Additionally,
since each part of the said shielded fuel unit assembly is made of plastic, hence the
drawback of corrosion has reduced outstandingly. Thus, the present subject matter
ensures least requirement of servicing and maintenance that subsequently lowers the
overall cost of any fuel level measuring apparatu,~. Moreover, the present subject
matter discloses an improved, advanced, reliable, and customers' fiiendly hermetic
fuel tank assembly for ethanol fuel vehicles.
It will be appreciated by those skilled in the art that changes could be made to
the embodiments described above without departing from the broad inventive concept
thereof. The present embodiments are therefore to be considered in all respects as
illustrative and not restrictive, the ;cope of the invention being indicated by the
appended clairqs rather than by the foregoing description and all variations,
substitutions and changes which come within the meaning and range of equivalency
of the claims are therefore intended to be embraced therein.

WE CLAIM:
1. A hermetic fuel unit assembly 2'00 for ethanol fuel vehicles comprising:
a top plate 202 suspended fiom the top inside of a fuel tank 102 to hold the
hermetic fuel unit assembly 200;
a cenba! lower annular am 208 extending down from the center of the top
plate 202;
a bracket 210 snap-fitted to the extending arm 208 of the top plate 202;
a U-shaped housing 216 operably connected to the bracket 210 by fasteners;
wherein the U-shaped housing 216 comprising:
a base wall 218;
atleast four side walls 220 extending generally perpendicular to the base
wall 218 to create an enclosed compartment 222;
a.thin film resistor 224 disposed in the enclosed compartment 222 of the
U-shaped housing 216;
a wiper 228 placed above the thin film resistor 224 in the enclosed
compartment 222 for movement along an arc shaped conductive trace
carved on the thin film resistor 224; wherein
the U-shaped housing.216 is herme6cally shielded by a first cover 230
provided with an aperture 232 extending there through the first cover 230;
the aperture 232 is covered by a second carrier 238 projected to receive a
float arm 240 with a float 242 floating in the ethanol fuel in the fuel tank
102;
a second cover 244 covering the second carrier 238 providing the path for
guiding the movement of the float arm' 240 in the ethanol fuel in the fuel
tank 102.
2. The hermetic fuel unit assembly 200 for ethanol fuel vehicles as claimed in claim
1, wherein the second cover 244 is snap fitted with the U-shaped shielded
housing 216 and the first cover 230 respectively on opposite sides of the second
cover 244.
3. The hermetic fuel unit assembly 200 for ethanol fuel vehicles as claimed in claim
1, wherein the U-shaped housing 116 is connected to the first cover 230 .by
ultrasonic welding.
4. The hermetic fuel unit assembly 200 for ethanol fuel vehicles as claimed in claim
1, wherein the U-shaped housing 116, the first cover 230, the second cover 244,
the carriers (236,238), the top plate 202 and the fasteners are preferably made of
plastic.
5. The hermetic file1 unit assembly 200 for ethanol fuel vehicles as claimed in claim
1, wherein the lower surface of the top plate 202 is provided with a knife-edge
surface that engages a flat rubber gasket 206 to securely seal the opening of the
fuel tank 102.
6. The hermetic fuel unit assembly 200 for ethanol fuel vehicles as claimed in claim
1, wherein the top plate 202 is. provided with atleast two integral beehive shaped
structures 212 to receive a plurality of terminals 214. . .
7. The hermetic fuel unit assembly 200 for ethanol fuel vehicles as claimed in claim
1, wherein the thin film resistor 224 is operationally holded by a clamp 226 in the
enclosed compartment 22 of the U-shaped housing 216.
8. The hermetic fuel unit assembly 200 for ethanol fuel vehicles as claimed in claim
1, wherein the wiper 228 is riveted with metallic contacts to move on the thin
film resistor 224 for sensing the resistance value corresponding to the instant fuel
level in the fuel tank 102.
9. The hermetic fuel unit assembly 200 for ethanol fuel vehicles as claimed in claim
1, wherein the aperture 232 is provided with an elastomeric rubber seal 234
tightly gripped on a first carrier 236 implanted on the thin film resistor.224.
10. The hermetic fuel unit assembly 200 for ethanol fuel vehicles as claimed in claim
1, wherein the fasteners may include screws, snaps, rivets, buttons, zippers,
mushroom fasteners, and the like.