VALVE HOUSING FOR A FUEL TANK-MOUNTED VALVE ASSEMBLY AND
METHOD OF MANUFACTURING SAME
TECHNICAL FIELD
[0001] The invention relates to a valve housing for a fuel tank-mounted valve
assembly, and a method of manufacturing the same.
BACKGROUND
[0002] A valve assembly is often used in a fuel tank to control vapor pressure
within the fuel tank. The valve assembly is usually mounted to the fuel tank.
Sometimes the fuel tank is formed in two portions, and the valve assembly is mounted
to one of the portions so that it can be visibly inspected to ensure that it is properly
mounted before the two portions are heat welded or otherwise joined to one another to
enclose the valve assembly within the tank. In other configurations, the valve assembly
mounts to the tank at an opening. When the valve assembly is visibly mounted at the
opening, its proper orientation may be assured by visual inspection.
SUMMARY
[0003] While valve assemblies mounted to fuel tanks as described above are suitable
for their purposes, they require additional assembly steps, such as connecting the two
portions of the tank after installation of the valve, or connecting a cover over the valve
assembly after it is mounted to the tank. Some fuel tanks are formed as a completed
unit prior to installation of the valve assembly so that the valve assembly must be
installed to an inner surface of the tank "blindly", i.e., without being able to see the
inner surface, such as by reaching through an opening in the tank. A valve assembly
and a method of manufacturing such a valve assembly ensure that the valve assembly
will be properly positioned within the fuel tank, especially when installed blindly. The
valve assembly includes a valve housing with a recess that permits a component to be
inserted into the recess and retained in the recess by the housing. The component is
detectable by a location sensor located outside of the fuel tank when the valve assembly
is mounted in the fuel tank. Thus, although the installation of the valve assembly may
be done blindly, the orientation of the installed valve assembly can be confirmed with a
sensor located outside of the fuel tank. In one embodiment, the component is
substantially flat and has a side. The recess is a slot with an entrance sufficientiy deep
to receive the side of the component.
[0004] The above features and advantages and other features and advantages of the
present invention are readily apparent from the following detailed description of the
best modes for carrying out the invention when taken in connection with the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIGURE 1 is a schematic perspective illustration of a first embodiment of
the valve housing with a component retained in a recess of the housing;
[0006] FIGURE 2 is a fragmentary schematic plan view of the valve housing of
Figure 1;
[0007] FIGURE 3A is a fragmentary schematic illustration in cross-sectional view
of a portion of the valve housing of Figures 1-2 taken at the lines 3A-3A in Figure 2;
[0008] FIGURE 3B is a fragmentary schematic illustration in cross-sectional view
of a portion of the valve housing of Figures 1-2 taken at lines 3B-3B in Figure 2A,
showing the component retained in a recess formed by the housing;
[0009] FIGURE 4 is a schematic fragmentary side view of the valve housing of
Figures 1-3B;
[0010] FIGURE 5 is a schematic, partially cross-sectional illustration of a fuel tank
having a valve assembly with the valve housing of Figure 1 mounted to an inner surface
of the fuel tank;
[0011] FIGURE 6 is a schematic fragmentary cross-sectional illustration of a second
embodiment of a valve housing showing a second embodiment of a component pressed
into a recess formed in the valve housing;
[0012] FIGURE 7 is a schematic plan view illustration of the disc of Figure 6;
[0013] FIGURE 8 is a schematic perspective illustration of a third embodiment of a
valve housing for a valve assembly for the fuel tank of Figure 5, having another
component retained in a recess formed by the housing;
[0014] FIGURE 9 is a schematic plan view, fragmentary illustration of the recess in
the housing of Figure 7;
[0015] FIGURE 10 is a cross-sectional illustration of the portion of the housing
shown in Figure 9 taken at lines 10-10; and
[0016] FIGURE 11 is a flow diagram illustrating a method of manufacturing the
valve housings of Figures 1-10.
DETAILED DESCRIPTION
[0017] Referring to the drawings, wherein like reference numbers refer to like
components, Figure 1 shows a valve housing 10 that is part of a valve assembly 11 shown
schematically in Figure 5. The valve housing 10 is mounted to an inner surface 1 of a
wall 13 of fuel tank 14 of Figure 5. Additional components of the valve assembly 11 are
mounted to the housing 10. The valve assembly 11 is mounted in an interior space 15 of
the fuel tank 14, and may be used to control vapor pressure within the fuel tank 14. For
example, at a predetermined pressure, vapor may be routed out of the fuel tank 14
through a vapor line connected to a barbed port 20 shown in Figure 1. The valve housing
10 may be mounted to the inner surface 12 of the fuel tank 14 through an opening in the
tank 14 that is not shown in the cross-sectional view in Figure 5, and that is spaced from
the location of the mounting. Mounting features 2 1 of the housing 10 of Figure 1 mate
with features of the inner surface 12 of the wall 13 to secure the housing 10 to the tank 14
of Figure 5. Thus, the mounting operation is done "blindly" in that neither the valve
assembly 11 nor the inner surface 12 of the fuel tank 14 is visible to an operator reaching
into the tank 14.
[0018] To ensure proper mounting of the housing 10, the housing 10 is formed with a
recess 16, best illustrated in Figures 2 and 4, that is sized to retain a component 22 that
will be detectable by a sensor located outside of the fuel tank 14, as explained further
below. Various embodiments of valve housings formed with recesses that retain the
component 22, or another detectable component, are shown and described below. The
housings may be formed using relatively simple and cost effective methods.
[0019] Referring to Figures 1-4, the valve housing 10 is formed.as a one-piece,
injection-molded housing, although the housing 10 may alternately be formed by other
methods and in multiple pieces. The housing 10 is formed with the recess 16 that is a
slot, and also referred to as a pocket. The detectable component 22 is a substantially flat
metal disc with a side 23 that defines the periphery of the component 22 and is between
two opposing faces 25, 26, as shown in Figure 4. The recess 16 is formed with an
entrance 18 that has a depth D sufficient to allow the side 23 of the component 22 to be
inserted first. The component 22 is pushed into the recess 16 with the side 23 (see Figure
2) leading into the recess 16. A detectable component with a different shape than a disc,
such as a rectangular shape, may be used instead. A disc-shaped component may
decrease the number of assembly steps since a disc has only one continuous side, so a
specific side of the component need not be oriented to the entrance before insertion into
the recess.
[0020] The recess 16 is formed during injection molding by positioning two inserts
17 and 19 (shown in Figure 1) in a die. Insert 17, shown in phantom in Figure 1, extends
downward to form an opening 34 extending from an upper surface 24 of the housing 10
to an inner surface 36, shown in Figure 4, on which the component 22 will rest. Another
insert 19, also shown in phantom in Figure 1, is positioned orthogonal to the opening 34
and orthogonal to insert 17 to form the recess 16. The inserts 17, 19 are shown
schematically only. The shapes of the inserts 17, 19 may be more complex than is
shown.
[0021] During forming of the housing 10, the upper surface 24 of the housing 10 is
formed with a slight depression 28 to create a lip 30, shown in Figures 3A-4. The lip 30
is spaced slightly back from the entrance 18 toward the center of the housing 10, as
shown in Figure 3B, and angles downward from an outer portion 38 to an inner portion
40. The lip 30 ends at the opening 34 extending from the upper surface 24 (see Figure 1)
of the housing 10 to the inner surface 36 (see Figure 4) on which the component 22 rests.
The slight inward angling of the lip 30 allows the component 22 to slide into the recess
16 by slightly flexing the lip 30 upward. The inner portion 40 of the lip 30 will then
block the component 22 from backing out of the entrance 18 when the lip 30 flexes back
to its original, unstressed position, as shown in Figure 3B.
[0022] Figure 5 shows the valve housing 10 secured to the tank 14. A sensor 42
positioned outside of the tank 14 can be used to determine the depth and angular
orientation of the component 22 within the tank 14, as indicated by signal 43 emanating
from sensor 42 to determine the position of component 22. The component 22 may be a
stamped metal disc. The recess 16 is designed so that the inserted component 22 is
exposed at the opening 34 which will be adjacent the surface 12 when the valve assembly
11 is mounted to the tank 14 of Figure 5. The sensor 42 may be a metal detector. This
positioning data can be compared to a stored position value to verify that the housing 0
is correctly mounted.
[0023] Figures 6 and 7 show an alternative embodiment of a valve housing 110 for a
valve assembly 111 that can be mounted internally to tank 14 such as housing 10 is
mounted in Figure 5. The valve housing 110 is formed with a recess 116 formed in an
upper surface 125 of the housing 110. The housing 110 may be a one-piece, injectionmolded
component. The recess 116 is cylindrical in shape, but is not limited to a
cylindrical shape. A detectable component 122 is inserted into the recess 116. The
component 122 is a generally annular, stamped metal disc with an angled rim 130. The
angle A of the rim 130 may be thirty degrees, but other angles will also be sufficient.
The rim 130 has a toothed or variegated edge 134. As shown in Figure 6, an arbor press
133 has a passage 135 to which a vacuum source (not shown) is attached to hold the
component 122 to the press 133. The press 133 lowers the component 122 and presses the
component 122 into the recess 116. The variegated edge 134 interferes with the housing
110 at the recess 116, digging into the housing 110. The vacuum source is shut off, and
the arbor press 133 is withdrawn, with the detectable component 122 now retained to the
housing 110 in the recess 116. The position of the detectable component 122 is
detectable by the sensor 42 when the housing 110 is mounted to the inner surface 12 of
the tank 14 of Figure 5. The recess 116 is designed so component 122 is exposed and
will be positioned adjacent surface 12 of Figure 5 when the valve assembly 111 is
mounted to tank 14. The position of the detectable component 122 is indicative of the
mounted position of the housing 110, and can thus be used to verify appropriate
installation of the housing 110 within the tank 14.
[0024] Figures 8-10 illustrate a third embodiment of a housing 10 for a valve
assembly 211. The housing 210 mounts to the surface 12 of the tank 14 of Figure 5 by
any means, such as by welding, etc. An opening 234 extends from the outer surface 224
of the housing 210 all the way through the housing 210. The opening 234 and a recess
216 are formed with an injection molding tool from above and below. The recess 216
retains a detectable component 222. Referring to Figure 10, the component 222 has a
side 223 and opposing surfaces 225, 226. Referring to Figure 8, the housing 210 maybe
injection-molded. Referring to Figure 9, the housing 210 has side ledges 262 that
overhang the recess 216 both above and below the component 222 to retain the edges of
the component 222. The recess 216 extends beyond the ledges 262 so that the ledges 262
act as sleeves to partially cover portions of the component 222. The housing 210 forms a
lip 230 that extends upward at an edge of the recess 216, as shown in Figure 10. The lip
230 and ledges 262 are flexible enough to allow the component 222 to be slid with side
223 entering first into an entrance 218 of the recess 216. Once inserted, the lip 230
interferes with the component 222 when the component 222 moves toward the lip 230,
retaining the component 222 within the recess 216. The component 222 is exposed at the
opening 234 adjacent the inner surface 12 of the fuel tank 14 of Figure 5 when the
assembly 2 11 is installed in the tank 14.
[0025] Figure 11 shows a flowchart of a method 300 of manufacturing a valve
assembly for mounting internally to a fuel tank 14, such as valve assemblies 11, 11 1 and
211 of Figures 1-10. The method 300 begins with step 302, forming a valve housing 10,
110 or 210 with a recess 16, 116 or 216 sized to retain a component 22, 122, 222 inserted
into the recess 16, 116, 216. Step 302 may be carried out by an injection-molding
process, but other manufacturing methods, such as machining, may also be used.
Forming the housing 10, 110 or 210 with a recess 16, 116 or 216 may include forming an
opening 34, 234 and/or a lip 30, 230, and may require holding inserts 17, 19 to form the
opening 34 and recess 16.
[0026] After the housing 10, 110 or 210 is fully formed, the detectable component 22,
122 or 222 is inserted into the recess 16, 116 o 216 in step 304. For some types of
formed housings 10 or 210, such as recess 16 or 216, the component 22 or 222 is inserted
side-first, because the recess 16 or 216 is formed like a pocket or slot. For other
configurations of formed housings, such as housing 110, the component 2 is inserted
by pressing the component 122 into the recess 116 face-first, using an arbor press or the
like.
[0027] Once the component 22, 122 or 222 is inserted into the housing 10, 110 or
210, the housing 10, 110 or 210 may be mounted to the inner surface 12 of the fuel tank
14, and the component 22, 122 or 222 will be detectable by sensor 42. Forming the
housing 10, 110 or 210 with a recess 16, 116 or 216, and in some embodiments with a lip
30, 230, enables a relatively quick and easy insertion process for the disc 22, 122 or 222.
[0028] While the best modes for carrying out the invention have been described in
detail, those familiar with the art to which this invention relates will recognize various
alternative designs and embodiments for practicing the invention within the scope of the
appended claims.
CLAIMS
1. A method (300) of manufacturing a valve assembly (11, 111,
211) for a fuel tank (14) comprising:
forming (302) a valve housing (10, 110, 210) with a recess (16, 116,
216) that is sized to permit a component (22, 122, 222) to be inserted into the recess
and retained by the housing in the recess; wherein the component is detectable by a
sensor (42) located outside of the fuel tank when the valve assembly is mounted in the
fuel tank.
2 . The method of claim 1, further comprising:
after forming the valve housing, inserting (304) the component into the
recess.
3. The method of claim 2, wherein the component is substantially
flat and has a side (23, 223); wherein the recess is a slot with an entrance (18, 218)
sufficiently deep to receive the side of the component; and wherein the inserting the
component into the recess is achieved by inserting the side of the component into the
entrance first.
4 . The method of claim 3, wherein the forming the valve housing
includes forming an opening (34, 234) that is substantially orthogonal to the entrance
and that extends from an outer surface of the valve housing to the recess.
5. The method of claim 4, wherein the forming the valve housing
includes forming a lip (30, 230) that extends into the recess sufficiently to retain the
component in the recess after the inserting.
6. The method of claim 4, wherein the forming the valve housing is
by injection molding and includes holding inserts (17, 19) within a die at predetermined
locations to injection mold around the inserts, thereby creating the recess and the
opening substantially orthogonal to the recess at the location of the inserts.
7. The method of claim 2, wherein the inserting the component
(122) is via pressing the component into the recess.
8. The method of claim 7, wherein the component has an edge (134)
that interferes with the housing when pressed into the recess to thereby be retained within
the recess.
9. The method of claim 1, wherein the forming is by injection
molding.
10. A valve assembly (11, 111, 211) comprising:
a valve housing (10, 110, 210) having a recess (16, 116, 216);
a component (22, 122, 222) retained in the recess by the valve housing;
and
wherein the component is a material that can be sensed by a sensor (42).
11. The valve assembly of claim 10, wherein the component is
substantially flat and has a side (23, 223); and wherein the recess is a slot with an
entrance (18, 218) sufficiently deep to receive the side of the component.
12. The valve assembly of claim 10, wherein the valve housing
includes an opening (34, 234) that is substantially orthogonal to the entrance and that
extends from an outer surface (24, 224) of the valve housing to the recess.
13. The valve assembly of claim 10, wherein the valve housing forms
a lip (30, 230) that extends into the recess and retains the component in the recess.
14. A valve assembly (11, 211) comprising:
a one-piece, injection-molded valve housing (10, 210) having a recess (16,
216) that forms an entrance (18, 218); wherein the housing has an opening (34, 234)
orthogonal to the entrance; and
a metal disc (22, 222) sized to f t through the entrance into the recess and
to be retained in the recess by the valve housing at the opening so that the metal disc is
exposed at the opening.