Fuel tank fill assembly

A fuel tank fill assembly includes a fuel fill tube adapted to be coupled to a fuel tank and configured to receive fuel discharged by a pump nozzle. The assembly includes a tube mounting bracket for mounting the fuel fill tube in a stationary position in a vehicle to conduct fuel to the fuel tank. A process for coating the tube mounting bracket is disclosed.

BACKGROUND

The present disclosure relates to a fuel tank fill assembly. More particularly, the present disclosure relates to a fuel tank fill assembly for a vehicle fuel tank.

SUMMARY

According to the present disclosure, a fuel tank fill assembly comprises an inlet cup and a fuel filler pipe extending from the inlet cup to a fuel tank. The fuel filler pipe is adapted to conduct liquid fuel from the inlet cup to the fuel tank during refueling.

In illustrative embodiments, a filler-pipe anchor bracket is mounted on the fuel filler pipe made of carbon steel to provide an uncoated fuel-delivery conduit that can be used to conduct liquid fuel to a vehicle fuel tank. The pipe mount of the filler-pipe anchor bracket is coupled to the fuel filler pipe using a friction-fit system in accordance with the present disclosure to maximize application of a two-layer protective coating to all exposed portions of the filler-pipe anchor bracket and the fuel filler pipe that are included in the uncoated fuel-delivery conduit and especially in dual-coat flow gaps that are formed between the friction-fit pipe mount and the fuel filler pipe in accordance with the present disclosure so that corrosion of the friction-fit pipe mount and fuel filler pipe is minimized.

In an illustrative process in accordance with the present disclosure, a pipe mount of the filler-pipe anchor bracket is mounted on the fuel filler pipe using a friction-fit system disclosed herein to form several dual-coat flow gap therebetween. Then a corrosion-resistant first coating material is applied to an exposed inner surface of the friction-fit pipe mount and an opposed exterior surface of the fuel filler pipe to establish a first coating layer in dual-coat flow gap. Subsequently, a corrosion-resistant second coating material is applied to exposed surfaces of the first coating layer to establish a second coating layer in each dual-coat flow gap. Each gap is sized to allow the first and second coating materials to flow into the gap in sequence to establish a multi-layer protective coating on the friction-fit pipe mount and the fuel filler pipe in the dual-coat flow gap. The multi-layer protective coating is applied to the inlet cup in addition to the fuel filler pipe and the filler-pipe anchor bracket to provide a corrosion-resistant fuel tank fill assembly.

In illustrative embodiments, the pipe mount is coupled to a curved exterior surface of the fuel filler pipe using a friction-fit system disclosed herein to form the several dual-coat flow gap between the pipe mount and a convex outer surface of the fuel filler pipe. A mount-support flange also included in the filler-pipe anchor bracket is coupled to the friction-fit pipe mount and arranged to extend away from the fuel filler pipe to accommodate coupling of the filler-pipe anchor bracket to another component of a vehicle, e.g., a vehicle frame.

In illustrative embodiments, the friction-fit pipe mount includes several friction tabs that are arranged to lie in circumferentially spaced-apart relation about and in engagement with the curved exterior surface of the fuel filler pipe. The friction-fit pipe mount also includes several coating bridges. Each of the coating bridges is arranged to interconnect proximal ends of two adjacent friction tabs and lie in radially outwardly spaced-apart relation to a portion of the curved exterior surface of the fuel filler pipe that extends between those two adjacent friction tabs to form therebetween a dual-coat flow gap in accordance with the present disclosure.

In illustrative embodiments, each dual-coat flow gap is sized to provide means for allowing a first coating material such as an undercoat zinc-rich primer and then a second coating material such as a top-coat anti-corrosion paint to move into the flow gap and coat the interior surface of the friction-fit pipe mount and the opposed exterior surface of the fuel filler pipe so that portions of the uncoated fuel-delivery conduit in the dual-coat flow gap are now coated and thus protected from corrosive influences during use. A protective coating comprising the first and second coating materials is also applied to exterior portions of the fuel filler pipe, filler-pipe anchor bracket, and the inlet cup to improve corrosion-resistance of the fuel tank fill assembly. The result is that a corrosion-resistant fuel tank fill assembly is provided in accordance with the present disclosure.

In illustrative embodiments, the friction tabs and the coating bridges of the friction-fit pipe mount cooperate to form a band that surrounds the curved outer surface of the fuel filler pipe. The friction-fit pipe mount also includes a fastener that is coupled to the band to tighten the band around the fuel filler pipe to establish a friction fit between free ends of the friction tabs and the curved outer surface of the fuel filler pipe and hold the band in a stationary position surrounding a portion of the fuel filler pipe. The fastener is a bolt that is coupled to opposite ends of the band in illustrative embodiments. It is within the scope of the present disclosure to use weldment or other suitable fastening means to provide the fastener.

In illustrative embodiments, the band of the friction-fit pipe mount includes a top strap, a bottom strap arranged to lie in side-by-side mating relation to the top strap, and a loop that interconnects the top and bottom straps and is formed to include the friction tabs and the coating bridges. The mount-support flange is coupled to free ends of the side-by-side top and bottom straps of the band. The fastener is coupled to the side-by-side top and bottom straps of the band to block movement of the bottom strap relative to the top strap and tighten the loop to lie in a stationary position wrapped around and in engagement with the fuel filler pipe.

Additional features of the disclosure will become apparent to those skilled in the art upon consideration of illustrative embodiments exemplifying the best mode of carrying out the disclosure as presently perceived.

DETAILED DESCRIPTION

A fuel tank fill assembly10is configured to conduct fuel from a fuel-dispensing pump nozzle12to a fuel tank14as suggested inFIG. 1. Fuel fill tank assembly10includes an inlet cup16sized to receive nozzle12, a fuel filler pipe18configured to conduct liquid fuel discharged by nozzle12into inlet cup16to an interior region14I of fuel tank14, and a filler-pipe anchor bracket20. Fuel tank fill assembly10also includes a two-layer corrosion-resistant protection coating30applied in accordance with the present disclosure as suggested inFIGS. 4-6.

Filler-pipe anchor bracket20is mounted on fuel filler pipe18using a friction-fit system in accordance with the present disclosure to produce an uncoated fuel-delivery conduit11as suggested inFIG. 2and to establish several dual-coat flow gaps (G) between fuel filler pipe18and filler-pipe anchor bracket20as suggested inFIGS. 3 and 4. A corrosion-resistant protective coating30is applied to the uncoated fuel-delivery conduit11as suggested inFIGS. 5 and 6so that exposed portions of pipe18and bracket20bordering dual-coat flow gaps (G) are coated in accordance with the present disclosure along with all other exposed portions of the uncoated fuel-delivery conduit11.

It is within the scope of the present disclosure to vary the configuration of coating maximizer filler-pipe anchor bracket20to produce various dual-coat flow gaps. In each of the alternative embodiments described herein a friction-fit system in accordance with the present disclosure is used to mount the coating maximizer filler-pipe anchor bracket on the fuel filler pipe. A fuel tank fill assembly10B comprising a filler-pipe anchor bracket20B in accordance with a second embodiment of the present disclosure is shown inFIGS. 7-9. A fuel tank fill assembly10C comprising a filler-pipe anchor bracket20C in accordance with a third embodiment of the present disclosure is shown inFIGS. 10-12. A fuel tank fill assembly10D in accordance with a fourth embodiment of the present disclosure is shown inFIGS. 13-15and discloses that a filler-pipe anchor bracket20D is coupled to a fuel filler pipe18and to a fuel vapor conduit that is arranged to extend alongside fuel filler pipe18from an outlet end18O of fuel filler pipe18to a vapor space in a fuel tank14.

In a two-step coating sequence used to coat the uncoated fuel-delivery conduit11and illustrated inFIGS. 5 and 6, a corrosion-resistant first coating material31flows onto filler-pipe anchor bracket20and fuel filler pipe18and into dual-coat flow gaps (G) to form a first coating layer31L in dual-coat flow gaps (G). Next, a corrosion-resistant second coating material32flows onto the first coating layer31L on filler-pipe anchor bracket20and fuel filler pipe18and into dual-coat flow gaps (G) to form a second coating layer32L in dual-coat flow gaps (G). These coating layers31L,32L cooperate to form a multi-layer corrosion-resistant protective coating30all over fuel-delivery conduit11and inside the dual-coat flow gaps (G) associated with fuel-delivery conduit11in accordance with the present disclosure. In a similar manner, dual-coat flow gaps (G2), (G3), or (G4) are created in the other embodiments disclosed herein to facilitate formation of a two-layer corrosion-resistant protective coating on uncoated components included in the companion fuel tank fill assembly.

In illustrative embodiments of the present disclosure, fuel filler pipe18is made of carbon steel, first coating material31is an undercoat zinc-rich primer, and second coating material32is a top-coat anti-corrosion paint made, for example, of a durable thermoset material. It is within the scope of the present disclosure to apply second coating material32to a carbon steel pipe carrying an electroplated zinc-nickel primer using dip, drain, or spray applications. In accordance with the present disclosure, the multi-layer corrosion-resistant protective coating30is applied to an uncoated fuel-delivery conduit11to provide a fuel tank fill assembly10shown inFIGS. 1 and 6that meets establish fifteen year laboratory and vehicle corrosion testing standards.

Fuel filler pipe18of fuel-delivery conduit11includes a nozzle-receiving outer end18O associated with and linked to inlet cup16and a fuel-discharging inner end18I adapted to be coupled to fuel tank14to discharge fuel into interior region14I of fuel tank14as shown inFIG. 1. Fuel filler pipe18also includes an interior surface18N arranged to define a fuel-conducting conduit18C extending between and interconnecting nozzle-receiving outer end18O and fuel-discharging inner end18I and an exterior surface18E arranged to face away from fuel-conducting conduit18C as shown inFIGS. 2 and 3.

Coating maximizer filler-pipe anchor bracket20of the uncoated fuel-delivery conduit11includes a mount-support flange21and a friction-fit pipe mount22as shown inFIGS. 1-3. Filler-pipe anchor bracket20is made of carbon steel in illustrative embodiments. Mount-support flange21is adapted to be coupled to a vehicle frame10F to support fuel filler pipe18relative to vehicle frame10F to cause fuel-discharging inner end18I to communicate with interior region14I of fuel tank14. Friction-fit pipe mount22is coupled to mount-support flange21and to exterior surface18E of fuel filler pipe18to retain mount-support flange21in fixed relation to fuel filler pipe18. Friction-fit pipe mount22includes several inner surfaces22I that face toward exterior surface18E of fuel filler pipe18as shown inFIG. 3.

Multi-layer protective coating30covers exposed portions of exterior surface18E of fuel pipe18, filler-pipe anchor bracket20, and inlet cup16as suggested inFIGS. 1 and 6. In illustrative embodiments, multi-layer protective coating30also covers an inner surface18N of fuel filler pipe18as shown inFIG. 6. Protective coating30comprises a first coating layer31L made of primer31and adhered to exterior surface18E of fuel filler pipe18and filler-pipe anchor bracket20and a second coating layer32L made of paint32and adhered to exposed surfaces of first coating layer31L as suggested inFIG. 6.

Each dual-coat flow gap (G) is sized in accordance with the present disclosure to allow a zinc-rich primer31and a top-coat anti-corrosion paint32to flow into dual-coat flow gap (G) when the primer31and paint32are applied in sequence as suggested inFIGS. 5 and 6after the filler-pipe anchor bracket20has been coupled to the fuel filler pipe18using a friction-fit system in accordance with the present disclosure as suggested inFIG. 4. Inner surfaces22I of friction-fit pipe mount22of coating maximizer filler-pipe anchor bracket20and opposed portions of the cylindrical exterior surface18E of fuel filler pipe18are arranged to lie in confronting spaced-apart relation to one another as shown, for example, inFIGS. 2 and 3. Inner surfaces22I and the opposed portions of cylindrical exterior surface18E cooperate to form therebetween dual-coat flow gap (G) means for first allowing first coating layer31L to adhere to exposed portions of inner surface22I of pipe mount22and the undercoat primer31on the opposed portion of cylindrical exterior surface18E of fuel filler pipe18during deposition of first coating layer31L on pipe mount22and fuel filler pipe18and thereafter allowing second coating layer32L of top-coat paint32to adhere to exposed portions of first coating layer31L located in a dual-coat flow gap (G) provided between friction-fit pipe mount22and fuel filler pipe18. An exposed surface of second coating layer32L located in the dual-coat flow gap (G) cooperates to form an open space (S) located between friction-fit pipe mount22and the opposed portions of exterior surface18E of fuel filler pipe18as suggested inFIG. 6.

Friction-fit pipe mount22of filler-pipe anchor bracket20includes three friction tabs T1, T2, and T3and three coating bridges B1, B2, and B3as suggested inFIG. 3. Friction tabs T1, T2, and T3are arranged to lie in circumferentially spaced-apart relation from one another about and in engagement with a an exterior surface18E of fuel filler pipe18as suggested inFIG. 3. Each friction tab T1, T2, T3is formed to include a series of teeth that engage cylindrical exterior surface18E as shown inFIG. 3. Coating bridge B1interconnects friction tabs T1and T3. Coating bridge B2interconnects friction tabs T1and T2. Coating bridge B3interconnects friction tabs T2and T3. Each of coating bridges B1, B2, and B3is arranged to lie in radially outwardly spaced-apart relation to a confronting portion of the cylindrical exterior surface18E of fuel filler pipe18that lies between the two friction tabs that are coupled to the selected coating bridge so as to define therebetween a dual-coat flow gap (G) as shown inFIGS. 3 and 4. Thus, three separate dual-coat flow gaps (G) are formed—one dual-coat flow gap (G) for each of the coating bridges B1, B2, and B3.

Each of coating bridges B2and B3is curved in cross-section as shown, for example, inFIGS. 3 and 4. Coating bridge B1is shaped differently in that it includes an upper segment B1U and a separate lower segment B1L as shown, for example, inFIGS. 3 and 4. An inner portion of upper segment B1U is curved in cross section and coupled to friction tab T1and an outer end of upper segment B1U is flat and coupled to mount-support flange21. An inner portion of lower segment B1L is curved in cross section and coupled to friction tab T3, an outer portion of lower segment B1L is flat and coupled to mount-support flange21, and a middle portion of the lower segment B1L is V-shaped in cross section and arranged to interconnect the inner and outer portions of lower segment B1L. Fastener222of pipe mount22is coupled to each of the flat upper and lower segments B1U, B1L of first coating bridge B1to tighten friction-fit pipe mount22around the circular outer surface18E of the fuel filler pipe18to establish a friction fit between the free ends of friction tabs T1, T2, and T3and the cylindrical exterior surface18E of fuel filler pipe18as suggested inFIGS. 3 and 4mount-support flange21is coupled to flat upper and lower segments B1U, B1L as suggested inFIG. 3.

Friction tabs T1, T2, and T3cooperate with coating bridges B1, B2, and B3as suggested inFIG. 4to form a band40that surrounds the curved exterior surface18E of fuel filler pipe18. Fastener222is coupled to band40to tighten band40around fuel filler pipe18to establish a friction fit between free ends of friction tabs T1, T2, and T3and the curved exterior surface18E of fuel filler pipe18and hold band40in a stationary position surrounding a portion of fuel filler pipe18. Fastener222is a bolt that is coupled to opposite ends of band40as shown inFIG. 4.

Band40includes a top strap40T, a bottom strap40B, and a loop40L as suggested inFIG. 4. Bottom strap40B is arranged to lie in side-by-side mating relation to top strap40T. Loop40L is arranged to interconnect top and bottom straps40T,40B and is formed to include friction tabs T1, T2, and T3and coating bridges B2and B3as suggested inFIG. 4. Loop40L has a width (W) as shown inFIG. 2and each of friction tabs T1, T2, and T3has a length that is about equal to loop width (W) as suggested inFIG. 2. Mount-support flange21is coupled to free ends of top and bottom straps40T,40B to block movement of bottom strap40B relative to top strap40T and to tighten loop40L to lie in a stationary position wrapped around and in engagement with curved exterior surface18E of fuel filler pipe18as suggested inFIGS. 2-4. Fastener222is coupled to top and bottom straps40T,40B as suggested inFIG. 4.

Each dual-coat flow gap (G) is sized to allow zinc-rich primer31and top-coat anti-corrosion paint32to move into dual-coat flow gap (G). Flow gap (G) is formed in accordance with the present disclosure to allow zinc-rich primer31and top-coat anti-corrosion paint32to coat a portion of exterior surface18E of fuel filler pipe18upon application of the zinc-rich primer31and the top-coat anti-corrosion paint32when filler-pipe anchor bracket20is coupled to fuel filler pipe18. It is contemplated that dual-coat flow gap (G) may be sized to a suitable height designed to facilitate the flow of primer and/or paint between fuel filler pipe18and friction-fit pipe mount22.

A fuel tank fill assembly10B in accordance with a second embodiment of the present disclosure is configured to conduct fuel from a fuel-dispensing pump nozzle12to a fuel tank14as suggested inFIG. 7. Fuel fill tank assembly10B includes an inlet cup16sized to receive nozzle12, a fuel filler pipe18configured to conduct liquid fuel discharged by nozzle12into inlet cup16to an interior region14I of fuel tank14, and a filler-pipe anchor bracket20B. Fuel tank fill assembly10B also includes a two-layer corrosion-resistant protection coating30applied in accordance with the present disclosure as suggested inFIGS. 7 and 9.

Filler-pipe anchor bracket20B is mounted on fuel filler pipe18using a friction-fit system in accordance with the present disclosure to produce an uncoated fuel-delivery conduit11B as suggested inFIG. 8and to establish several dual-coat flow gaps (G2) between fuel filler pipe18and filler-pipe anchor bracket20B as suggested inFIGS. 8 and 9. A corrosion-resistant protective coating30is applied to the uncoated fuel-delivery conduit11B as suggested inFIG. 9so that exposed portions of pipe18and bracket20B bordering dual-coat flow gaps (G2) are coated in accordance with the present disclosure along with all other exposed portions of the uncoated fuel-delivery conduit11B.

In a two-step coating sequence used to coat the uncoated fuel-delivery conduit11B and illustrated inFIG. 9, a corrosion-resistant first coating material31flows onto filler-pipe anchor bracket20B and fuel filler pipe18and into dual-coat flow gaps (G2) to form a first coating layer31L in dual-coat flow gaps (G2). Next, a corrosion-resistant second coating material32flows onto the first coating layer31L on filler-pipe anchor bracket20B and fuel filler pipe18and into dual-coat flow gaps (G2) to form a second coating layer32L in dual-coat flow gaps (G2). These coating layers31L,32L cooperate to form a multi-layer corrosion-resistant protective coating30all over fuel-delivery conduit11B and inside the dual-coat flow gap (G2) associated with fuel-delivery conduit11B in accordance with the present disclosure.

In illustrative embodiments of the present disclosure, fuel filler pipe18is made of carbon steel, first coating material31is an undercoat zinc-rich primer, and second coating material32is a top-coat anti-corrosion paint made, for example, of a durable thermoset material. It is within the scope of the present disclosure to apply second coating material32to a carbon steel pipe carrying an electroplated zinc-nickel primer using dip, drain, or spray applications. In accordance with the present disclosure, the multi-layer corrosion-resistant protective coating30is applied to an uncoated fuel-delivery conduit11B to provide a fuel tank fill assembly10B shown inFIGS. 7 and 9that meets establish fifteen year laboratory and vehicle corrosion testing standards.

Fuel filler pipe18of fuel-delivery conduit11B includes a nozzle-receiving outer end18O associated with and linked to inlet cup16and a fuel-discharging inner end18I adapted to be coupled to fuel tank14to discharge fuel into interior region14I of fuel tank14as shown inFIG. 7. Fuel filler pipe18also includes an interior surface18N arranged to define a fuel-conducting conduit18C extending between and interconnecting nozzle-receiving outer end18O and fuel-discharging inner end18I and an exterior surface18E arranged to face away from fuel-conducting conduit18C as shown inFIGS. 8 and 9.

Coating maximizer filler-pipe anchor bracket20B of the uncoated fuel-delivery conduit11includes a mount-support flange21B and a friction-fit pipe mount22B as shown inFIGS. 8 and 9. Filler-pipe anchor bracket20B is made of carbon steel in illustrative embodiments. Mount-support flange21B is adapted to be coupled to a vehicle frame10F to support fuel filler pipe18relative to vehicle frame10F to cause fuel-discharging inner end18I to communicate with interior region14I of fuel tank14. Friction-fit pipe mount22B is coupled to mount-support flange21B and to exterior surface18E of fuel filler pipe18to retain mount-support flange21B in fixed relation to fuel filler pipe18. Friction-fit pipe mount22B includes several inner surfaces22BI that face toward exterior surface18E of fuel filler pipe18as shown inFIG. 9.

Multi-layer protective coating30covers exposed portions of exterior surface18E of fuel pipe18, filler-pipe anchor bracket20B, and inlet cup16as suggested inFIGS. 7 and 9. In illustrative embodiments, multi-layer protective coating30may also cover an inner surface18N of fuel filler pipe18. Protective coating30comprises a first coating layer31L made of primer31and adhered to exterior surface18E of fuel filler pipe18and filler-pipe anchor bracket20B and a second coating layer32L made of paint32and adhered to exposed surfaces of first coating layer31L as suggested inFIG. 9.

Each dual-coat flow gap (G2) is sized in accordance with the present disclosure to allow a zinc-rich primer31and a top-coat anti-corrosion paint32to dual-coat flow into flow gap (G2) when the primer31and paint32are applied in sequence as suggested inFIG. 9after the filler-pipe anchor bracket20B has been coupled to the fuel filler pipe18using a friction-fit system in accordance with the present disclosure as suggested inFIG. 9. Inner surfaces22BI of pipe mount22B of coating maximizer filler-pipe anchor bracket20B and opposed portions of cylindrical exterior surface18E of fuel filler pipe18are arranged to lie in confronting spaced-apart relation to one another as shown, for example, inFIGS. 8 and 9. Inner surfaces22BI and opposed portions of cylindrical exterior surface18E cooperate to form therebetween dual-coat flow gap (G2) means for first allowing first coating layer31L to adhere to exposed portions of inner surfaces22BI of friction-fit pipe mount22B and the undercoat primer31on the opposed portions of exterior surface18E of fuel filler pipe18during deposition of first coating layer31L on friction-fit pipe mount22B and fuel filler pipe18and thereafter allowing second coating layer32L of top-coat paint32to adhere to exposed portions of first coating layer31L located in a dual-coat flow gap (G2) provided between friction-fit pipe mount22B and fuel filler pipe18. An exposed surface of second coating layer32L located in the dual-coat flow gap (G2) cooperates to form an open space (S) located between pipe mount22B and the opposed portions of exterior surface18E of fuel filler pipe18as suggested inFIG. 9.

Friction-fit pipe mount22of filler-pipe anchor bracket20includes four pairs of side-by-side friction tabs T1, T2, T3, and T4and four coating bridges B1, B2, B3, and B4as suggested inFIGS. 8 and 9. The pairs of side-by-side friction tabs T1, T2, T3, and T4are arranged to lie in circumferentially spaced-apart relation from one another about and in engagement with a an exterior surface18E of fuel filler pipe18as suggested inFIGS. 3 and 4. Each friction tab T1, T2, T3, and T4is formed to include a series of teeth that engage exterior surface18E as shown inFIG. 3. Coating bridge B1interconnects pairs of side-by-side friction tabs T1and T2. Coating bridge B2interconnects pairs of side-by-side friction tabs T2and T3. Coating bridge B3interconnects pairs of side-by-side friction tabs T3and T4. Coating bridge B4interconnects pairs of side-by-side friction tabs T4and T1. In illustrative embodiments, each friction tab T1-T4is formed by using a moving tool to apply a force to one side of the friction-fit pipe mount in a press to form a protrusion shaped to provide one of friction tabs T1-T4.

Each of coating bridges B1, B2, B3, and B4is arranged to lie in radially outwardly spaced-apart relation to a confronting portion of the cylindrical exterior surface18E of fuel filler pipe18that lies between the pairs of side-by-side friction tabs that are coupled to the selected coating bridge so as to define therebetween a dual-coat flow gap (G2) as shown inFIGS. 3 and 4. Thus, four separate dual-coat flow gaps (G2) are formed—one dual-coat flow gap (G2) for each of the coating bridges B1, B2, B3, and B4.

Each of coating bridges B1, B2and B3is curved in cross-section as shown, for example, inFIG. 9. Coating bridge B4is shaped differently in that it includes an upper segment B4U and a lower segment B4L as shown, for example, inFIGS. 8 and 9. An inner portion of upper segment B4U is curved in cross section and coupled to friction tab T1and an outer end of upper segment B4U is flat and coupled to mount-support flange21. An inner portion of lower segment B4L is curved in cross section and coupled to friction tab T4and an outer portion of lower segment B4L is flat and coupled to mount-support flange21. Fastener222of friction-fit pipe mount22B is coupled to each of the flat upper and lower segments B4U, B4L of fourth coating bridge B4to tighten friction-fit pipe mount22around the circular outer surface18E of the fuel filler pipe18to establish a friction fit between the free ends of pairs of side-by-side friction tabs T1, T2, T3, and T4and the cylindrical exterior surface18E of fuel filler pipe18as suggested inFIGS. 8 and 9. Mount-support flange21B is coupled to flat upper and lower segments B4U, B4L as suggested inFIG. 9.

Friction tabs T1, T2, T3, and T4cooperate with coating bridges B1, B2, B3, and B4as suggested inFIG. 2to form a band40B that surrounds the exterior surface18E of fuel filler pipe18as shown inFIGS. 8 and 9. Fastener222B is coupled to band40B as suggested diagrammatically inFIG. 8to tighten band40B around fuel filler pipe18to establish a friction fit between free ends of friction tabs T1, T2, T3, and T4and the cylindrical exterior surface18E of fuel filler pipe18and hold band40B in a stationary position surrounding a portion of fuel filler pipe18. Fastener222B may be a bolt or weldment that is coupled to opposite ends of band40B.

Band40B includes a top strap40BT, a bottom strap40BB, and a loop40BL as suggested inFIG. 8. Bottom strap40BB is arranged to lie in side-by-side mating relation to top strap40BT. Loop40BL is arranged to interconnect top and bottom straps40BT,40BB and is formed to include friction tabs T1, T2, T3, and T4and coating bridges B1, B2, and B3. Mount-support flange21is coupled to free ends of top and bottom straps40BT,40BB to block movement of bottom strap40BB relative to top strap40BT and to tighten loop40BL to lie in a stationary position wrapped around and in engagement with cylindrical exterior surface18E of fuel filler pipe18.

A fuel tank fill assembly10C in accordance with a third embodiment of the present disclosure is configured to conduct fuel from a fuel-dispensing pump nozzle12to a fuel tank14as suggested inFIG. 10. Fuel fill tank assembly10C includes an inlet cup16sized to receive nozzle12, a fuel filler pipe18configured to conduct liquid fuel discharged by nozzle12into inlet cup16to an interior region14I of fuel tank14, and a filler-pipe anchor bracket20C. Fuel tank fill assembly10C also includes a two-layer corrosion-resistant protection coating30applied in accordance with the present disclosure as suggested inFIGS. 10 and 12.

Filler-pipe anchor bracket20C is mounted on fuel filler pipe18using a friction-fit system in accordance with the present disclosure to produce an uncoated fuel-delivery conduit11C as suggested inFIG. 11and to establish several dual-coat flow gaps (G3) between fuel filler pipe18and filler-pipe anchor bracket20C as suggested inFIGS. 11 and 12. A corrosion-resistant protective coating30is applied to the uncoated fuel-delivery conduit11C as suggest inFIG. 12so that exposed portions of pipe18and bracket20C bordering dual-coat flow gaps (G3) are coated in accordance with the present disclosure along with all other exposed portions of the uncoated fuel-delivery conduit11C.

In a two-step coating sequence used to coat the uncoated fuel-delivery conduit11C and illustrated inFIG. 12, a corrosion-resistant first coating material31flows onto filler-pipe anchor bracket20C and fuel filler pipe18and into dual-coat flow gaps (G3) to form a first coating layer31L in dual-coat flow gaps (G3). Next, a corrosion-resistant second coating material32flows onto the first coating layer31L on filler-pipe anchor bracket20C and fuel filler pipe18and into dual-coat flow gaps (G3) to form a second coating layer32L in dual-coat flow gaps (G3). These coating layers31L,32L cooperate to form a multi-layer corrosion-resistant protective coating30all over fuel-delivery conduit11C and inside the dual-coat flow gap (G3) associated with fuel-delivery conduit11C in accordance with the present disclosure.

In illustrative embodiments of the present disclosure, fuel filler pipe18is made of carbon steel, first coating material31is an undercoat zinc-rich primer, and second coating material32is a top-coat anti-corrosion paint made, for example, of a durable thermoset material. It is within the scope of the present disclosure to apply second coating material32to a carbon steel pipe carrying an electroplated zinc-nickel primer using dip, drain, or spray applications. In accordance with the present disclosure, the multi-layer corrosion-resistant protective coating30is applied to an uncoated fuel-delivery conduit11C to provide a fuel tank fill assembly10C shown inFIGS. 10 and 12that meets establish fifteen year laboratory and vehicle corrosion testing standards.

Fuel filler pipe18of fuel-delivery conduit11C includes a nozzle-receiving outer end18O associated with and linked to inlet cup16and a fuel-discharging inner end18I adapted to be coupled to fuel tank14to discharge fuel into interior region14I of fuel tank14as shown inFIG. 10. Fuel filler pipe18also includes an interior surface18N arranged to define a fuel-conducting conduit18C extending between and interconnecting nozzle-receiving outer end18O and fuel-discharging inner end18I and an exterior surface18E arranged to face away from fuel-conducting conduit18C as shown inFIGS. 11 and 12.

Coating maximizer filler-pipe anchor bracket20C of the uncoated fuel-delivery conduit11includes a mount-support flange21C and a friction-fit pipe mount22C as shown inFIGS. 11 and 12. Filler-pipe anchor bracket20C is made of carbon steel in illustrative embodiments. Mount-support flange21C is adapted to be coupled to a vehicle frame10F to support fuel filler pipe18relative to vehicle frame10F to cause fuel-discharging inner end18I to communicate with interior region14I of fuel tank14. Friction-fit pipe mount22C is coupled to mount-support flange21C and to exterior surface18E of fuel filler pipe18to retain mount-support flange21C in fixed relation to fuel filler pipe18. Friction-fit pipe mount22C includes several inner surfaces22CI that face toward exterior surface18E of fuel filler pipe18as shown inFIG. 12.

Multi-layer protective coating30covers exposed portions of exterior surface18E of fuel pipe18, filler-pipe anchor bracket20C, and inlet16as suggested inFIGS. 10 and 12. In illustrative embodiments, multi-layer protective coating30may also cover an inner surface18N of fuel filler pipe18. Protective coating30comprises a first coating layer31L made of primer31and adhered to exterior surface18E of fuel filler pipe18, fuel vapor conduit118, and filler-pipe anchor bracket20C and a second coating layer32L made of paint32and adhered to exposed surfaces of first coating layer31L as suggested inFIG. 12.

Each dual-coat flow gap (G3) is sized in accordance with the present disclosure to allow a zinc-rich primer31and a top-coat anti-corrosion paint32to flow into dual-coat flow gap (G3) when the primer31and paint32are applied in sequence as suggested inFIG. 12after the filler-pipe anchor bracket20C has been coupled to the fuel filler pipe18using a friction-fit system in accordance with the present disclosure as suggested inFIG. 12. Inner surfaces22CI of friction-fit pipe mount22C of coating maximizer filler-pipe anchor bracket20C and opposed portions of cylindrical exterior surface18E of fuel filler pipe18are arranged to lie in confronting spaced-apart relation to one another as shown, for example, inFIGS. 11 and 12. Inner surfaces22CI and the opposed portions of cylindrical exterior surface18E cooperate to form therebetween dual-coat flow gap (G3) means for first allowing first coating layer31L to adhere to exposed portions of inner surface22CI of friction-fit pipe mount22C and the undercoat primer31on the opposed portion of cylindrical exterior surface18E of fuel filler pipe18during deposition of first coating layer31L on pipe mount22C and fuel filler pipe18and thereafter allowing second coating layer32L of top-coat paint32to adhere to exposed portions of first coating layer31L located in a dual-coat flow gap (G3) provided between pipe mount22C and fuel filler pipe18. An exposed surface of second coating layer32L located in the dual-coat flow gap (G3) cooperates to form an open space (S) in each region (G3), (G32) of dual-coat flow gap (G3) that is located between pipe mount22C and the opposed portions of cylindrical exterior surface18E of fuel filler pipe18as suggested inFIG. 12.

Friction-fit pipe mount22of filler-pipe anchor bracket20includes four friction tabs T1, T2, T3, and T4and four coating bridges B1, B2, B3, and B4as suggested inFIG. 12. Friction tabs T1, T2, T3, and T4are arranged to lie in circumferentially spaced-apart relation from one another about and in engagement with an exterior surface18E of fuel filler pipe18as suggested inFIGS. 11 and 12. Each friction tab T1, T2, T3, and T4is formed to include a series of teeth that engage exterior surface18E as shown inFIG. 12. Coating bridge B1interconnects friction tabs T1and T2. Coating bridge B2interconnects friction tabs T2and T3. Coating bridge B3interconnects friction tabs T3and T4. Coating bridge B4interconnects friction tabs T4and T1. Each of coating bridges B1, B2, B3, and B4is arranged to lie in radially outwardly spaced-apart relation to a confronting portion of the cylindrical exterior surface18E of fuel filler pipe18that lies between the two friction tabs that are coupled to the selected coating bridge so as to define therebetween a dual-coat flow gap (G3) as shown inFIGS. 3 and 4. Thus, four separate dual-coat flow gaps (G3) are formed—one dual-coat flow gap (G3) for each of the coating bridges B1, B2, B3, and B4.

Each of coating bridges B1, B2and B3is curved in cross-section as shown, for example, inFIG. 12. Coating bridge B4is shaped differently in that it includes an upper segment B4U and a lower segment B4L as shown, for example, inFIGS. 11 and 12. An inner portion of upper segment B4U is curved in cross section and coupled to friction tab T1and an outer end of upper segment B4U is flat and coupled to mount-support flange21. An inner portion of lower segment B4L is curved in cross section and coupled to friction tab T4and an outer portion of lower segment B4L is flat and coupled to mount-support flange21. Fastener222of friction-fit pipe mount22C is coupled to each of the flat upper and lower segments B4U, B4L of fourth coating bridge B4to tighten friction-fit pipe mount22C around the circular outer surface18E of the fuel filler pipe18to establish a friction fit between the free ends of friction tabs T1, T2, T3, and T4and the cylindrical exterior surface18E of fuel filler pipe18as suggested inFIGS. 11 and 12. Mount-flange support21C is coupled to flat upper and lower segments B4U, B4L as suggested inFIG. 12.

Friction tabs T1, T2, T3, and T4cooperate with coating bridges B1, B2, B3, and B4as suggested inFIG. 4to form a band40C that surrounds the exterior surface18E of fuel filler pipe18. Fastener222C is coupled to band40C to tighten band40C around fuel filler pipe18to establish a friction fit between free ends of friction tabs T1, T2, T3, and T4and the exterior surface18E of fuel filler pipe18and hold band40C in a stationary position surrounding a portion of fuel filler pipe18. Fastener222C may be a bolt or weldment that is coupled to opposite ends of band40C.

Band40C includes a top strap40CT, a bottom strap40CB, and a loop40CL as suggested inFIG. 11. Bottom strap40CB is arranged to lie in side-by-side mating relation to top strap40CT. Loop40CL is arranged to interconnect top and bottom straps40CT,40CB and is formed to include friction tabs T1, T2, T3, and T4and coating bridges B1, B2, and B3. Mount-support flange21is coupled to free ends of top and bottom straps40CT,40CB to block movement of bottom strap40CB relative to top strap40CT and to tighten loop40CL to lie in a stationary position wrapped around and in engagement with exterior surface18E of fuel filler pipe18.

Loop40CL of band40C has a width (W) as shown inFIG. 11. Each of friction tabs T1, T2, T3, and T4has a length that is about equal to loop width (W) as suggested inFIG. 11.

Band40C is made of a single strip of metal material as suggested inFIG. 11. Band40C is formed (e.g., folded) to produce, in series, from end to end, upper segment B4U of coating bridge B4, first friction tab T1, first coating bridge B1, second friction tab T2, second coating bridge B2, third friction tab T3, third coating bridge B3, fourth friction tab T4, and lower segment B4L of coating bridge B4as suggested inFIG. 12.

A fuel tank fill assembly10D in accordance with a fourth embodiment of the present disclosure is configured to conduct fuel from a fuel-dispensing pump nozzle12to a fuel tank14as suggested inFIG. 13. Fuel fill tank assembly10D includes an inlet cup16sized to receive nozzle12, a fuel filler pipe18configured to conduct liquid fuel discharged by nozzle12into inlet cup16to an interior region14I of fuel tank14, and a filler-pipe anchor bracket20D. Fuel vapor conduit118is configured to conduct fuel vapor from a vapor space provided in fuel tank14under the control of a differential pressure valve118V to an outlet end18O of fuel filler pipe to be re-entrained into liquid fuel being dispensed by nozzle12under certain conditions during vehicle refueling. Fuel tank fill assembly10D also includes a two-layer corrosion-resistant protection coating30applied in accordance with the present disclosure as suggested inFIGS. 13 and 15.

Filler-pipe anchor bracket20D is mounted on fuel filler pipe18using a friction-fit system in accordance with the present disclosure to produce an uncoated fuel-delivery conduit11D as suggested inFIG. 14and to establish several dual-coat flow gaps (G4) between fuel filler pipe18and filler-pipe anchor bracket20D as suggested inFIGS. 14 and 15. Filler-pipe anchor bracket20D is also coupled to the uncoated fuel vapor conduit118that is arranged to extend alongside fuel filler pipe18as suggested inFIGS. 13 and 14to provide several dual-coat flow gaps (G4) between fuel vapor conduit118and filler-pipe anchor bracket20D as suggested inFIGS. 14 and 15. A corrosion-resistant protective coating30is applied to the uncoated fuel-delivery conduit11D and uncoated fuel vapor conduit118as suggested inFIG. 15so that exposed portions of pipe18and conduit118and bracket20D bordering dual-coat flow gaps (G4) are coated in accordance with the present disclosure along with all other exposed portions of the uncoated fuel-delivery conduit11D and fuel vapor conduit118.

In a two-step coating sequence used to coat the uncoated fuel-delivery conduit11D and fuel vapor conduit118and illustrated inFIG. 15, a corrosion-resistant first coating material31flows onto filler-pipe anchor bracket20D and fuel filler pipe18and fuel vapor conduit118and into dual-coat flow gaps (G4) to form a first coating layer31L in dual-coat flow gaps (G4). Next, a corrosion-resistant second coating material32flows onto the first coating layer31L on filler-pipe anchor bracket20D and fuel filler pipe18and fuel vapor conduit118and into dual-coat flow gaps (G4) to form a second coating layer32L in dual-coat flow gaps (G4). These coating layers31L,32L cooperate to form a multi-layer corrosion-resistant protective coating30all over fuel-delivery conduit11D and fuel vapor conduit118and inside the dual-coat flow gaps (G4) associated with fuel-delivery conduit11D and fuel vapor conduit118in accordance with the present disclosure.

In illustrative embodiments of the present disclosure, each of fuel filler pipe18and fuel vapor conduit118is made of carbon steel, first coating material31is an undercoat zinc-rich primer, and second coating material32is a top-coat anti-corrosion paint made, for example, of a durable thermoset material. It is within the scope of the present disclosure to apply second coating material32to a carbon steel pipe carrying an electroplated zinc-nickel primer using dip, drain, or spray applications. In accordance with the present disclosure, the multi-layer corrosion-resistant protective coating30is applied to an uncoated fuel-delivery conduit11D and an uncoated fuel vapor conduit118to provide a fuel tank fill assembly10D shown inFIGS. 13 and 15that meets establish fifteen year laboratory and vehicle corrosion testing standards.

Fuel filler pipe18of fuel-delivery conduit11D includes a nozzle-receiving outer end18O associated with and linked to inlet cup16and a fuel-discharging inner end18I adapted to be coupled to fuel tank14to discharge fuel into interior region14I of fuel tank14as shown inFIG. 13. Fuel filler pipe18also includes an interior surface18N arranged to define a fuel-conducting conduit18D extending between and interconnecting nozzle-receiving outer end18O and fuel-discharging inner end18I and an exterior surface18E arranged to face away from fuel-conducting conduit18D as shown inFIGS. 14 and 15.

Coating maximizer filler-pipe anchor bracket20D of the uncoated fuel-delivery conduit11includes a mount-support flange21D and a friction-fit pipe mount22D as shown inFIGS. 14 and 15. Filler-pipe anchor bracket20D is made of carbon steel in illustrative embodiments. Mount-support flange21D is adapted to be coupled to a vehicle frame10F to support fuel filler pipe18and fuel vapor conduit118relative to vehicle frame10F to cause fuel-discharging inner end18I of fuel filler pipe18to communicate with interior region14I of fuel tank14. An inner end of fuel vapor conduit118is also supported to communicate with a valve118V that communicates with interior region14I of fuel tank14as suggested inFIG. 13. Friction-fit pipe mount22D is coupled to mount-support flange21D and to exterior surface18E of fuel filler pipe18to retain mount-support flange21D in fixed relation to fuel filler pipe18. Friction-fit pipe mount22D includes an inner surface22DI facing toward exterior surface18E of fuel filler pipe18as shown inFIG. 15.

Multi-layer protective coating30covers exposed portions of exterior surface18E of fuel pipe18, fuel vapor conduit118, filler-pipe anchor bracket20D, and inlet16as suggested inFIGS. 13 and 15. In illustrative embodiments, multi-layer protective coating30may also cover an inner surface of fuel filler pipe18and fuel vapor conduit118. Protective coating30comprises a first coating layer31L made of primer31and adhered to exterior surface18E of fuel filler pipe18and filler-pipe anchor bracket20D and a second coating layer32L made of paint32and adhered to exposed surfaces of first coating layer31L as suggested inFIG. 15.

Each dual-coat flow gap (G4) is sized in accordance with the present disclosure to allow a zinc-rich primer31and a top-coat anti-corrosion paint32to flow into dual-coat flow gap (G4) when the primer31and paint32are applied in sequence as suggested inFIG. 15after the filler-pipe anchor bracket20D has been coupled to the fuel filler pipe18and fuel vapor conduit118using a friction-fit system in accordance with the present disclosure as suggested inFIG. 9. Inner surfaces22DI of friction-fit pipe mount22D of coating maximizer filler-pipe anchor bracket20D and opposed portions of cylindrical exterior surface18E of fuel filler pipe18are arranged to lie in confronting spaced-apart relation to one another as shown, for example, inFIGS. 14 and 15. Inner surfaces22DI and opposed portions of cylindrical exterior surface18E cooperate to form therebetween dual-coat flow gap (G4) means for first allowing first coating layer31L to adhere to exposed portions of inner surface22DI of friction-fit pipe mount22D and the undercoat primer31on the opposed portion of cylindrical exterior surface18E of fuel filler pipe18during deposition of first coating layer31L on friction-fit pipe mount22D and fuel filler pipe18and thereafter allowing second coating layer32L of top-coat paint32to adhere to exposed portions of first coating layer31L located in dual-coat flow gaps (G4) provided between friction-fit pipe mount22D and fuel filler pipe18. An exposed surface of second coating layer32L located in the dual-coat flow gaps (G4) cooperates to form an open space (S) in each region of dual-coat flow gap (G4) that is located between friction-fit pipe mount22D and the opposed portions of cylindrical exterior surface18E of fuel filler pipe18as suggested inFIG. 15. The dual-coat flow gaps (G4) are also formed around fuel vapor conduit118as suggested inFIGS. 14 and 15.

Friction tabs T1-T7are arranged to lie in circumferentially spaced-apart relation from one another about and in engagement with an exterior surface18E of fuel filler pipe18as suggested inFIG. 15. Each friction tab T1, T2, T3, and T4is formed to include a series of teeth that engage cylindrical exterior surface18E of fuel filler pipe18as shown inFIG. 15. Coating bridge B1interconnects friction tabs T1and T2. Coating bridge B3interconnects friction tabs T3and T4. Each of coating bridges B1, B3, and B4is arranged to lie in radially outwardly spaced-apart relation to a confronting portion of the cylindrical exterior surface18E of fuel filler pipe18that lies between the two friction tabs that are coupled to the selected coating bridge so as to define therebetween a dual-coat flow gap (G4) as shown inFIGS. 3 and 4. Thus, three separate dual-coat flow gaps (G4) are formed—one dual-coat flow gap (G4) for each of the coating bridges B1, B3, and B4.

Each of coating bridges B1and B3is curved in cross-section as shown, for example, inFIG. 15. Coating bridge B4is shaped differently in that it includes an upper segment B4U and a lower segment B4L as shown, for example, inFIGS. 14 and 15. An inner portion of upper segment B4U is curved in cross section and coupled to friction tab T1and an outer end of upper segment B4U is flat and coupled to mount-support flange21. An inner portion of lower segment B4L is curved in cross section and coupled to friction tab T4and an outer portion of lower segment B4L is flat and coupled to mount-support flange21. Fastener222D of pipe mount22is coupled to each of the flat upper and lower segments B4U, B4L of fourth coating bridge B4to tighten friction-fit pipe mount22D around the circular outer surface18E of the fuel filler pipe18to establish a friction fit between the free ends of friction tabs T1, T3, and T4and the cylindrical exterior surface18E of fuel filler pipe18as suggested inFIGS. 14 and 15.

Friction tabs T5-T7are arranged to lie in circumferentially spaced-apart relation from one another about and in engagement with a cylindrical exterior surface of fuel vapor conduit118as suggested inFIG. 15. Each friction tab T5, T6, and T7is formed to include a series of teeth that engage the cylindrical exterior surface of fuel vapor conduit118as shown inFIG. 15. Coating bridge B5interconnects friction tabs T5and T6. Coating bridge B6interconnects friction tabs T6and T7. A dual-coat flow gap (G4) is formed between fuel vapor conduit118and each of coating bridges B5and B6as shown inFIG. 15.

Coating bridge B2is shaped differently in that it includes an upper segment B2U, a middle segment B2M, and a lower segment B2L in accordance with one way to define coating bridge B2as shown inFIG. 15. Upper segment B2U interconnections friction tabs T2and T5. Middle segment B2M is provide by a portion of fuel vapor conduit118as shown inFIG. 15. Lower segment B2L interconnects friction tabs T7and T3. As suggested inFIG. 15, a relatively larger space (S4) is bounded by an exposed surface of coating layer32L located in the dual-coat flow gap (G4) associated with second coating bridge B2and formed between fuel vapor conduit118and fuel filler pipe18as suggested inFIG. 15

Friction tabs T1-T7cooperate with coating bridges B1-B6as suggested inFIG. 15to form a band40D that surrounds portions of the cylindrical exterior surface18E of fuel filler pipe18and portions of the cylindrical exterior surface of fuel vapor conduit118as suggested inFIG. 15. Fastener222D is coupled to band40D to tighten band40D around fuel filler pipe18to establish a friction fit between free ends of friction tabs T1, T2, T3, and T4and the cylindrical exterior surface18E of fuel filler pipe18and hold band40D in a stationary position surrounding a portion of fuel filler pipe18. Band40D is also tightened using suitable means around fuel vapor conduit118to establish a friction fit between free ends of friction tabs T5, T6, and T7and the cylindrical exterior surface of fuel vapor conduit118and hold band40D in a stationary position surrounding a portion of fuel vapor conduit118. Fastener222may be a bolt or weldment that is coupled to opposite ends of band40D.

Band40D includes a top strap40DT, a bottom strap40DB, and a loop40DL as suggested inFIG. 15. Bottom strap40DB is arranged to lie in side-by-side mating relation to top strap40DT. Loop40DL is arranged to interconnect top and bottom straps40DT,40DB and is formed to include friction tabs T1-T7and coating bridges B1-B5. Mount-support flange21is coupled to free ends of top and bottom straps40DT,40DB to block movement of bottom strap40DB relative to top strap40DT and to tighten loop40DL to lie in a stationary position wrapped around and in engagement with exterior surface18E of fuel filler pipe18and exterior surface of fuel vapor conduit118.