VEHICLE FILLER NECK MOUNTED FUEL FILTER SYSTEM

A vehicle filler neck mounted fuel filter system (“filter system”) is disclosed. The filter system may be configured to filter undesirable particulate matter and impurities from entering a vehicle's gas tank from a gas pump nozzle. The filter system may provide a filter tube that incorporates the primary filtering elements (e.g. mesh) and slides into a vehicles filler neck, secured and mounted in an assembly that can include a filter tube holder, compression sleeve, a pressure valve assembly and other backpressure-alleviating features, and a cap. A filter system can be sized and configured to accommodate a wide array of form factors and vehicles, including gasoline and diesel engine vehicles and high-flow commercial vehicles.

FIELD OF THE INVENTION

The present disclosure generally relates to fuel filters. More specifically, various embodiments of the present disclosure may relate to devices and systems for filtering fuel as it is dispensed into a vehicle.

BACKGROUND

Combustion engine vehicles such as cars as trucks are commonly fueled from fuel storage tanks at commercial gas stations. Such storage tanks can harbor a nontrivial amount of, dirt, sludge, sediment, and other particulate matter that, if left in the fuel stream, can have negative effects on a vehicle fuel system. Such undesirable matter can be found in the dispensable fuel volume even in quiescent tanks, but it can be particularly stirred up by events such as a tanker truck refill.

Gas stations may be subject to regulatory regimes that require filtration systems to decrease the concentration of undesired particulates. However, an individual vehicle owner has little means to determine the compliance regime to which a particular station is subject. This is particularly true when traveling long distances and filling up in unfamiliar locales. The user also has no way of knowing if a gas station actually complies with the regulations or whether the station has maintained its filters. Ultimately, the user puts their vehicle at risk because they do not know if the actual particulate count of the dispensed fuel is within acceptable limits.

Vehicles frequently have their own internal filtration systems, as well. However, an internal fuel filter is often placed immediately before the fuel injectors in the fuel delivery system after the gas tank, fuel pump, and associated fuel lines. That means any impurities that exit the nozzle of a gas station pump will necessarily be deposited into the vehicle's gas tank along with the fuel. Such sediments and sludge can be deleterious to the gas tank and other fuel system components, even if the undesirable matter is largely prevented (by the fuel filter) from reaching the combustion chamber.

Additionally, fuel filters have varying effectiveness at filtering out contaminants at various particulate sizes. A filter with 99% efficiency, when functioning optimally, will still pass 1% of impurities at or above its size rating. Fuel filters accumulate impurities over time, which can cause efficiency to drop, allowing undesirable matter from the gas tank to enter the combustion system and reduce the lifespan of engine components. The dirtier the upstream fuel from the gas tank, the quicker the accumulation of impurities in the filter.

While internal fuel filters are generally designed to be replaceable, accessing and replacing one can be a non-trivial (and potentially costly) task. Therefore, users would prefer to delay doing so by providing the filter a relatively cleaner stream of incoming fuel.

Therefore, a need exists for an additional filtration stage between the gas station pump and the vehicle's gas tank, such as a fuel filter that can be mounted into a vehicle's fuel filler neck.

SUMMARY

A vehicle filler neck mounted fuel filter system may be provided. This brief overview is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This brief overview is not intended to identify key features or essential features of the claimed subject matter. Nor is this brief overview intended to be used to limit the claimed subject matter's scope.

The present disclosure describes a vehicle filler neck mounted fuel filter that can provide a filtration stage at the entry point to the vehicle's gas tank. In one example of a vehicle filler neck mounted fuel filter, the filter assembly can include: a cap; a pressure valve casing that houses a spring, a spring retention ring, and a pressure valve base; a filter tube; a filter tube holder; and, a compression sleeve.

In such a system, a compression sleeve may be inserted into the mouth of a gas tank, into the filler neck, with its seating ring against the outer edge of the mouth of the gas tank. A filter tube may itself incorporate threading features that allow it to be screwed directly into a compression sleeve without a filter holder component, or a filter tube holder may be screwed, using integrated external threads, into matching internal threads on the interior wall of the compression sleeve. With a filter tube holder, the filter tube can be inserted into the through hole in the holder's center to rest on a filter tube seating shelf.

At the mouth of a filter tube, a pressure valve system can keep the tube assembly in place while allowing for the release of back pressure from tank vapors. A cap may interface with the filter system, holding the pressure valve assembly and sealing the entire assembly when affixed. A filter tube can have a lattice that supports a filter mesh. Such mesh can provide the filtering mechanism as fuel passes through it.

DETAILED DESCRIPTION

The following detailed description refers to the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the following description to refer to the same or similar elements.

Consistent with embodiments of the present disclosure, a vehicle filler neck mounted fuel filter (“fuel filter”, “filter system”, or simply “system”)100may be provided, as illustrated inFIGS. 1A-1F. A vehicle filler neck mounted fuel filter100may be used to provide a particulate-removing filtration stage at the point of entry for fuel filling (commonly a gas pump). The terms “gas”, “gas station”, “gas pump”, and “gas tank”, are used in the broad sense of common parlance, and include various fuel compositions such as gasoline fuel, diesel fuel, biodiesel fuel, ethanol, kerosene, fuel oil, fuel blends, etc., as well as various different filling and storage mechanisms.

In an embodiment, system100can comprise a compression sleeve700that can fit in a filler neck of a vehicle. The filler neck can be the input point for a gas nozzle. The system100can include a filter holder600that can fit inside the inner wall of the filler neck hole710. It can also include a filter tube500that can be inserted through the filter holder hole610and seat on the filter holder seating ring610. The filter tube500can include filter mesh550, which can facilitate the fuel filtering function of system100. The filter tube500can be structurally supported by filter lattice540. In one example, a cap200can seal and secure system100in the vehicle's fuel system, which may prevent or mitigate the egress of fluids (e.g. liquid fuel, fuel vapors, or other gasses) from the fuel tank. For example, fuel can be pumped through, and filtered by, system100by first removing the cap200and then inserting a fuel pump's fuel filler nozzle into the filter tube mouth510and then pumping the gas.

In another embodiment, system100can comprise a compression sleeve700, with a filter tube500going through and seating against the compression sleeve hole710. In one example, this can be done without a filter holder600. In such an embodiment, threading features630that might otherwise be found on a filter holder600may be found as threading features530on the filter tube500itself. In yet another embodiment, system100may not comprise a cap200, and/or may not comprise a pressure valve system (e.g. valve casing300and pressure valve assembly400).

In yet another embodiment, system100can comprise a filter tube500with a flexible filter mesh550but without filter lattice540. In such an embodiment, the filter tube500may be inserted through the filter holder600(or compression sleeve700). This can be accomplished, in an example, without exerting force on the filter tube500at the end closest to the filter tube seating ring520. Instead, the user can push the mesh550itself through by using an assisting rod that is inserted through the filter tube mouth510to the (distal) tip580of the filter mesh550.

Filter system100can be mounted into the filler neck (i.e., the opening to the gas tank, into which fuel is pumped) of a vehicle. Filler necks frequently have an entry point diameter smaller than 2 inches. In various embodiments, filler necks may be sized to accommodate fuel filler nozzles having diameters of approximately, e.g., 13/16 inches (some gasoline nozzles), 15/16 inches (some diesel nozzles), or 1¼ inches (some high flow-rate diesel nozzles). System100can be dimensioned to both a) securely fit into such varied filler neck entry points, while also b) allowing ingress of the respective filler nozzle into the opening so that the vehicle can be fueled.

The exterior and interior diameters of the components that are inserted into the filler neck can accommodate various fueling regimes. For example, a “noncommercial” (e.g. passenger vehicle and light duty truck) gasoline or diesel fueling regime may have a slower maximum flow rate and narrower diameter filler nozzle than a “commercial” (e.g. tractor trailer) diesel fueling regime. The maximum flow rates may be set by law or regulation to be lower than the fuel filling pump's maximum physical capacity to dispense fuel. Some noncommercial fuelling regimes may have maximum flow rates such as 10 gal/min, 30 L/min, 50 L/min, etc. Some commercial fuelling regimes may have maximum flow rates such as 35 gal/min, 90 L/min, 130 L/min, etc. System100can have component dimensions and filter tube500characteristics to accommodate the sizes and flow rates of these various fueling regimes and others in various embodiments. The capacity for even higher flow rate fueling regimes (e.g., for watercraft, aircraft, heavy construction vehicles, or military vehicles) is also contemplated in various embodiments of system100.

Referring now toFIGS. 1A-1I, there are shown filter systems100consistent with embodiments of the present disclosure. A filter system100can accommodate numerous types of vehicle fuel systems, fuel compositions, filler neck diameters, entry point configurations (e.g., screw cap, capless, built-in misfueling prevention features), and backpressure mitigation needs. Filter system100can accommodate gasoline engine vehicles such as cars and motorcycles (see, for exampleFIGS. 1A-E), non-commercial diesel engine vehicles such as pickup trucks (see, for exampleFIGS. 1F-G), and commercial diesel engine vehicles such as tractors and tractor trailers (see, for exampleFIGS. 1H-I).

Embodiments of fuel filter100can operate with a filter tube500and one or more additional components such as valve casing300, filter holder600, and compression sleeve700. Some embodiments can be configured to operate as a “standalone” fuel filter100consisting of just a filter tube500.

Other vehicles/equipment (e.g. lawn mowers, RVs, ATVs, boats, alternative fuel vehicles that utilize biodiesel, ethanol, kerosene, etc.) may be consistent with certain of the above categories and/or be accommodated with their own configurations in various embodiments.

Filter system100can also incorporate anti-static features. This can be accomplished through material selection and features designed to suppress or eliminate the introduction of static arcs. Such instances of electrical discharge or sparking could pose a hazard in the vicinity of the gas tank and fuel dispensing equipment. Thus the individual components and system100as a whole can be configured to inhibit triboelectric charging and static discharge. As examples, this can be done with naturally anti-static structural materials, incorporation of static preventing agents into component materials, anti-static coatings, various physical arrangements, and other anti-triboelectric mechanisms.

Referring now toFIGS. 2A-C, there is shown a cap200consistent with embodiments of the present disclosure. A cap200can have a handle210used for removing and affixing the cap200. Cap200can have a hole or other affixing mechanism for a tether800. Some embodiments may not have or require a cap200, and some embodiments may be configured to interface with a vehicle-integral cap (e.g., as part of the door to the filler neck compartment. Cap200can have a gasket250(e.g., a ring gasket in approximately the space indicated) to help effect a seal between system100and the vehicle's fueling system.

In some embodiments, cap200can be a dedicated component of the filter system100. In other embodiments, cap200may be the vehicle manufacturer-provided gas cap, or one provided by the vehicle operator, or be integrated with the fuel door. System100can work in conjunction with its own cap200, any of the other cap200regimes listed above, and many other configurations of gas tank entry chamber.

Referring now toFIGS. 3A-C, there is shown a valve casing300consistent with embodiments of the present disclosure. Valve casing300can have a valve cavity310that accommodates a pressure valve assembly400. Further, it may have one or more retention tabs320that can interface with one or more valve casing retention posts230on the cap200, so as to secure the valve casing300and its attendant pressure valve assembly400in place on the cap200(and in spatial relation to the filter tube mouth510with which it can also interface). Valve casing300may have one or more pressure valve holes350,360that can be part of a system for alleviating backpressure from the gas tank. There may be one primary hole350, an array of same sized holes360, a large350and one or more smaller360holes, or other shapes or configurations (e.g. slit vents, square ports, or any other shape suitable for the backpressure mitigation function).

Referring now toFIGS. 4A-H, there is shown a pressure valve assembly400consistent with embodiments of the present disclosure. A pressure valve assembly400can include a spring retention ring420, pressure valve base430, valve interior spring440, and a valve bottom spring. In an embodiment, spring retention ring420can be employed with the spring housing450upward protruding, as shown inFIGS. 4A-D, such that the upper portion of spring440seats in the corresponding “trough” on the underside of spring retention ring420. In another embodiment, spring retention ring420can be employed upside-down from the views shown inFIGS. 4A-D, such that upper portion of spring440seats around the downward protruding spring housing450.

Referring now toFIGS. 5A-F, there are shown filter tubes500consistent with embodiments of the present disclosure. Filter tubes500and their constituent components (e.g. seating ring520) can be of varying lengths, tube diameters, and shapes to accommodate different types and models of vehicle, fuel composition, flow rates, etc.

Note that different shapes and configurations of filter tube seating ring520(solid wall, separated wall, stacked double ring, notched single ring, cylindrical, conical, off-center, etc.) can address varying needs. In various embodiments, filter tube500may have one or more pressure relief channels590that can be (or be part of) a mitigating feature for backpressure buildup from the gas tank.

Some embodiments, such as those depicted inFIGS. 1D-E, may be configured to operate with a cap that is supplied by the vehicle operator (e.g. an OEM cap or fuel door-attached cap-like structure). In such embodiments, the seating ring520may have a conical shape, which can help fuel filter100fit within the confines of the cap and/or gas tank entry chamber.

In order to accommodate the wide variety spatial configurations of vehicle fuel doors, caps, and gas tank entry chambers, or due to other factors, embodiments may comprise seating rings520that are non-circular in shape (e.g. ovoid, polygonal, irregular) and/or off-center from the filter tube shaft570.

Mesh550can be sized and patterned to filter out particulate matter above a desired size threshold. Mesh550can have anti-foaming qualities. In various embodiments, mesh550can incorporate or form structural components that serve the role of filter lattice540. Mesh550may be embedded in (and thus attached to) the bottom of seating ring520. This may occur as part of the manufacturing process.

Lattices540can come in a wide variety of configurations; a few of the many possibilities are depicted inFIGS. 1A, 1C, and 1H. In some embodiments, mesh550can be used without filter lattice540, as is depicted inFIG. 1E. In mesh-only embodiments, an assistive tool (e.g. a rod) may be inserted into the filter tube500in order to feed the non-rigid filter tube shaft570. Mesh550may be molded to, affixed to, integrated with, or embedded in lattice540. This may occur as part of the manufacturing process. In one example, a cylindrical mesh550may undergo an injection molding process that forms the supporting lattice540, these components together forming the filter tube shaft570.

The filtration feature represented diagrammatically by mesh550may also be accomplished by configurations other than a mesh-patterned material—e.g. depth filtering.

Filer tube500can comprise a removal mechanism such as one or more removal notches560. Such a feature can allow a user to manually, or with the help of a tool, extricate a filter tube500from the filler neck of a vehicle.

Referring now toFIGS. 6A-C, there is shown a filter holder600consistent with embodiments of the present disclosure. A filter holder600can include a hole610through its cylindrical center. A filter holder600can also include a filter holder seating ring620, the underside (or filter holder lip660) of which can seat against the area outside the entrance to the vehicle's filler neck. A filter holder600can include filter tube seating shelf670configured to interface with the filter tube seating ring520of a filter tube500.

A filter tube holder600may be inserted into the through hole710in a the compression sleeve700. A filter tube holder600can act as a positioning guide, mechanical securing element, and stopping point (i.e. preventing filter tube ingress down the filler neck and into the gas tank) for a filter tube500. A filter tube holder600can have threading630, and this threading630can interface with corresponding threading730on a compression sleeve700.

Referring now toFIGS. 7A-C, there is shown a compression sleeve700consistent with embodiments of the present disclosure. A compression sleeve700can be made of a flexible or semi-rigid polymer material that can be inserted into the externally accessible mouth of a gas tank and down the filler neck, contacting the inner walls of the filler neck and leaving a through hole710for additional components (and of course, ultimately, fuel). In an embodiment, a compression sleeve700can be inserted into the filler neck, up to its compression sleeve seating ring720. The compression sleeve700can be a feature that helps achieve a secure fit for system100in the filler neck, by, for example, constructing the compression sleeve's700out of a pliable or semi-flexible material, and/or by including compression features740such as bumps or protrusions on the outer surface of the compression sleeve700.

A compression sleeve700can have compression features740that enhance the grip and sealing characteristics of the assembly, which can be beneficial in mechanically securing the assembly in place (against, e.g., vapor backpressure from the gas tank, or pulling forces experienced in fuel pump operation). Compression features740may, but need not, be a series of bumps, ridges, or protrusions. Additionally or alternatively, compression features740may comprise other suitable structures and combinations thereof.

A compression sleeve700may comprise a spring, inflation, or expansion mechanism that extends from an outer surface of filter tube500to actively tension system100against the interior wall of the filler neck. In some embodiments compression sleeve700may be detachable or otherwise separate from filter tube500, while in other embodiments it may be integrated therewith. Compression sleeve700components may be variously detachable and integrated in some embodiments.

Referring now toFIG. 8, there is shown a tether800consistent with embodiments of the present disclosure. Tether800can be affixed to a cap200in order to prevent misplacement or loss of the cap200.

Referring now toFIG. 9A-D, there are shown filter tube seating rings520consistent with embodiments of the present disclosure (jagged lines indicate matter cut off from the depicted view).FIGS. 9A-Billustrate a filter tube seating ring520which may have a circular exterior face and a tapered profile from external face to shaft570(the shape when viewed from the side resembling a conical frustum). Pressure relief channels590may provide a gas flow channel connecting the interior of the filler neck with the exterior beyond the face of the seating ring520. In some embodiments, various other components of system100may be shaped to interface with a seating ring520that has a tapered profile.

FIGS. 9C-Dillustrate a filter tube seating ring520which may have an irregular-shaped exterior face and a tapered profile from external face to shaft570, with the filter tube mouth510off-center with respect to the exterior face and pressure relief channels590arranged asymmetrically. Vehicles have a wide variety of filler neck entry point configurations. An off-center filter tube mouth510may assist in the proper seating and fitting of filter tube500into the filler neck of some vehicles. A seating ring520having a shape and arrangement of pressure relief channels590similar to that depicted inFIG. 9Cmay provide favorable seating and pressure relief characteristics with certain configurations of filler neck. Embodiments having any one or more of the following features need not have any one or more of the other listed features: an irregular-shaped exterior face, an off-center filter tube mouth510, a tapered profile, or an asymmetrical arrangement of pressure relief channels590.

In general, depicted or described variations in features may be found in combination with other depicted or described variations, whether or not such combination is itself depicted or described. Various aspects and components of system100, depicted or described as separate may in some embodiments be combined, attached, integrally incorporated, etc. Likewise, various aspects and components may in some embodiments be separated into more or different components while still achieving similar functions and system100functionality.

Referring now toFIG. 10, there is shown a method of installing and using a filter system100consistent with embodiments of the present disclosure. At step1010, a compression sleeve700can be inserted in the filler neck of a vehicle, up to the compression sleeve seating ring720. The outer wall of the compression sleeve700and/or its compression features740(if any) may contact the inner wall of the filler neck. The next step may be1020if system100comprises a filter holder600, or step1030if system100does not comprise a filter holder600(e.g., when aspects of the filter tube500is configured to achieve various goals that could otherwise be achieved by a filter holder600).

At step1020, a filter holder600can be inserted into compression sleeve700up to filter holder seating ring620(i.e., with the bottom lip660of seating ring620contacting the upper surface of seating ring720). The insertion process may include simply translational (straight in) motion, or may also include rotational (twisting) motion. The latter may be the case, e.g., in an embodiment where the filter holder600comprises threading features630. In such an embodiment, compression sleeve700may comprise threading features730. Threading features630and730may be designed to physically interface.

At step1040, a filter tube500can be inserted into filter holder600. In an embodiment, filter tube500can have a seating ring520that can seat against a filter tube seating shelf feature670of filter holder600. In embodiments where filter tube500lacks supporting lattice540, the insertion process may involve an aid such as a push rod.

At step1030, a filter tube500(which may have integral features for interfacing with a compression sleeve700) can be inserted through the hole710in the compression sleeve700. The insertion process may include simply translational (straight in) motion, or may also include rotational (twisting) motion.

At step1050, a user can insert the fuel filler nozzle of a fuel pump into the filter tube mouth510that is now the entry point into the vehicle fuel system.

At step1060, a user can pump fuel through system100, thereby passing the fuel stream through the mesh550and its filtrative properties.

At step1070, a user may optionally place or replace the cap200in position affixed to the vehicle. This step may not be necessary or possible, as with embodiments of system100that do not comprise a cap200.

The order of steps presented herein and in the figures are only illustrative of the possibilities and those steps can be executed or performed in any suitable fashion. Moreover, the various features of the examples described here are not mutually exclusive. Rather any feature of any example described here can be incorporated into any other suitable example. It is intended that the specification and examples be considered as exemplary only.

Other examples of the disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the examples disclosed herein. The examples are not limited to use with a particular vehicle type, and may be applied to the fueling of any compatible vehicle.

Though some of the described methods have been presented as a series of steps, it should be appreciated that one or more steps can occur simultaneously, in an overlapping fashion, or in a different order. The order of steps presented is only illustrative of the possibilities and those steps can be executed or performed in any suitable fashion. Moreover, the various features of the examples described here are not mutually exclusive. Rather any feature of any example described here can be incorporated into any other suitable example. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the disclosure being indicated by the following claims.