Patent ID: 7677098

Claim:
A sealed fuel level sensor for a fuel tank comprising: a frame having a cavity therein; a cover connected to said frame to enclose said cavity; a float arm coupled to one of said frame and said cover; a float connected to said float arm and configured such that said float moves said float arm as a level of fuel increases and decreases in the fuel tank; and a light-responsive sensor configured to generate a fuel level signal indicative of a fuel level in the fuel tank based on the movement of said float arm; wherein said frame includes a boss projecting therefrom into said cavity towards said cover, said boss including a cylindrical through-bore having an axis, said boss comprising translucent material; said frame further includes a support projecting therefrom into said cavity towards said cover, said support including a mounting surface; a light source; said light-responsive sensor includes a photoelectric sensor disposed on said mounting surface so as to face said boss; said fuel level sensor further including a hub disposed in said through bore, said hub having a main cylindrical body portion with a first, outside diameter, said hub further having a retaining flange extending from said cylindrical body portion at a first end thereof, said retaining flange having a second, outside diameter greater than a third diameter of said cylindrical through-bore so as to retain said hub in said through bore, said hub having a first, light-source recess at said first end thereof configured to receive said light source, said hub further having a second recess formed at a second end thereof axially opposite said first end configured to receive and retain a proximal portion of said float arm such that said movement of said float arm causes rotation of said hub in said cylindrical bore; wherein said cylindrical body further includes an opening through an outer surface thereof in light communication with said light-source recess, said opening configured in size and shape to vary an amount of light passing out of said opening and into a line-of-sight to be received by said photoelectric sensor as a function of a rotational position of said hub.