Fuel flange with molded-in wire harness and diode structure

• US 20090061692A1
• Filed: 08/26/2008
• Published: 03/05/2009
• Est. Priority Date: 08/31/2007
• Status: Active Grant

• Current Assignee: Continental Automotive Systems US Incorporated (Continental AG)
• Original Assignee: Continental Automotive Systems US Incorporated (Continental AG)
• Inventors: Brusoe, Michael T., Nederegger, Matthias
• Granted Patent: US 7,637,788 B2
• Time in Patent Office: Days
• US Class Current: 439/655
• CPC Class Codes: F02D 2400/22 Connectors or cables specially adapted for engine management applications
• CPC Class Codes: F02D 41/3005 Details not otherwise provided for
• CPC Class Codes: F02D 41/3082 Control of electrical fuel pumps
• CPC Class Codes: F02M 2037/082 Details of the entry of the current supply lines into the pump housing, e.g. wire connectors, grommets, plugs or sockets
• CPC Class Codes: F02M 37/0058 Returnless fuel systems, i.e. the fuel return lines are not entering the fuel tank
• CPC Class Codes: Y10T 29/53243 Multiple, independent conductors

Abstract

A wire harness assembly and flange combination of a mechanical returnless fuel system includes a wire harness assembly (10) having at least two terminals (14′). Each terminal is joined with at least one wire (12′) via an electrical connection (15′). Diode structure (16) is electrically connected between the at least two terminals. A body (18) of plastic material encapsulates at least the electrical connection. A flange (20) is molded from plastic material and defines an inside region (26) and an outside region (22). The terminals are accessible from the outside region of the flange, with ends of the wires being accessible from the inside region of the flange. The plastic material of the flange encapsulates at least a portion of body, the diode structure, and at least a portion of the terminals.

Claims

1. A wire harness assembly and flange combination of a mechanical returnless fuel system, the combination comprising:

a wire harness assembly including at least two terminals, each terminal being joined with at least one wire via an electrical connection, diode structure electrically connected between the at least two terminals, and a body of plastic material encapsulating at least the electrical connection, and

a flange molded from plastic material, the flange defining an inside region and an outside region, the terminals being accessible from the outside region of the flange, with ends of the wires being accessible from the inside region of the flange, wherein the plastic material of the flange encapsulates at least a portion of body, the diode structure, and at least a portion of the terminals.

2. The combination of claim 1, wherein the electrical connection is a crimp connection.

3. The combination of claim 1, wherein the electrical connection is a solder connection.

4. The combination of claim 1, wherein the plastic material of the flange and of the body is acetel resin.

5. The combination of claim 1, wherein four terminals and four associated wires are provided, two of the terminals and associated wires being constructed and arranged to provide power to a fuel pump, the diode structure being a single diode electrically connected between the two terminals that power the fuel pump.

6. The combination of claim 1, wherein the body of plastic material encapsulates at least the electrical connection and the diode structure.

7. A wire harness assembly and flange combination of a mechanical returnless fuel system, the combination comprising:

a wire harness assembly including at least two terminals, each terminal being joined with at least one wire via an electrical connection, diode structure electrically connected between the at least two terminals, and a body of plastic material encapsulating at least the electrical connection, and

a flange defining an inside region and an outside region, the terminals being accessible from the outside region of the flange, with ends of the wires being accessible from the inside region of the flange,

wherein the at least a portion of the body and the entire diode structure is in sealed relation with the flange.

8. The combination of claim 7, wherein the flange is metal and the body of plastic material encapsulates at least the electrical connection and the diode structure, with the body being in sealed relation with the flange.

9. The combination of claim 7, wherein the body of plastic material encapsulates at least the electrical connection and the diode structure and wherein the flange is of plastic material with the plastic material of the flange encapsulating at least a portion of body, the diode structure, and at least a portion of the terminals.

10. The combination of claim 7, wherein the flange is of plastic material with the plastic material of the flange encapsulating at least a portion of body, the diode structure, and at least a portion of the terminals.

11. The combination of claim 7, wherein the electrical connection is a crimp connection.

12. The combination of claim 7, wherein the electrical connection is a solder connection.

13. The combination of claim 9, wherein the plastic material of the flange and of the body is acetel resin.

14. The combination of claim 10, wherein the plastic material of the flange is acetel resin.

15. The combination of claim 7, wherein four terminals and four associated wires are provided, two of the terminals and associated wires being constructed and arranged to provide power to a fuel pump, the diode structure being a single diode electrically connected between the two terminals that power the fuel pump.

16. A method of providing a wire harness assembly and flange combination of a mechanical returnless fuel system, the method including:

providing a wire harness assembly including at least two terminals, with diode structure electrically connected between the at least two terminals, and

molding a flange from plastic material, the flange defining an inside region and an outside region, the terminals being accessible from the outside region of the flange, wherein the molding step includes molding the plastic material of the flange to encapsulate the diode structure and at least a portion of the terminals.

17. The method of claim 16, wherein the plastic material is acetel resin.

18. The method of claim 16, wherein prior to the molding step, the method includes forming a connector body, associated with the terminals, from plastic material, and during forming of the connector body, the diode structure is over-molded with the plastic material forming the connector body.

19. The method of claim 17, wherein the step of providing the wire harness includes connecting a wire to each terminal via an electrical connection.

20. The method of claim 19, wherein during the forming step, the electrical connection is encapsulated by the plastic material forming the connector body.