Sealed fuel level sensors

• US 7,555,946 B2
• Filed: 04/19/2007
• Issued: 07/07/2009
• Est. Priority Date: 08/30/2004
• Status: Active Grant

• Current Assignee: Delphi Technologies Ip Limited (BorgWarner Incorporated)
• Original Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Inventors: Ireland, Hugh, Sawert, Ulf
• Primary Examiner(s): Williams; Hezron
• Assistant Examiner(s): Shah; Samir M
• Application Number:
  US11/737,543
• Publication Number:
  US 20070214882A1
• Time in Patent Office: 810 Days
• Field of Search: 733/13, 733/14, 733/17, 732/90.R, 732/91, 733/01, 733/04.R, 733/05, 733/09, 733/11, 733/225
• US Class Current: 73/305
• CPC Class Codes: G01F 23/32 using rotatable arms or other pivotable transmission elements
• CPC Class Codes: G01F 23/36 using electrically actuated indicating means G01F23/38 takes precedence
• CPC Class Codes: G01F 23/363 using electromechanically actuated indicating means

Abstract

A sealed fuel level sensor for a fuel tank is provided. The sealed fuel level sensor includes a frame having a cavity therein. The sealed fuel level sensor further includes a variable resistor disposed in the cavity and operatively supported by the frame. The sealed fuel level sensor further includes a wiper disposed in the cavity for rotation relative to the variable resistor and for contacting the variable resistor. The sealed fuel level sensor further includes a cover connected to the frame to enclose the cavity. The cover includes an aperture extending therethrough. The sealed fuel level sensor further includes a bushing disposed within the aperture. The bushing having a body portion and a lip seal portion disposed on the body portion. The lip seal portion and the body portion having a bore therein. The sealed fuel level sensor further includes a float arm having an end extending through the aperture of the cover and the bore of the bushing and connected to the wiper. The lip seal portion engages the float arm to form a seal.

Claims

1. A sealed fuel level sensor for a fuel tank, comprising:

a frame having a cavity therein;

a variable resistor disposed in the cavity and operatively supported by the frame;

a wiper disposed in the cavity for rotation relative to the variable resistor and for contacting the variable resistor;

a cover connected to the frame to enclose the cavity, the cover including an aperture extending therethrough;

a bushing disposed within the aperture, the bushing having an annular body portion disposed about an axis and a coaxial annular lip seal portion affixed to the body portion wherein the lip seal portion covers an axial end surface of the body portion and peripherally encircles a portion of the outer peripheral surface of the body portion, the lip seal portion and the body portion having an axial bore therethrough;

a float arm having an end extending through the aperture of the cover and the bore of the bushing and connected to the wiper, the lip seal portion engaging the float arm to form a seal; and

a float connected to the float arm such that the float moves the float arm and the wiper relative to the variable resistor as a level of fuel increases and decreases in the fuel tank.

2. The sealed fuel level sensor of claim 1, wherein the lip seal portion is an elastomeric lip seal portion.

3. The sealed fuel level sensor of claim 2, wherein the elastomeric lip seal portion is constructed from at least one of a fluorocarbon, a fluorosilicon, a nitrile, a hypalon, an epichlorohydrin, and an a perfluoroelastomer.

4. The sealed fuel level sensor of claim 2, wherein the elastomeric lip seal portion is chemically treated with an adhesive to bond the elastomeric lip seal portion to the body portion.

5. The sealed fuel level sensor of claim 1, wherein the body portion has an undercut groove thereon configured to receive a portion of the lip seal portion therein for mechanically locking the body portion to the lip seal portion.

6. The sealed fuel level sensor of claim 1, wherein the body portion is constructed from at least one of brass, carbon, stainless, steel, and a ceramic material.

7. The sealed fuel level sensor of a fuel tank, comprising;

a frame having a cavity therein;

a variable resistor disposed in the cavity and operatively supported by the frame;

a wiper disposed in the cavity for rotation relative to the variable resistor and for contacting the variable resistor;

a cover connected to the frame to enclose the cavity, the cover including an aperture extending therethrough

a bushing disposed within the aperture. the bushing having a body portion and a lip seal portion disposed on the body portion. the lip seal portion and the body portion having a bore

a float arm having an end extending through the aperture of the cover and the bore of the bushing arid connected to the wiper, the lip seal portion engaging the float arm to form a seal; and

a float connected to the float arm such that the float moves the float arm and the wiper relative to the variable resistor as a level of fuel increases and decreases in the fuel tank;

wherein the bushing further has a pair of posts extending outwardly and spaced radially to limit movement of the float arm.

8. A sealed fuel level sensor for a fuel tank, comprising:

a frame having a cavity therein;

a variable resistor disposed in the cavity and operatively supported by the frame;

a wiper disposed in the cavity for rotation relative to the variable resistor and for contacting the variable resistor;

a cover connected to the frame to enclose the cavity, the cover including an aperture extending therethrough;

a bushing disposed within the aperture, the bushing having an annular metallic body portion disposed about an axis and a coaxial elastomeric lip seal portion affixed to the body portion wherein the lit seal portion covers an axial end surface of the body portion and peripherally encircles a portion of the outer peripheral surface of the body portion, the elastomeric lip seal portion and the metallic body portion having an axial bore therethrough;

a float arm having an end extending through the aperture of the cover and the bore of the bushing and connected to the wiper, the elastomeric lip seal portion engaging the float arm to form a seal; and

a float connected to the float arm such that the float moves the float arm and the wiper relative to the variable resistor as a level of fuel increases and decreases in the fuel tank.

9. The sealed fuel level sensor of claim 8, wherein the elastomeric lip seal portion is constructed from a polymeric material.

10. A sealed fuel level sensor for a fuel tank, comprising:

a frame having a cavity therein;

a variable resistor disposed in the cavity and operatively supported by the frame;

a wiper disposed in the cavity for rotation relative to the variable resistor and for contacting the variable resistor;

a cover connected to the frame to enclose the cavity, the cover including an aperture extending therethrough;

a bushing disposed within the aperture, the bushing having a body portion, a lip seal portion disposed on a first end of the body portion, and a flange portion disposed on a second end of the body portion, the lip seal portion and the body portion and the flange portion having a bore extending therethrough, the flange portion having a pair of posts extending outwardly to limit movement of a float arm;

the float arm having an end extending through the aperture of the cover and the bore of the bushing and connected to the wiper, the lip seal portion engaging the float arm to form a seal; and

a float connected to the float arm such that the float moves the float arm and the wiper relative to the variable resistor as a level of fuel increases and decreases in the fuel tank.

11. A sealed fuel level sensor for a fuel tank, comprising:

a frame having a cavity therein;

a variable resistor disposed in the cavity and operatively supported by the frame;

a wiper disposed in the cavity for rotation relative to the variable resistor and for contacting the variable resistor;

a cover connected to the frame to enclose the cavity, the cover including an aperture extending therethrough, the cover having a pair of posts extending outwardly to limit movement of a float arm;

a bushing disposed within the aperture, the bushing having a body portion and a lip seal portion disposed on the body portion, the lip seal portion and the body portion having a bore therein;

the float arm having an end extending through the aperture of the cover and the bore of the bushing and connected to the wiper, the lip seal portion engaging the float arm to form a seal; and

a float connected to the float arm such that the float moves the float arm and the wiper relative to the variable resistor as a level of fuel increases and decreases in the fuel tank.