Fuel filler tube assembly and manufacturing method

1. A method comprising:

forming a funnel insert with a first diameter portion larger than a second diameter portion;

forming a filler tube including a funnel portion having a first diameter and a first axis and an elongated portion having a second diameter smaller than said first diameter and a second axis offset from said first axis;

attaching said funnel portion of said filler tube to said second portion of said funnel insert; and

configuring a transition portion of said funnel portion to induce a swirl to passing fuel for venting vapors from said fuel tank during fuel filling.

2. The method of claim 1 , further comprising forming a sealing surface about an inlet opening to said funnel insert.

3. The method of claim 2 , wherein said forming a sealing surface includes rolling over an edge defining the inlet opening.

4. The method of claim 1 , further comprising cutting a length of tube stock to form said filler tube.

5. The method of claim 1 , further comprising forming a nozzle receptor in said funnel insert.

6. The method of claim 1 , further comprising joining opposite ends of a vent tube to said funnel portion and said fuel tank, respectively.

7. The method of claim 1 , further comprising joining a vent tube to said funnel portion of said filler tube.

8. The method of claim 1 , further comprising forming threads in said funnel insert.

9. A fuel filler tube assembly comprising:

a funnel portion of a filler tube including a tubular body defining an inlet larger than an outlet, said inlet of said funnel portion having a first axis and receiving a funnel insert including a nozzle opening positioned to cooperate with an internal configuration of said tubular body between said inlet and said outlet to induce a swirl to vent vapors from fuel flowing through said tubular body, said outlet having a second axis offset from said first axis.

10. The fuel filler tube assembly of claim 9 , wherein said outlet of said filler tube is attached to a fuel tank.

11. The fuel filler tube assembly of claim 9 , further comprising a vent tube connected to said filler tube.

12. The fuel filler tube assembly of claim 11 , wherein said vent tube also connects said filler tube and said fuel tank.

13. The fuel filler tube assembly of claim 9 , wherein said internal configuration of said tubular body includes a tapered section of said tubular body.

14. The fuel filler tube assembly of claim 13 , wherein said tapered section includes an elliptically shaped junction between a first portion of said tubular body including said inlet and a second portion of said tubular body including said outlet.

15. The fuel filler tube assembly of claim 14 , wherein said elliptically-shaped junction lies on a plane inclined at an angle to an axis of at least one of said inlet and said outlet.

16. The fuel filler tube assembly of claim 14 , wherein said inlet has a diameter D 1 , said outlet has a diameter D 2 , and D 1 is at least one and a half times D 2 .

17. The fuel filler tube assembly of claim 9 , wherein said filler tube is a seamless tube.

18. The fuel filler tube assembly of claim 9 , wherein said funnel insert is a seamless tube.

19. The fuel filler tube assembly of claim 9 , wherein said funnel insert includes integrally formed threads.

20. The fuel filler tube assembly of claim 9 , further comprising a fuel cap selectively engaging said funnel insert.

21. The fuel filler tube assembly of claim 9 , wherein said funnel insert includes a sealing surface operable to selectively engage said fuel cap.

22. The fuel filler tube assembly of claim 21 , wherein said funnel insert includes a larger diameter portion having an inlet opening creating said sealing surface.

23. A method comprising:

drawing a funnel insert with a first diameter portion larger than a second diameter portion;

forming a funnel portion at an end of a filler tube, an opposite end of said filler tube being operable to be directly attached to a fuel tank;

forming a relatively large inlet at one end of said funnel portion, said inlet having a first axis;

forming a relatively small outlet at said opposite end of said funnel portion, said outlet having a second axis offset from said first axis;

joining said second diameter portion of said funnel insert and said funnel portion of said filler; and

configuring a transition of a tubular body between said inlet and outlet to induce a swirl to and vent vapors from fuel flowing through said funnel portion.

24. The method of claim 23 , further comprising attaching said opposite end of said filler tube to a fuel tank.

25. The method of claim 23 , further comprising forming threads in said first diameter portion of said funnel insert.

26. The method of claim 23 , further comprising forming a sealing surface about said first diameter portion of said funnel insert.

27. The method of claim 26 , wherein said forming a sealing surface includes rolling over an edge defining an inlet opening.

28. The method of claim 23 , further comprising forming a nozzle receptor in said second diameter portion of said funnel insert.

29. The method of claim 23 , further comprising cutting a length of tubing stock to form said filler tube.

30. The method of claim 23 , further comprising joining an end of said filler tube opposite said funnel insert to said fuel tank.

31. The method of claim 30 , further comprising joining opposite ends of a vent tube to said funnel portion and said fuel tank, respectively.

32. The method of claim 23 , further comprising joining a vent tube to said funnel portion of said filler tube.

33. A fuel filler tube assembly comprising:

a filler tube including a tubular body defining an inlet larger than an outlet; and

a funnel insert including a first cylindrical section, a second cylindrical section, a third cylindrical section disposed between said first cylindrical section and said second cylindrical section, and a tapered surface extending between said first cylindrical section and said third cylindrical section, said first cylindrical section received in said inlet of said filler tube with said tapered surface engaging a surface of said inlet when said first cylindrical section is disposed within said inlet of said filler tube.

34. The fuel filler tube assembly of claim 33 , wherein said funnel insert is a seamless tube.

35. The fuel filler tube assembly of claim 33 , wherein said funnel insert includes integrally formed threads.

36. The fuel filler tube assembly of claim 33 , further comprising a fuel cap selectively engaging said funnel insert.

37. The fuel filler tube assembly of claim 33 , wherein said funnel insert includes a sealing surface formed about said second cylindrical section.

38. The fuel filler tube assembly of claim 37 , wherein said second cylindrical section includes an inlet opening and a portion of said funnel insert defining said inlet opening creates a sealing surface.

39. A fuel filler tube assembly comprising:

a filler tube including a tubular body defining an inlet larger than an outlet; and

a funnel insert including a first section, a second section, and a tapered surface extending between said first section and said second section, said first section received by said inlet of said filler tube and including a nozzle retainer;

wherein said tapered surface engages a surface of said inlet when said first section is disposed within said inlet of said filler tube.

40. The fuel filler tube assembly of claim 39 , wherein said funnel insert is a seamless tube.

41. The fuel filler tube assembly of claim 39 , wherein said funnel insert includes integrally formed threads.

42. The fuel filler tube assembly of claim 39 , further comprising a fuel cap selectively engaging said funnel insert.

43. The fuel filler tube assembly of claim 39 , wherein said funnel insert includes a third section formed adjacent said second section.

44. The fuel filler tube assembly of claim 43 , wherein a sealing surface is formed about said third section.

45. The fuel filler tube assembly of claim 44 , wherein said third section includes an inlet opening and a portion of said funnel insert defining said inlet opening creates a sealing surface.

46. A method comprising:

drawing a funnel insert with a first diameter portion larger than a second diameter portion;

forming a funnel portion at an end of a filler tube, an opposite end of said filler tube being operable to be directly attached to a fuel tank;

forming a relatively large inlet at one end of said funnel portion, said inlet having a first axis;

forming a relatively small outlet at said opposite end of said funnel portion, said outlet having a second axis offset from said first axis;

joining said second diameter portion of said funnel insert and said funnel portion of said filler tube; and

forming a nozzle receptor in said second diameter portion of said funnel insert.

47. The method of claim 46 , further comprising attaching said opposite end of said filler tube to a fuel tank.

48. The method of claim 46 , further comprising configuring a transition of said tubular body between said inlet and outlet to induce a swirl to and vent vapors from fuel flowing through said funnel portion.

49. The method of claim 46 , further comprising forming threads in said first diameter portion of said funnel insert.

50. The method of claim 46 , further comprising forming a sealing surface about said first diameter portion of said funnel insert.

51. The method of claim 50 , wherein said forming a mug surface includes rolling over an edge defining an inlet opening.

52. The method of claim 46 , further comprising cutting a length of tubing stock to form said filler tube.

53. The method of claim 46 , further comprising joining an end of said filler tube opposite said funnel inert to said fuel tank.

54. The method of claim 53 , further comprising joining opposite ends of a vent tube to said funnel portion and said fuel tank, respectively.

55. The method of claim 46 , further comprising joining a vent tube to said funnel portion of said filler tube.