Cover for fuel system component and method of making

1. A cover for an opening in a fuel system component, the cover comprising:

a one-piece body of a first thermoplastic material constructed so that when assembled to a fuel system component the body has a central portion that extends over at least part of and closes an opening in the fuel system component, a homogeneously integral peripheral flange extending radially outwardly of the opening and having a generally radially extending bottom surface of the flange adjacent the fuel system component, at least one first connecting feature having a recess in the peripheral flange, the recess having a non-uniform section with a first portion of the section opening both through the bottom surface of the peripheral flange and into a second portion of the section within the peripheral flange that is radially enlarged relative to the first portion of the section and communicating within the peripheral flange with the first portion of the section, and an axial flange having a circumferentially continuous side surface extending generally axially relative to the bottom surface, and

a circumferentially continuous seal ring of an elastomer different than the first thermoplastic material and at least chemically bonded with a mechanically interlocked molecular architecture circumferentially continuously to the bottom surface and circumferentially continuously to the side surface and providing a first annular sealing surface to bear against the fuel system component radially outwardly of the opening when the cover is mated therewith, and a second sealing surface to bear on a generally axially extending surface defining the periphery of the opening in the fuel system component, and the seal ring having at least one second integral connecting feature extending into, engaging, molded into and complimentary with the recess and having a stem projecting from the ring seal and terminating in a homogenously integral head projecting from the stem and radially enlarged relative to the stem, the stem received in, filling and engaging the first portion of the section and the homogenously integral enlarged head received in, filling and engaging the second portion of the section to at least mechanically connect the flange of the body and the seal ring together.

2. The cover of claim 1 wherein the seal ring is composed of a thermoplastic elastomer.

3. A cover for an opening in a fuel system component, the cover comprising:

a one-piece body of a first thermoplastic material constructed so that when assembled to a fuel system component the body has a central portion that extends over at least part of and closes an opening in the fuel system component, a homogeneously integral radial flange extending radially outwardly of the opening and having a generally radially extending bottom surface of the radial flange adjacent the fuel system component, and at least one first connecting feature having a recess in the radial flange, the recess having a non-uniform section with a first portion of the section opening both through the bottom surface of the radial flange and into a second portion of the section within the radial flange that is radially enlarged relative to the first portion of the section and communicating within the radial flange with the first portion of the section; and

a circumferentially continuous seal ring of an elastomer different than the first thermoplastic material and at least mechanically bonded to the bottom surface of the radial flange of the body and around the periphery providing an annular sealing surface to bear against the fuel system component outwardly of the opening when the cover is mated therewith, the seal ring having at least one second integral connecting feature extending into, engaging and complimentary with the recess and having a stem projecting from the ring seal and terminating in a homogenously integral head projecting from the stem and radially enlarged relative to the stem, the stem received in and engaging the first portion of the section and the homogenously integral enlarged head received in and engaging the second portion of the section to at least mechanically connect the radial flange of the body and the seal ring together; and

the body further comprises an axial flange having a side surface extending axially of the radial flange and in assembly projecting into the opening, and wherein the seal is injection molded circumferentially to both the bottom surface and to the side surface to constitute an integral part of the cover, and wherein, when the cover is mated with the opening, the seal bears against the fuel system component to form a first seal that, in cross-section, is parallel to the bottom surface, and the seal bears against the fuel system component to form a second seal that, in cross-section, is parallel to the side surface.

4. The cover of claim 3 wherein the at least one first connecting feature comprises a plurality of cylindrical recesses spaced along and defined in the bottom surface of the radial flange, and wherein the at least one second connecting feature comprises a plurality of complementary projections, with each projection received in a respective one of the plurality of cylindrical recesses.

5. The cover of claim 3 wherein the at least one first connecting feature comprises a plurality of arcuate recesses spaced along and defined in the bottom surface of the radial flange, and wherein the at least one second connecting feature comprises a plurality of complementary projections, with each projection received in a respective one of the plurality of arcuate recesses.

6. The cover of claim 3 wherein the at least one first connecting feature comprises a plurality of recesses that are spaced along and defined in the bottom surface of the radial flange, each recess having a first section and a second section that is enlarged as compared to the first section, and wherein the at least one second connecting feature comprises a plurality of complementary projections, each projection having a stem and an enlarged terminal head, with each projection being received in a respective one of the plurality of recesses.

7. The cover of claim 3 wherein the seal comprises an appendage extending radially beyond the radial flange to act as a visual aid when mating the cover with the opening of the fuel system component.

8. The cover of claim 3 wherein the seal ring is composed of a thermoplastic elastomer.

9. The cover of claim 3 wherein the first thermoplastic material is at least one of acrylonitrile butadiene styrene (ABS), polyamide (PA), polypropylene, polyethylene, polyvinyl chloride (PVC), or polyoxymethylene (POM).

10. The cover of claim 3 wherein the elastomer is at least one of thermoplastic polyurethane copolymers, thermoplastic polyester copolymers, thermoplastic styrene copolymers, thermoplastic olefins, thermoplastic polyamide copolymers, or thermoplastic elastomeric alloys.

11. The cover of claim 9 wherein the elastomer is at least one of thermoplastic polyurethane copolymers, thermoplastic polyester copolymers, thermoplastic styrene copolymers, thermoplastic olefins, thermoplastic polyamide copolymers, or thermoplastic elastomeric alloys.

12. An assembly, comprising:

a fuel system component defining an opening;

a separate one-piece cover of a first thermoplastic material having a central portion that extends over at least part of and closes the opening, a homogeneously integral peripheral flange extending radially outwardly of the opening and having a bottom surface adjacent the fuel system component, at least one first connecting feature having a recess in the peripheral flange, the recess having a non-uniform section with a first portion of the section opening both through the bottom surface of the flange and into a second portion of the section within the flange that is radially enlarged relative to the first portion of the section and communicating within the peripheral flange with the first portion of the section, and an axial flange with a side surface extending axially of the bottom surface; and

a circumferentially continuous seal ring of a second thermoplastic material different than the first thermoplastic material, having at least one second connecting feature integral with and extending from the seal rine and complimentary to and received in the at least one first connecting feature, and at least mechanically bonded to and extending circumferentially around the bottom surface and at least mechanically bonded to and extending circumferentially around and axially along at least part of the side surface to bond the seal ring to the side and bottom surfaces and constitute an integral part of the cover, and wherein, when the cover is mated with the opening, the seal ring bears against the fuel system component to form a first seal that, in cross-section, is parallel to the bottom surface, and to form a second seal that, in cross-section, is parallel to the side surface and bears on an axial surface of the perimeter of the opening in the fuel system component.

13. The assembly of claim 12 wherein the at least one first connecting feature comprises a plurality of recesses spaced along and defined in the bottom surface of the radial flange, and wherein the at least one second connecting feature comprises a plurality of complementary projections, with each projection being received in a respective one of the plurality of recesses.

14. The assembly of claim 13 wherein each of the plurality of recesses is cylindrically shaped.

15. The assembly of claim 12 wherein the at least one first connecting feature comprises a plurality of arcuate recesses spaced along and defined in the bottom surface of the radial flange, and wherein the at least one second connecting feature comprises a plurality of complementary projections, with each projection received in a respective one of the plurality of arcuate recesses.

16. The assembly of claim 12 wherein the at least one first connecting feature comprises a plurality of recesses that are spaced along and defined in the bottom surface of the radial flange, each recess having a first section and a second section that is enlarged as compared to the first section, and wherein the at least one second connecting feature comprises a plurality of complementary projections, each projection having a stem and an enlarged terminal head, with each projection being received in a respective one of the plurality of recesses.

17. The assembly of claim 12 wherein the seal comprises an appendage extending radially beyond the radial flange to act as a visual aid when mating the cover with the opening.

18. The cover of claim 12 wherein the seal ring of the elastomer is at least chemically bonded with a mechanically interlocked molecular architecture to the cover of the first thermoplastic material.