Method for making a filler neck closure

Abstract

A fuel cap is provided for use in a filler neck of a tank of a vehicle having body portions which are conductive. The fuel cap includes a housing sized to fit into the filler neck and a cover coupled to an upper end of the housing. The cover is made of a non-conductive resin and an electrically conductive coating covering at least a portion of the non-conductive resin. The coating has a thickness of between approximately 0.1 and 0.6 mil. The fuel cap further includes a conductive discharge member having a first end engaged with the electrically conductive coating of the cover and a second end adapted to be coupled to one of the filler neck and the body of the vehicle to dissipate static charge.

1 . A method for making a fuel cap for use on a filler neck of a tank of a vehicle and through which an accumulated static charge can be discharged, the method comprising the acts of: 
 (a) molding the resin to form a cover of the fuel cap,    (b) applying a conductive composition at least to an outer surface of the cover, and    (c) drying the conductive composition on the cover to form a conductive coating on the cover including a particulate conductor dispersed in a solid polymer matrix comprising a covalently cross-linked thermoset polymer and a non-covalently cross-linked thermoplastic polymer.    
     
     
         2 . The method of  claim 1 , wherein the act of applying the conductive composition includes applying the conductive composition to an inner surface of the cover.  
     
     
         3 . The method of  claim 2 , wherein the act of applying the conductive composition includes atomizing the conductive composition and spraying the conductive composition onto the cover.  
     
     
         4 . The method of  claim 2 , further comprising the act of drying the resin for approximately four hours at approximately 135 degrees Fahrenheit prior to molding the resin to form the cover of the fuel cap.  
     
     
         5 . The method of  claim 2 , wherein the act of drying the conductive composition on the cover includes drying the conductive composition on the cover for approximately 5 to 7 minutes at approximately 180 degrees Fahrenheit.  
     
     
         6 . A method for coating at least a portion of a plastic handle component of a fuel cap for a vehicle fuel tank with a relatively thin, durable, and fuel resistant layer of material that has sufficient conductive particles to dissipate a static charge from the hand of a person gripping the handle component, the method comprising the acts of: 
 (a) providing a mixture of a thermosetting resin, a thermoplastic resin, conductive particles, and solvents,    (b) applying a relatively thin layer of the mixture on at least a portion of the handle component, and    (c) curing the mixture layer to set the mixture layer on the handle component portion.    
     
     
         7 . The method of  claim 6 , wherein the curing act comprises the step of heating the mixture layer for a period of time sufficient to drive off the solvents and set the thermosetting and thermoplastic resins.  
     
     
         8 . The method of  claim 6 , wherein the relatively thin layer has a thickness from about 0.1 mil to about 0.6 mil.  
     
     
         9 . The method of  claim 6 , wherein the thermosetting resin is an alkyd resin.  
     
     
         10 . The method of  claim 6 , wherein the thermoplastic resin is chlorinated polyoleffin.  
     
     
         11 . The method of  claim 6 , wherein the conductive particles are carbon black particles.  
     
     
         12 . The method of  claim 6 , wherein the carbon black particles make up approximately 1% to 10% of the conductive coating.  
     
     
         13 . The method of  claim 6 , wherein the handle component portion is molded nylon resin, the thermosetting resin is an alkyd resin, the thermoplastic resin is chlorinated polyoleffin, and the conductive particles are carbon black particles.  
     
     
         14 . The method of  claim 13 , wherein the thickness of the relatively thin layer is from about 0.1 mil to about 0.6 mil.