Method of coupling fuel system components

Abstract

A method of coupling two or more components is provided particularly for use in joining components of a vehicle fuel delivery system. At least one of the components includes a tubular body defining a fluid passageway and is formed as a laminate having an inner metallic layer and an outer polymeric layer. In one preferred embodiment, the component includes an aluminum inner layer and a nylon outer layer. The components are joined together by moving one of the components relative to the other (e.g., through ultrasonic or vibrational welding) causing frictional heat and resulting deformation of the outer polymeric layer of the one component to form a fluid tight, pressurized joint. A fluid passageway is formed between the two components at the joint.

1 . A method of coupling first and second components of a fluid handling system, comprising the steps of: 
 providing said first component, said first component including a tubular body defining a fluid passageway and formed as a laminate having an inner metallic layer and an outer polymeric layer;    positioning said second component relative to said first component; and,    moving one of said first and second components relative to another of said first and second components to generate heat and deform said outer layer of said first component and bond said second component to said first component while forming a fluid tight joint; and    forming a fluid passageway between said first and second components at said joint.    
     
     
         2 . The method of  claim 1  wherein said first and second components are components of a fuel delivery system.  
     
     
         3 . The method of  claim 2  wherein said first component comprises a fuel filler neck.  
     
     
         4 . The method of  claim 2  wherein said first component comprises a body of a fuel rail.  
     
     
         5 . The method of  claim 1  wherein said second component comprises an aluminum component.  
     
     
         6 . The method of  claim 1  wherein said inner layer comprises steel.  
     
     
         7 . The method of  claim 1  wherein said inner layer comprises aluminum.  
     
     
         8 . The method of  claim 7  wherein said outer layer comprises nylon.  
     
     
         9 . The method of  claim 1  wherein said outer layer comprises nylon.  
     
     
         10 . The method of  claim 1  wherein outer layer is directly adjacent said inner layer.  
     
     
         11 . The method of  claim 1  wherein outer layer is extruded over said inner layer.  
     
     
         12 . The method of  claim 1  wherein said positioning step includes the substep of aligning fluid apertures in said first and second components.  
     
     
         13 . The method of  claim 1 , further comprising the step of positioning a third component relative to said first component wherein said moving step bonds said third component to said first component substantially simultaneous with said bonding of said second component to said first component.