Toyoda Gosei develops world’s lightest capless fuel filler

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  • Refueling nozzle can inserted directly into a gas tank, no need to remove cap
  • First mass production by a Japanese auto parts manufacturer
  • Production at Toyota Gosei’s Lebanon, Kentucky factory

Toyoda Gosei Co., Ltd. has become the first Japanese auto parts manufacturer to develop and mass produce a “capless fuel filler,” with which a vehicle can be refueled by simply inserting the refueling nozzle directly into a gas tank, without the need to remove or replace a cap. The newly developed product is the smallest and lightest in the world, according to the company (as of September 2015, based on Toyoda Gosei survey).

 Capless Fuel Filler

Capless Fuel Filler (source: Toyoda Gosei)

Production at Toyota Gosei’s Lebanon, Kentucky factory

Toyoda Gosei’s aims in developing this capless fuel filler were to structurally prevent the need for drivers to remember to replace the fuel cap after refueling, to contribute to improved automobile convenience and safety and to respond to user needs and demand in countries where self-service gas stations are the norm. The capless devices have been moved into mass production at Toyota Gosei’s Lebanon, Kentucky, manufacturing facility.

Nozzle inserted (fuel filler opening "open")

Nozzle inserted (fuel filler opening “open”)

Nozzle removed (fuel filler opening "closed")

Nozzle removed (fuel filler opening “closed”)

Weight and size reductions of about 10%

The features of the capless fuel filler, made from an undisclosed material, include pressure regulation within the fuel tank and a conduction function to prevent ignition of fumes from static electricity. At the same time Toyoda Gosei has achieved weight and size reductions of about 10% compared with similar products on the market. With the adoption of a unique mechanism for the valve portion of the filler opening, the company has also been able to achieve an operational feel that is about 20% lighter than other products on the market, while maintaining the filler’s performance in preventing fuel leakage, it is said.

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