The present disclosure relates generally to fuel valves and methods of controlling fuel flow between a fuel tank and an engine, and in particular, fuel valves that are configured for use in supplying fuel to boats and methods of controlling fuel flow to an engine.
Boats, including pleasure boats, are subject to a variety of federal regulations, including regulations defined in 33 CFR Part 183, which prescribes standards and regulations for boats and associated equipment, including fuel systems. In particular, 33 CFR § 183.568(b) requires each fuel line from the fuel tank to the fuel inlet connection of the engine to have “an anti-siphon device or an electrically operated fuel stop valve” at the fuel tank withdrawal fitting or installed so the line from the fuel tank is above the top of the tank, or meet the requirements in 33 CFR § 183.568(c). As used in the regulations and in this specification, “fuel” refers to all oils of any kind, which may be used to supply power or lubrication for primary or auxiliary purposes onboard the vessel in which it is carried. Therefore, as use herein, fuel includes, but is not limited to gasoline and diesel fuel.
In addition, boats are subject to 40 CFR Part 1060, which pertains to control of evaporative emissions from new and in-use nonroad and stationary equipment. In particular, 40 CFR § 240 (e) (1) requires that “[a] Marine SI fuel tank sealed up to a positive pressure of 7.0 kPa (1.0 psig).” This positive pressure is diurnally induced due to volumetric expansion of fuel within the installed tank. As used in the regulations and herein, “Marine SI” relates to vessels powered by engines that are subject to exhaust and evaporative emission standards in 40 CFR part 1045, which includes boats and pleasure boats.
Simultaneously meeting these anti-siphon and sealed pressure regulations has become a major challenge. In particular, as the regulations pertains to pleasure boat fuel systems that must include a low pressure-actuated <5 PSIG (pounds per square inch gauge) valve that works as a static anti-siphon valve device, and that when vacuum is applied to the outlet, a fuel valve device instantly needs to provide low and high flow, up to as much as 60 gallon per hour (GPH) as demanded by large outboard mounted engines in some cases. A caveat to this components function is the added resistance in fuel flow systems in general that can cause fuel starvation on smaller engines at low revolutions per minute (rpm) when required, such as at idling or trolling speeds used in fishing or bodies of water subject to slow sped (no wake) mandates. Additionally, these same reduced flow rates can cause engine air mixture shortfalls in larger outboard motors, causing a common scenario where there is not sufficient fuel to combust in the appropriate volumetric fuel air mixture in the engine cylinder during the ignition process. This latter scenario is often referred to as “leaning out.”
Typical inline ball and spring actuated valves of the type shown in
While existing fuel valve devices have existed for a number of years, the above discussion reveals that existing fuel valve devices have several disadvantages and limitations, and there remains a need for improved fuel valve devices that meet the current regulations and that can address one or more of the limitations discussed above.
One or more embodiments of the disclosure are directed to A fuel valve device configured to control fuel flow between a fuel tank and an engine, the fuel valve device comprising an inlet conduit including an inlet end configured for connection to a fuel tank, the inlet conduit having an inlet conduit central axis; an outlet conduit including an outlet end opposite the inlet end in fluid communication with the inlet end and configured for connection to an engine, the outlet conduit having an outlet conduit central axis that is offset from the inlet conduit central axis; and a movable valve ball responsive to a fuel flow from the inlet end, the movable valve ball configured to block fuel flow from the inlet end to the outlet end at a predetermined pressure and to permit the fuel flow from the inlet end to the outlet end when pressure in the fuel valve device exceeds the predetermined pressure, the movable valve ball being movable along a travel axis defining an angle with the inlet conduit central axis that is greater than 5 degrees and less than 90 degrees.
In another aspect, one or more embodiments are directed to a fuel valve device configured to control fuel flow between a fuel tank and an engine, the fuel valve device comprising an inlet conduit including an inlet end configured for connection to a fuel tank, the inlet conduit having an inlet conduit central axis; an outlet conduit including an outlet end opposite the inlet end in fluid communication with the inlet end and configured for connection to an engine, the outlet conduit having an outlet conduit central axis that is offset from the inlet conduit central axis; and a movable valve ball resting on a valve seat and responsive to a fuel flow from the inlet end, the movable valve ball configured to block the fuel flow from the inlet end to the outlet end at a predetermined pressure while resting on the valve seat in a fuel blocking position and configured to travel along a travel axis defining an angle with the inlet conduit central axis that is greater than 5 degrees and less than 90 degrees to permit the fuel flow from the inlet end to the outlet end when pressure in the fuel valve exceeds the predetermined pressure.
Another aspect of the disclosure pertains to a method to control fuel flow between a fuel tank and an engine, the method comprising flowing fuel through a fuel valve device including an inlet conduit including an inlet end configured for connection to a fuel tank, the inlet conduit having an inlet conduit central axis and an outlet conduit including an outlet end opposite the inlet end in fluid communication with the inlet end and configured for connection to an engine, the outlet conduit having an outlet conduit central axis that is offset from the inlet conduit central axis. The method further comprises blocking a fuel flow with a movable valve ball positioned between the inlet end and the outlet end when the movable valve ball is in a blocking position; and permitting the fuel flow when the movable valve ball is displaced along a travel axis that is at an angle with respect to the inlet conduit central axis.
So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this disclosure and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments.
Before describing several exemplary embodiments of the disclosure, it is to be understood that the disclosure is not limited to the details of construction or process steps set forth in the following description. The disclosure is capable of other embodiments and of being practiced or being carried out in various ways.
The term “horizontal” as used herein is defined as a plane parallel to the plane or surface of a floor, a deck or a deck of a boat, regardless of its orientation. The term “vertical” refers to a direction perpendicular to the horizontal as just defined. The term “non-horizontal” includes planes that are at 20 degrees to 120 degrees from a horizontal plane, including, but not limited to vertical. Terms, such as “above”, “below”, “bottom”, “top”, “side” (as in “sidewall”), “higher”, “lower”, “upper”, “over”, and “under”, are defined with respect to the horizontal surface as shown in the figures.
The term “on” indicates that there is direct contact between elements. The term “directly on” indicates that there is direct contact between elements with no intervening elements.
As discussed above, existing fuel valves have several limitations and disadvantages, and they are unable to meet the regulatory requirements and address one more of the issues discussed above. For example, referring to
After careful study of the prior art fuel valve 100 design, it was determined that the prior art fuel valve show in
Referring now to
The exemplary embodiment of the fuel valve device 200 further comprises a movable valve ball 210 configured to be moved in response to a flow of fuel 214 from the inlet end 203. The movable valve ball is further configured to block fuel 214 flowing from the inlet end 203 to the outlet end 205 at a predetermined pressure and to permit the fuel 214 flow from the inlet end 203 to the outlet end 205 when pressure in the fuel valve device 200 exceeds the predetermined pressure. The movable valve ball 210 is movable along a travel axis 230 defining an angle 232 that is obtuse with the inlet conduit central axis 216a that is greater than 90 degrees and less than 175 degrees. It will be understood that this range of angles is exemplary only, and other ranges are within the scope of the disclosure. For example, the angle 232 in some embodiments is greater than 90 degrees and less than 170, 165, 160, 155, 150, 145, 140, 135, 130, 125, 120, 115 or 110 degrees. In one or more embodiments the angle is in a range of from 115 degrees to 150 degrees, 115-145 degrees, 115-140 degrees, 120-150 degrees, 120-145 degrees, 120-140 degrees, 125-150 degrees, 120-145 degrees, 120-140 degrees, 130-150 degrees, 130-145 degrees, or 130-140 degrees, for example 135 degrees.
In some embodiments, the travel axis 230 defines the angle 232 with the inlet conduit central axis 216a that is greater than 100 degrees and less than 170 degrees. In other embodiments, the travel axis 230 defines the angle 232 with the inlet conduit central axis 216a that is greater than 110 degrees and less than 165 degrees.
The travel axis 230 of movable valve ball 210 is defined by a valve housing 240 which contains the movable valve ball 210 and is at an angle to the inlet conduit 216 and the outlet conduit 226. The valve housing further contains a spring 208 engaged with the movable valve ball 210, which is movable in the direction of arrow 211 along the travel axis 230, wherein the spring 208 and the movable valve ball 210 are movably disposed in the valve housing 240. The valve housing may further comprise a cap 242 which can include a fitting 244 to permit removal of the cap 242 to permit cleaning, servicing and/or replacement of the spring 208 and/or the movable valve ball 210.
Referring now to
Additionally, according to one or more embodiments described herein, the fuel valve device 200 maximizes the fuel flow between the inlet end 203 and the outlet end 205 in the fuel path cavity defined by the inlet conduit 216 outer diameter OD1, wall thickness and inner diameter and the outlet conduit 226 inner diameter ID2 to minimize fuel flow restriction through the fuel valve device 200. The dimensions of the fuel valve device 200 takes into account fixed manufacturing standard dimensions of both ⅜ inch and ½ inch hose which are fit over outlet end 205 barbed outlet end 205b and ⅜ inch Male National Pipe Thread (MNPT) on the inlet end 203 threads to provide a threaded fitting 203t, which are standard sizes in boats and yachts. In one or more embodiments, a thin wall thickness is provided for the fuel valve device 200. According to one or more embodiments, embodiments of the fuel valve device 200 provided herein are configured to be retrofitted into existing boats and yachts already placed in service. As used herein, the term “boat” includes both boats and yachts, with yachts being larger recreational boats. In exemplary embodiments, the fuel valve device 200 has an OD1 at the inlet end 203 of 0.67 inches, a length L of 3.67 inches, an OD2 at the outlet end 205 of 0.43 inches, an ID2 of 0.38 inches, and a wall thickness of 0.0.05 inches. The fuel valve device of some embodiments has a height H measured from the outlet conduit central axis 226a to the top surface on the valve housing 240 is 0.85 inches. This height H provides adequate swing diameter during installation to meet the required clearance between the substrate 286 of the deck and the top surface 262 of the fuel tank 260. These dimensions are non-limiting, exemplary values.
In one or more embodiments, the fuel valve device 200 is sized to have a maximum height H from the outlet conduit central axis 226a to the top surface of the valve housing 240 so that when the fuel valve device is rotated about the inlet conduit central axis, the fuel valve device defines a rotational radius about the inlet conduit central axis that is less than 1 inch, less than or equal to 0.95 inches, 0.90 inches or 0.85 inches. In one or more embodiments, the fuel valve device 200 is configured so that fuel flows from the inlet end 203 to the outlet end 205, and the fuel 214 does not encircle or completely surround the entire circumference of the movable valve ball 210 during and after the movable valve ball 210 travels along the travel axis 230 to an open position. As used herein, a “closed position” refers to the position shown in
In an open position, vapor and fluid pressure has been exerted against the movable valve ball that is sufficient to exert a force on the movable valve ball 210 to cause the movable valve ball 210 to overcome the force exerted by the spring 208 which pushes the movable valve ball 210 away from the valve seat, compressing the spring 208 and moving the movable valve ball further into the valve housing 240 closer to the lid 242, allowing fuel 214 to flow underneath the movable valve ball 210, but not around the entire circumference of the movable valve ball 210. The movable valve ball moves in the directions of the arrow 211 when moving between the open position and the closed position.
The fuel valve device 200 is configured so that fuel 214 flows from the inlet end 203 to the outlet end 205 and underneath the movable valve ball 210 as the movable valve ball travels along the travel axis 230. In some embodiments, the inlet conduit 203 has an internal diameter ID1 defining a fuel bore through which fuel flows, and the movable valve ball 210 is configured to open and close the fuel bore and maintain a minimum 0.500″ fuel bore opening when the movable valve ball 210 is in an open position. In the closed position, the fuel valve device 200 is configured to so that the movable valve ball 210 remains in a closed position blocking the fuel bore to prevent flow therethrough there is a fluid pressure in the fuel bore that is less than 1.00 PSIG.
In another embodiment, a fuel valve device configured to control fuel flow between a fuel tank 260 and an engine 312 comprises the inlet conduit 216 including an inlet end 203 configured for connection to the fuel tank 260, an outlet conduit 226 including an outlet end 205 opposite the inlet end 203 in fluid communication with the inlet end 203 and configured for connection to the engine 312, the outlet conduit 226 having an outlet conduit central axis 226a that is offset from the inlet conduit central axis 216a. The fuel valve device 200 includes a movable valve ball 210 resting on a valve seat 239 and configured to be moved in response to a flow of fuel 214 from the inlet end 203, the movable valve ball 210 configured to block the fuel flow from the inlet end 203 to the outlet end 205 at a predetermined pressure while resting on the valve seat 239 in a fuel blocking position and configured to travel along a travel axis 230 defining an angle with the inlet conduit central axis that is greater than 90 degrees and less than 175 degrees to permit the fuel flow from the inlet end to the outlet end when pressure in the fuel valve exceeds the predetermined pressure. In one or more embodiments, the fuel valve device 200 is configured so that fuel 214 flows from the inlet end 203 to the outlet end 205, and the fuel 214 does not encircle the entire circumference the movable valve ball 210 during and after the movable valve ball 210 travels along the travel axis 230 to an open position in which the fuel 214 is permitted to flow to the outlet conduit 226.
Referring to
In embodiments of the method, the fuel valve device 200 further comprises a spring 208 disposed in a valve housing 240. The method 300 may further include forcing a flow of fuel through to the outlet end wherein fuel does not encircle the entire circumference of the movable valve ball 210, but instead the fuel flows only along an underside of the movable valve ball 210. In embodiments, the fuel valve device 200 is sized to have a maximum height so that when the fuel valve device 200 is rotated about the inlet conduit central axis 216a, the fuel valve device defines a rotational radius about the inlet conduit central axis that is less than 1 inch. In embodiments of the method 300, the inlet conduit 216 has an internal diameter defining a fuel bore through which fuel flows, and the movable valve ball 210 is configured to open and close the fuel bore and maintain a minimum 0.500 inch fuel bore opening when the movable valve ball 210 is in an open position.
Although embodiments of the present disclosure have been described in detail hereinabove in connection with certain exemplary embodiments, it should be understood that the disclosure is not limited to the disclosed exemplary embodiments, but is intended to cover various modifications and/or equivalent arrangements included within the spirit and scope of the present disclosure.
Reference throughout this specification to “one embodiment,” “certain embodiments,” “one or more embodiments” or “an embodiment” means that a particular feature, structure, material, or characteristic described in connection with the embodiment is included in at least one embodiment of the disclosure. Thus, the appearances of the phrases such as “in one or more embodiments,” “in certain embodiments,” “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily referring to the same embodiment of the disclosure. Furthermore, the particular features, structures, materials, or characteristics may be combined in any suitable manner in one or more embodiments.
Although the disclosure herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present disclosure. It will be apparent to those skilled in the art that various modifications and variations can be made to the method and apparatus of the present disclosure without departing from the spirit and scope of the disclosure. Thus, it is intended that the present disclosure include modifications and variations that are within the scope of the appended claims and their equivalents.