Patent Application
20080251153
This invention relates to an improved liquid dispensing system, and more particularly to fuel pump, valve and nozzle assemblies configured for eliminating topping off and overfill of a gasoline or diesel tank.
Due to the seriousness of smog in Southern California, the Air Quality Management District (AQMD) Board has adopted progressively stricter regulations dealing with sources of smog. AQMD considers so-called “five percent” contributors to be important, as several of these add up to serious pollution. For this reason, AQMD has regulations covering lawn mowers and barbeque lighter fluids—both comparatively small contributors to smog. Much of the automotive gasoline and diesel fuel sold is through self-service pumps. When motorists fill their car's gasoline tanks, they often keep filling them after the hose clicks off, to get the tank as full as possible. The current device that is used to prevent “topping off” is composed of technology that is typically outdated, being twenty-five to fifty years old. The pump dispenses a little gasoline each time the motorist clicks the handle, before it senses the tank is already full. So motorists continue to keep clicking the pump on repeatedly to coax in extra gasoline. When tanks are overfilled in this way, gasoline is often spilled out and evaporative recovery systems can be damaged, causing increased smog emissions.
Such unburned gasoline vaporizes and contributes directly to smog far more than it would if it were burned in the engine and the exhaust passed through a catalytic converter. The State of California has tried to deal with this—it is against the law to top off a tank. There are signs prohibiting it at each gasoline pump and fines are posted for the practice, but in reality it is probably impossible to stop the practice, despite attempts to educate the ten million California motorists, and the many out of state drivers.
Chemical Problems from Gasoline
Hydrocarbon and other Organic Compounds
Toxic Chemicals
Produces Vapors
Produces Smog
Produce Ozone
Benzene
Primary Toxic Air Pollutant to Public Health
Carcinogen—Linked to leukemia and other cancers
Central Nervous System
Respiratory Tract-Asthma
Immune System
Toluene
Developmental Toxicant
Potential to affect fetal development
Central Nervous System Depressant
Associated with:
Cardiac Arrhythmias
Liver & Kidney Injury
Spillage from current customer
Excess in hose from previous customer
Problems of mechanical shut-off
Spilling, splashing, or being spit back
Mechanical failure
Filling tube speed increase
Dripping from Nozzle
Common for customers to re-click nozzle and “top-off” Tank
Customers want more fuel or even dollar amount
Valve is reset, but no time system to react
Fuel spills on ground
Fuel backs-up in filling tube
Fuel spills for next customer
Warm weather—fuel expands after tank is filled
Difference in Volume
Fuel tank much larger than fill tube
Fuel level speeds-up at top of fill tube
Turbulence results in fuel vapors being released from fill tube
Fuel splashes out of fill tube
Fuel spills out
Old technology in nozzle inadequate to solve problem
Accordingly, what has been needed and heretofore unavailable is an improved fuel valve system that overcomes the deficiencies of existing fuel valve configurations so as to eliminate the problem of intentional gasoline top-offs and overfilling of gasoline tanks. The present invention disclosed herein satisfies these and other needs.
The present invention is directed to a system that can effectively eliminate the problem of intentional gasoline or other fuel top-offs, thereby effectively providing a significant contribution to national health and environmental problems related to fueling automobiles at gas stations. In one embodiment, the present invention uses an electronic (for example, piezoelectric) pressure sensor with electronic and mechanical actuator subassemblies in a fluid (for example, gasoline or other fuel) valve assembly (dispenser) to determine the liquid level in a vessel (for example, in the fill tube of an automobile gasoline tank). Current gasoline dispensing fuel valve assemblies use a mechanical system to detect pressure changes at the nozzle tip to shut off the fluid flow through the fuel valve assembly to the nozzle subassembly. In those assemblies, fluid (gasoline) flow shutdown is actuated by a pressure differential on either side of a diaphragm that is positioned between two chambers in the main body of the fuel valve assembly. The pressure in the gasoline tank fill tube is communicated from the nozzle tip via a small lumen tube connected to a chamber on one side of the diaphragm.
In one embodiment of the present invention, the pressure sensing electronics in the fuel valve assembly sense the pressure change in the fill tube as the fluid reaches the nozzle tip. The electronic and mechanical actuator subassemblies of the present invention work with the existing mechanical systems in the fuel valve assembly to stop fluid flow through the nozzle. The present invention is configured to avoid placing electronics at the nozzle tip where it can be exposed to an inflammable such as gasoline and other fuels. In one aspect, the present invention may also include using wireless or other suitable technologies to transmit information from the fuel valve assembly to the pump electronics to shut off the pump to prevent an overfill condition for example (i.e., to prevent a motorist from re-clicking to top-off after the nozzle has shut off).
The present invention is further directed to a multi-component fuel valve system that will improve gasoline (or other fuel) pumps by eliminating the topping off of gasoline tanks. The technologies used in the present invention may allow much faster filling of motor vehicles. The technology of the present invention can be used for, but is not limited to, filling of fuel tanks for motor vehicles, trains and airplanes. The system of the present invention may incorporate known and mainstream technologies such as electrical, optical and mechanical sensors, and may incorporate yet to be developed devices that include nanotechnology materials or other cutting edge technologies. Examples of devices that may be used in or with the system of the present invention include, but are not limited to, U.S. patent and Publication Nos. 4,274,705; 4,641,025; 5,588,558; 5,712,934; 5,867,403; 6,049,088; 6,333,512; 6,363,784; 2004/0021,100 and 2004/0079,149; which are incorporated herein in their entirety by reference.
One aspect of the system of the present invention is a position sensor—for example, pressure sensors, distance probes, fuel vapor detection systems, collar (bellows) spring detection systems, laser or other electronic device—that may be located at the portion of the nozzle to be inserted into a receptacle (fill tube) for the fuel tank. Unless the position sensor indicated that the nozzle was fully inserted into the tank, the system of the present invention would not allow gasoline or other fuel to be pumped. In one aspect of the invention, multiple position sensors may be used with the present invention to enhance the system. Accordingly, the system may be configured to prevent motorists from withdrawing the nozzle partway out of the filling tube in an attempt to circumvent other anti-overfill features of the gasoline pump. In particular, the system of the present invention would be configured to terminate the flow of fuel to the nozzle when one or more of the sensors indicate that the nozzle is incorrectly positioned. So configured, the system would prevent motorists from pulling the nozzle further and further out of the tank when the tank is full, so as to overfill the tank. In one aspect of the present invention, a bypass switch, under control of a gas station attendant, could be incorporated into the system of the present invention to inactivate the position sensor to allow filling of an unusual receptacle (lawn mower, gas can, etc.) so as to fill it with gasoline.
In one embodiment of the present invention, sensors (e.g., watchdog circuitry) is used to detect if components of the system are malfunctioning. During filling of fuel tanks, if electronics within the system are malfunctioning or if the power source (e.g., batteries) are low, fuel flow through the system is precluded. In one aspect fueling sequences may not even begin if the system is malfunctioning. In another aspect, fueling sequences are terminated if the system is malfunctioning. Advantageously, due to the increased sensitivity of electronic shutoff, aspects of the present invention allow for faster fuel or liquid flow without the increased risk of significant fuel spillage from malfunctioning shut off components.
It is to be understood that the present invention is not limited by the configurations of the fuel valve described herein or by the materials of construction disclosed. The inventive concept may also be extended beyond conventional fuel dispensers. Other features and advantages of the present invention will become more apparent from the following detailed description of the invention, when taken in conjunction with the accompanying exemplary drawings.
The present invention is directed to a fuel valve assembly having an improved pressure sensor configuration. The fuel valve of the present invention includes a reliable liquid sensor that can effectively eliminate the problem of intentional gasoline top-off's—effectively providing a significant contribution to national health and environmental problems related to fueling cars at gas stations. It should be appreciated that the embodiments of the fuel valve assembly described herein are illustrated and described by way of example only and not by way of limitation. Also, while the present invention is described in detail as applied to a pressure sensor with an electronic interface to determine the liquid level in an automobile gas tank, those skilled in the art will appreciate that it can also be used in other vessels, such as trucks, trains, ships, farm vehicles and aircraft. Additionally, the present invention can be utilized in nonmoving vessels, such as storage tanks and mixing vessels.
Turning now to the drawings, in which like reference numerals represent like or corresponding elements in the drawings,
The main body subassembly 200 of the fuel valve 100 of the present invention includes a parts housing 220 and connector system 240 that may be configured from presently available fuel valves, such as those from Emco Wheaton Corporation of Oakville, Canada, NC; Emco Wheaton Retail Corporation of Wilson, N.C., OPW Fueling Components of Cincinnati. Ohio; and Healy Systems, Inc of Hudson, N.H. Likewise, the handle subassembly 300 may be configured from mechanisms available from the manufacturers of the main body subassembly or may be customized for the present application as would be understood by those of ordinary skill in the art.
The nozzle subassembly 400 is attached to the connector system 240 of the main body subassembly 200, and may also be configured from presently available systems or may be customized for the present invention. The nozzle subassembly may include a main tubular body 420 having an end orifice 440. At the orifice, the inside of the main tubular body includes a small orifice or venturi port 462 connected to a hollow conduit 460 for creating a pressure differential used by the pressure sensor subassembly 600.
Referring specifically now to
Referring now to
When the piezoelectric disk 630 senses a pressure differential between the two sides of the disk, it passes the electric current provided by the connector plate 610 to the solenoid subassembly 700. In the fuel valve 100 of the present invention, one side of the piezoelectric disk is in a closed environment that is connected to the venturi tube 460. The other side of the piezoelectric disk 630 is open to atmospheric pressure. When the nozzle subassembly 400 is placed into a fuel receiving receptacle (for example, the inlet to an automobile gas tank), the venturi tube 460 provides atmospheric pressure to the piezoelectric disk 630 and there is no pressure differential and no electric current is passed to the solenoid subassembly. When fuel rises to the level of the venturi tube opening 462 in the end orifice 420 of the nozzle 420, then the fuel moving past the venturi tube opening 462 causes a drop in pressure on one side of the piezoelectric disk. Thus, as the fuel rises in an automobile tank to the level of the opening in the nozzle of the fuel valve, an electric current is sent to the solenoid subassembly 700.
As shown in
Referring now to
The solenoid plunger 820 and roller bracket mechanism 840 are configured to work with an adapter (linear actuator) mechanism 890 including the spring-loading rod 892, a bottom slider 894, a central grommet 896 having a round hole and a top slider 898. The adaptor mechanism is configured to reside within the parts housing 220 of the main body subassembly 200 and to interface with the handle subassembly 300 and the poppet mechanism of the fuel valve assembly to stop the flow of fuel when the piezoelectric disk 630 detects fuel flowing at the orifice 440 at the nozzle subassembly 400.
Referring now to
In one embodiment of the invention, the solar cell subassembly may include an optional light source 990 that may reside in the cradle 1200 of the pump subsystem 1000. The light source is positioned to illuminate the light transparent window 970 secured to the top portion of the solar cell cap 920. The light source may be configured with a main housing 992, a receiver board assembly 994 and a lens 996. The receiver board assembly may be configured with a plurality of light emitting diodes 997 or other light source and a power conduit 998. The light transparent window 970 is secured to the top portion of the solar cell cap window may be configured for use with the light source. In one aspect, the light source may be positioned within a cradle 1200 of the pump subsystem 1000. In an additional aspect, the fuel valve assembly 100 further comprises an audible or visual indicator (not shown) configured to indicate when the power reserve of the power source drops below a predetermined level.
In yet another embodiment, the fuel valve assembly 100 of the present invention may be adapted for use with a rechargeable battery 930, 950 configured to provide electrical power to the solenoid subassembly 700. The power conduit 998 may be configured to connect to a contact member disposed on a portion of the fuel valve assembly 100 when docked within the cradle 1200. In another aspect, the power conduit 998 may be configured to recharge the batteries 930 through use of a suitable induction coil/induction core arrangement like that described in U.S. Pat. No. 7,180,265 which incorporated herein by reference in its entirety.
Referring now to
As will be appreciated by those of ordinary skill in the art, multiple position sensors may be used with the present invention to enhance the system. Accordingly, the system may be configured to prevent motorists from withdrawing the nozzle partway out of the filling tube in an attempt to circumvent other anti-overfill features of the gasoline pump. In particular, the system of the present invention may be configured to terminate the flow of fuel to the nozzle when one or more of the sensors indicates that the nozzle is incorrectly positioned. So configured, the system would prevent motorists from pulling the nozzle further and further out of the tank when the tank is full, so as to overfill the tank. A bypass switch, under control of a gas station attendant, could be incorporated into the system of the present invention to inactivate the position sensor to allow filling of an unusual receptacle (lawn mower, gas can, etc.) so as to fill it with gasoline.
Referring now to
Referring generally to
As shown in
In one embodiment, as shown in
In one aspect of the invention, signal transmission between the fuel valve assembly 100 and the pump subsystem 1000 may be configured for two-way communication. For example, a radio frequency transmitter subassembly 5100 and a sending antenna subassembly 5200 may be disposed on both the fuel valve assembly 100 (or other suitable portion of the main body subassembly 200) and the pump subsystem 1000. Likewise a receiving antenna subassembly 5300 may be disposed on both the pump subsystem 1000 and the fuel valve assembly 100. Advantageously, information regarding the operation of the fuel valve assembly 100 may be transmitted to the pump subsystem 1000. Additionally, information regarding the pump subsystem 1000 may be communicated to the fuel valve assembly 100. For example, when the power reserve on the battery 930, 950 falls below a predetermined level, a signal could be transmitted to the pump subsystem 1000 to shut down the pump or provide an indicator to service personnel that the fuel valve assembly requires servicing. In another aspect of the invention, a signal may be sent from the pump subsystem 1000 to the fuel valve assembly 100 seeking a confirmatory indication that electronics and/or other components of the fuel valve assembly 100 are operating properly. If a confirmatory signal is not received from the fuel valve assembly 100, a visual or auditory indicator may activated to notify service station personnel or other interested party that the fuel valve assembly requires service.
In another aspect, if a confirmatory signal is not received from the fuel valve assembly 100, the pump subsystem 1000 may actuate a pump shutdown sequence thereby terminating any fluid flow from the pump subsystem 1000. In an additional aspect, if a confirmatory signal is not received from the fuel valve assembly 100, the pump subsystem 1000 will not initiate any fueling sequence (i.e., without a signal indicating that the fuel valve assembly 100 is functioning properly, the pump subsystem 1000 will not pump fuel.) It is understood and contemplated herein that the confirmatory signal may be communicated to and from the fuel valve assembly 100, the pump subsystem 1000, and any other entity or computer system as desired (e.g., cell phone, web-based communication device, or other mobile device).
In an additional embodiment of the present invention, the fuel valve assembly 100 and/or the pump subsystem 1000, and related electrical components may be equipped with a watchdog circuit to minimize the hazards associated with electrical failure. In one aspect of the invention, the watchdog circuitry may incorporate structures and principles of operation as described in U.S. Pat. No. 5,627,867 which is incorporated herein by reference in its entirety. Advantageously, if the components within the main body subassembly 200 are not functioning properly (particularly components which relate to flow shut off within the main body subassembly) fuel flow from the pump subsystem 1000 may not be initiated by a motorist. In one aspect, the fuel valve assembly 100 will be biased in a closed position unless corresponding electrical components within the main body subassembly 200 are functioning properly. In another embodiment, a fail-safe switch may trigger the actuator subassembly 800 within the main body subassembly 200 if components within the main body subassembly 200 (e.g., low battery power, malfunctioning pressure sensor, malfunctioning solenoid, etc.) are not working properly. In this manner, the triggered actuator subassembly 800 precludes initiation of a fueling sequence.
In one aspect of the invention, a signal may be sent from the fuel valve assembly 100 to the pump subsystem 1000 indicating if the actuator subassembly 800 was activated by some stimulus other than the solenoid subassembly 700. As described further below, other means may be employed to activate the actuator subassembly 800 in combination with the solenoid subassembly 700 in an effort to ensure proper shut down of the fuel valve assembly 100. Advantageously, transmission of a signal if the actuator subassembly 800 is activated by some stimulus other than the solenoid subassembly 700 provides notice to service personnel when the actuator subassembly 800 or the solenoid subassembly 700 is malfunctioning.
In an additional aspect, when the fuel valve assembly 100 is removed from the cradle 1200 of the pump subsystem 1000, a signal could be transmitted to the pump subsystem indicating that a fueling sequence is about to begin. Advantageously, in one aspect of the invention, if the pressure sensor subassembly 600 is accidentally actuated during the beginning of the fueling sequence thereby precluding flow of gasoline from the pump subsystem 1000, a signal from the fuel valve assembly 100 could be sent to the pump system overriding the pump systems termination of fluid flow. This may be accomplished, for example, by sending a signal to the pump subsystem 1000 to ignore any signals related to pump subsystem shutdown for a sixty second interval after the initial fueling sequence begins. It is understood and contemplated herein, however, that any suitable time interval may be used as suits a particular application. In this manner, any initial accidental actuation from the pressure sensor subassembly 600 would not affect the pumping sequence. It is understood and contemplated herein that the signals sent to and from the pump subsystem 1000 or to and from the fuel valve assembly 100 could also be transmitted to a central server or any suitable computer module via a wireless internet connection or any other suitable means for remote communication.
In another embodiment of the invention, a tilt sensor (now shown) may be disposed within a portion of the main body subassembly 200 to detect the position of the main body subassembly with respect to the cradle 1200 and the gasoline tank fill tube. In this manner, a signal may be transmitted to the pump subsystem 1000 and/or the actuator subassembly 800 indicating when the main body subassembly 200 is in an upright position (e.g., docked with the cradle) or in a downward position (e.g., engaged in a fueling sequence). In one aspect, the tilt sensor comprises a mercury switch or a microelectromechanical system (MEMS) sensor configured to detect the position of the main body subassembly with respect to the cradle 1200 and the gasoline tank fill tube. It is understood, however, and contemplated herein that any suitable switch may be used as desired for a particular application. In one aspect of the invention, the electrical components incorporated within the main body subassembly 200 are protected via dipping or lacquered coatings or are otherwise compartmentalized within an explosion proof member to minimize risk of ignition of the fueling vapors.
In another embodiment of the present invention, the spring 850 of the solenoid subassembly 700 may be replaced with an additional solenoid assembly (not shown) for resetting the actuator subassembly 800. In this manner, when the solenoid 740 is tripped, rather than being reset automatically by spring 850, a reset switch would be engaged to activate the additional solenoid assembly (not shown) which would push the plunger 820 back into place. In like manner the plunger of the additional solenoid assembly would be reset by the triggering of the primary solenoid subassembly 700. In one aspect, the additional solenoid assembly could be activated upon receipt of signal from a tilt sensor (not shown) as discussed above. In this manner, a consumer would need to return the main body subassembly to an upright position to reset the solenoid subassembly 700. In an additional aspect, the additional solenoid assembly could be configured to reset once it is placed within the cradle 1200 of the pump subsystem 1000.
In another aspect of the invention, spring 850 is replaced with a ferromagnetic material configured to cause the actuator in the solenoid 740 to move in an extended or retracted position depending in the direction of the last pulse of current through the solenoid. The direction of the last pulse of current would coincide with signals received from sensors placed within the fuel valve assembly 100 indicating whether the solenoid subassembly 700 should be positioned in an open or closed configuration.
With reference now
In one aspect of the invention, the venturi tube 460 is operably connected to both the diaphragm 631 and the piezoelectric disk 630, such that a change in pressure in the gasoline fill tube could actuate the termination of fluid flow by the piezoelectric disk 630 and/or the diaphragm 631. In yet another embodiment, a venturi tube 460 may be connected to the diaphragm and a separate venturi tube may be connected to the piezoelectric disk 630. Advantageously, in one aspect of the invention, the sensitivity of the piezoelectric disk 630 may be adjusted to be less sensitive during the beginning of a fueling sequence to minimize false termination of fluid flow and may also be adjusted to be more sensitive after the initial fueling sequence has begun to ensure quick termination of fluid flow.
In one aspect of the invention, a service station operator and/or owner of a pump subsystem would not pay for the installation and maintenance of the fuel valve assembly 100 up front. Rather, a fee based on the amount of gasoline pumped through the fuel valve assembly could be charged to cover the costs of the product as well as service, maintenance, and replacement of the fuel valve assembly 100 and/or other related components of the pump subsystem 1000.
Further modifications and improvements may additionally be made to the liquid dispensing system, pump subsystem, fuel valve assembly and methods of use disclosed herein without departing from the scope of the present invention. Accordingly, it is not intended that the invention be limited by the embodiments disclosed herein.
The present application claims priority to U.S. Provisional Application No. 60/921,117 filed on Mar. 29, 2007 and U.S. Provisional Application No. 61/033,768 filed on Mar. 4, 2008 each of which are incorporated herein by reference in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| 60921117 | Mar 2007 | US | |
| 61033768 | Mar 2008 | US |
