The invention relates to apparatus for controlling fluid flow into a holding tank, and more particularly, to mechanical devices that prevent overfilling of a holding tank.
There are many applications where it can be desirable to automatically limit the fill level of a holding tank or other liquid container. A very common example is the water-holding tank of a flush toilet, for which there are many different designs in use that automatically open the fill valve when the tank is emptied, and close the fill valve when the water level in the tank reaches a desired “full” level.
For most of these solutions, installation of the fill-limiting mechanism into the holding tank or vessel that is to be filled requires that ready access be available to the interior of the holding tank, so that a relatively large apparatus can be inserted into the tank while a much smaller pipe or fitting extends through a hole provided at the bottom of the tank for connection to a filling pipe or hose. Furthermore, many of these designs are directed to filling a tank with water or another innocuous fluid, such that exposure to the liquid is not toxic. This allows the design to be relatively complex and consequently less reliable, because the mechanism is easily replaced without any health or environmental concerns, so that it is not necessary for the mechanism to be highly reliable over long periods of time.
Applications exist, however, wherein the interior of a liquid-storing tank is not accessible, except possibly through a few small ports, and where it is necessary to retrofit the tank with a refilling mechanism that is prevented from overfilling of the tank. One example is the conversion of a liquid-fueled torch, such as a so-called “tiki” torch, from being manually refilled through an upper fill port to being automatically refilled via a fuel pipe that enters the tank through a small port from below.
When the interior of a liquid storage tank is not openly accessible, it can be difficult to implement a purely mechanical solution for preventing overfilling, because any such solution will generally require that a float or similar element be inserted into the interior of the tank through a large opening, such as an open top of the tank.
Instead, one approach is to control the flow of liquid into the holding tank through a liquid refill pipe using an electrically controlled valve that is located exterior to the holding tank, and to introduce at least one liquid level sensor into the holding tank through a small opening provided proximal to the top of the tank. In the case of a tiki torch that is converted for automatic refilling, for example, the level sensors can be inserted through the port near the top of the torch that was previously used for manual filling of the fuel tank. A controller is thereby able to actuate the electric valve according to data provided by the level sensors, and thereby initiate filling when the tank is nearly empty, and stop the flow of liquid into the tank when the tank is nearly full. According to this approach, the required access to the interior is limited, at most, to only a small opening through which the refill pipe is inserted, and a small opening through which the level sensor(s) is/are inserted.
While this electronic approach can be effective, it can also be too complex and expensive for some applications, especially when a plurality of holding tanks are to be automatically filled from a common source, due at least to the requirement that a controller and electric valve be associate with each of the tanks. Also, this approach may not be sufficiently reliable for some applications, because the electrically controlled valves and/or the controllers may require periodic maintenance and/or replacement.
What is needed, therefore, is an apparatus for refilling a liquid holding tank that can be inserted into the interior of the holding tank through a small opening, and that includes a simple, reliable, purely mechanical overfill prevention valve.
The present invention is an apparatus for refilling a liquid holding tank. The apparatus can be inserted into the interior of the holding tank through a small opening, and includes a simple, reliable, purely mechanical overfill prevention valve. According to the present invention, a substantially straight pipe, referred to herein as a “standpipe,” is inserted into the holding tank through a small port in the base of the tank, and extends vertically into the interior of the holding tank. The standpipe is essentially a liquid fill pipe that is configured to enable liquid to flow therethrough into the interior of the holding tank.
A simple mechanical overfill prevention valve is included, either in series with or entirely contained within an upper portion of the standpipe. The overfill prevention valve includes a float that is lifted within the standpipe by the liquid as the tank is filled, and a seat that is sealed by a plug when the float has been lifted to a sufficient degree. In some embodiments, the float also functions as the plug, while in other embodiments the float and plug are separate components that are interlinked, so that the plug is caused to rise when the float is lifted up by the liquid. In some embodiments, during filling, the liquid flows through the seat, and out of the top of the standpipe. In other embodiments, liquid passages or “fill ports” are provided in the side wall of the standpipe that permit the liquid to flow into the tank without having to flow out of the top of the standpipe. Embodiments can also include “overflow ports” that penetrate the side wall of the standpipe to enable the liquid within the tank to enter the standpipe and so that it can lift the float.
In embodiments, the liquid storage tank is the fuel tank of a liquid fuel burning torch, such as a so-called “tiki” torch. In some of these embodiments, a small opening is formed at the bottom of the torch fuel tank, through which the standpipe is inserted, for example when converting the tiki torch from a manually filled configuration to an automatically filled configuration.
System embodiments include a central liquid reservoir that is connected to a plurality of liquid fill pipes associated with a plurality of liquid holding tanks, as well as a pump that is configured to pressurize the liquid so that it flows into the holding tanks.
In some of these embodiments, the liquid in the liquid fill pipe is maintained at pressure, so that each holding tank is filled whenever its overfill prevention valve opens. As a result, a relatively constant liquid level is maintained in each liquid storage tank.
In other embodiments, each of the holding tanks includes at least one electronic level sensor that is inserted through a port provided near the top of the holding tank. The level sensors are monitored by a single controller, which activates the pump whenever any one of the sensors indicates a low liquid level, at which point each of the liquid storage tanks is filled until its overfill prevention valve is engaged. In some of these embodiments, the pump is deactivated after a specified interval of time, while other embodiments include additional level sensors in the liquid storage tanks that provide an indication of when the tank is full, and the central controller shuts off the pump when the sensors indicate that all of the tanks have been filled.
In various embodiments, the standpipe extends above the float so as to prevent interference between the float and other elements included within the tank interior, such as a level sensor or a torch wick.
A first general aspect of the present invention is a liquid filling apparatus compatible for installation within a liquid holding tank, the liquid filling apparatus being configured to enable filling of the liquid holding tank with the liquid while preventing the liquid from overfilling the holding tank. The liquid filling apparatus includes a standpipe having an outer wall, the standpipe being suitable for vertical insertion into the liquid holding tank, the standpipe being configured to permit the liquid to flow therethrough into the interior of the liquid holding tank, and a liquid overfill protection valve that is either in series with or is entirely contained within an upper portion of the standpipe, the liquid overfill protection valve having a valve diameter that is everywhere less than or equal to a diameter of an outer wall of the standpipe. The liquid overfill protection valve includes a central passage in liquid communication with the standpipe, a fill port in liquid communication with an interior of the holding tank, a valve seat penetrated by the central passage, a float, and a valve plug located within or below the valve seat and configured to be lifted by the float to form a seal with a constricted region of the valve seat when the liquid holding tank is filled with the liquid, the liquid overfill prevention valve being open when the valve plug is below the valve seat, and closed when the valve plug is sealed against the valve seat.
The liquid overfill protection valve, when open, is configured to allow the liquid to flow from the standpipe through the central passage, through the fill port, and into the interior of the liquid holding tank. The liquid overfill protection valve, when closed, is configured to prevent the liquid from flowing from the standpipe into the interior of the liquid holding tank.
In embodiments, the float is located above the valve seat, and is interconnected to the valve plug by a rod or filament extending from the float through the central passage of the valve seat to the valve plug.
In any of the above embodiments, the fill port can penetrate the valve seat, thereby providing liquid communication between the central passage of the valve seat and the interior of the liquid holding tank.
In any of the above embodiments, the standpipe can extend above the float, the float thereby remaining within the standpipe when the float is lifted by the liquid and the valve is closed. Some of these embodiments further include at least one overflow port located above the constricted region of the valve seat and configured to ensure that a liquid level at the float is equal to a liquid level in the holding tank. Or, the standpipe can extend both below and above the valve seat, but be interrupted by a region of the valve seat having an outer diameter that is the same as an outer diameter of the standpipe.
In any of the above embodiments, the central passage can be configured to direct a flow of the liquid through a flow path to the fill port without the liquid flow directly impinging on the valve plug. In some of these embodiments, when the liquid overflow prevention valve is open, the plug is suspended within a plug chamber that is in liquid communication with the liquid flow but is located below the flow path.
Any of the above embodiments can further include a draining valve configured to automatically open and allow the liquid to flow from the interior of the holding tank into the standpipe when the liquid overfill prevention valve is closed and a pressure of the liquid in the holding tank is greater than a pressure in the stovepipe by more than a threshold pressure difference.
Any of the above embodiments can further include a fill tube inserted within the standpipe, a distal end of the fill tube being shaped so as to be re-directed downward, the valve seat being installed within the downwardly directed portion of the fill tube, the liquid filling apparatus being configured when the liquid overfill prevention valve is open to enable the liquid to flow through the fill tube into the standpipe, and from thence into the interior of the liquid holding tank. In some of these embodiments, the valve plug is the float. Any of these embodiments can further include a constriction provided at the distal end of the fill pipe, the constriction being configured to confine the valve plug so that it remains within the fill pipe.
Any of the above embodiments can further include an elastomeric sealing ring included in the constricted region of the valve seat and configured to form a seal with the valve plug when the valve plug is lifted into contact with the sealing ring. Or, the valve plug can be elastomeric, and can be configured to form a liquid seal by direct contact thereof with the valve seat.
A second general aspect of the present invention is a liquid fuel burning torch that includes a fuel tank having an interior, an insertion port provided in a bottom of the fuel tank, and a liquid filling apparatus according to the first general aspect, the liquid filling apparatus being inserted through the access port into the interior of the fuel tank.
A third general aspect of the present invention is a system that includes a central liquid reservoir, a pump in liquid communication with the liquid reservoir, a plurality of liquid holding tanks, each of the liquid holding tanks having installed therein a corresponding liquid filling apparatus according to the first general aspect, and a liquid plumbing system interconnecting each of the liquid filling apparatuses with the pump.
In embodiments, the liquid plumbing system interconnects the liquid filling apparatuses in series.
In any of the above embodiments, the system can be configured to maintain liquid pressure within the liquid plumbing system, each of the holding tanks being automatically refilled thereby whenever its corresponding liquid overfill prevention valve is open. Or the central controller can be configured to cause the pump to be activated whenever a pressure of the liquid within the liquid plumbing system falls below a specified refill pressure, and to be deactivated when the pressure of the liquid within the liquid plumbing system rises above the specified refill pressure.
And in any of the above embodiments wherein the system is not configured to maintain liquid pressure within the liquid plumbing system, the central controller can be configured to cause the pump to be deactivated whenever a pressure of the liquid within the liquid plumbing system rises above a specified filled pressure.
The features and advantages described herein are not all-inclusive and, in particular, many additional features and advantages will be apparent to one of ordinary skill in the art in view of the drawings, specification, and claims. Moreover, it should be noted that the language used in the specification has been principally selected for readability and instructional purposes, and not to limit the scope of the inventive subject matter.
With reference to
According to the present invention, a standpipe 104 is inserted into the tank 102 through the small port 106 that is provided in the base of the tank 102, and extends vertically into the interior of the tank 102. The standpipe 104 functions as a liquid fill pipe that is configured to enable liquid to flow therethrough into the interior of the holding tank 102.
In
With reference to
In some embodiments, the incoming liquid flows past the float 200 so as to flow into the tank 102 from the top of the standpipe 104. In the embodiment of
The embodiment of
The diameter of the seat 202 in this embodiment is the same as the diameter of the standpipe 104, except for the stem 400 that is inserted into the standpipe 104. The seat 202 in this embodiment further includes a collar 402 that extends upward to surround the float 200 so that the float 200 can be lifted by the incoming liquid 212 within the collar 402, thereby eliminating any concern that the float 200 might contact any other structures within the holding tank 102, such as a wick 110 or level sensor 112. The collar 402 is essentially an extension of the standpipe 104 above the seat 202.
Another difference between the embodiment of
With reference to
Filling ports 604 are provided in the side of the liquid fill pipe 600 near the plug 602, and an O-ring 208 is provided above the filling ports 604. In the illustrated embodiment, the O-ring 208 functions as the seat 202 of the liquid overfill prevention valve. When the plug 204 is not pressed against the O-ring 208, as shown in
With reference to
In embodiments operation of the pump 810 is stopped after a fixed operating time has elapsed, or upon sensing a backpressure in the fill pipes 804 that is above a specified maximum, indicating that all of the overfill prevention valves 100 are closed. In the illustrated embodiment, each of the liquid storage tanks 102 includes at least one electronic level sensor 112 that is inserted through a port provided near the top of the liquid storage tank 102. The level sensors 112 are monitored by a single, centralized controller 806, which activates the pump 810 whenever any one of the sensors 112 indicates a low liquid level, at which point each of the liquid storage tanks 102 is filled until its overfill prevention valve 100 is closed. Embodiments include additional level sensors in the liquid storage tanks 102 that sense when the holding tank 102 is full, and the central controller 806 shuts off the pump 810 when the sensors indicate that all of the tanks 102 have been filled. This approach can be advantageous, for example, to avoid spillage of significant quantities of the liquid if one of the overfill prevention valves 100 fails to close for some reason.
The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description. Each and every page of this submission, and all contents thereon, however characterized, identified, or numbered, is considered a substantive part of this application for all purposes, irrespective of form or placement within the application. This specification is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of this disclosure.
Although the present application is shown in a limited number of forms, the scope of the invention is not limited to just these forms, but is amenable to various changes and modifications. The disclosure presented herein does not explicitly disclose all possible combinations of features that fall within the scope of the invention. The features disclosed herein for the various embodiments can generally be interchanged and combined into any combinations that are not self-contradictory without departing from the scope of the invention. In particular, the limitations presented in dependent claims below can be combined with their corresponding independent claims in any number and in any order without departing from the scope of this disclosure, unless the dependent claims are logically incompatible with each other.
This application claims the benefit of U.S. Provisional Application No. 63/142,225, filed Jan. 27, 2021. This application also claims the benefit of U.S. Provisional Application No. 63/208,811, filed on Jun. 9, 2021. Both of these applications are herein incorporated by reference in their entirety for all purposes.
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