Abstract:
This invention is a vertical fluid storage system with an upper container connected to a lower container. A fill port can be used to fill the upper container wherein the top fill hose is in fluid communications with the upper container. A first top valve in line with the top fill hose can be included to or controlling the flow rate of fluid into the upper container from the fill port. A top fluid level sensor can be included in the upper container for sensing the fluid level of the upper container. A gravity port included in the upper container can allow fluid to flow from the upper container to the lower container either during filling or when fluid is removed from the lower container. A dispensing port can be included in the lower container for dispending fluid from the lower container through gravity of a pump.

Description:
FIELD OF THE INVENTION 
       [0001]    This invention is directed to a vertical storage and dispenser unit and more specifically to a vertical storage and dispensing unit for DEF. 
       BACKGROUND OF THE INVENTION 
       [0002]    In the United States, the Clean Air Act established emission standards to regulate several pollutants that include nitrogen oxide (NOx), particulate matter (PM), carbon monoxide (CO), and hydrocarbons. One challenge for engine operators, under the Clean Air Act, is to limit the NOx emissions to comply with the ammonium g/bhp-hr standards. For operators of diesel engines, this standard proved to be problematic. One solution is known as the Selective Catalytic Reaction (SCR) technology. 
         [0003]    SCR is an “after treatment” technology to reduce the NOx in the exhaust emissions of a diesel engine. The SCR relies upon an operating fluid called Diesel Exhaust Fluid or DEF. DEF is injected into the exhaust pipe in front of a SCR catalyst and downstream of the engine. The heat of the engine exhaust causes the DEF to decompose into ammonia. The NOx reacts with the ammonia in the catalyst and the NOx molecules are converted into N 2  and H 2 O. 
         [0004]    DEF is a solution that is about 32% of a high-priority area in deionized water the DEF is stored as a separate DEF tank, which is connected to the DEF injector. The average consumption of DEF is about 3% per gallon of diesel fuel so that the DEF tank is significantly smaller than the fuel tank. 
         [0005]    Historically, operators would purchase DEF in small portable containers that would only hold a few gallons and use these portable containers to fill the DEF tanks associated with the diesel engine. Since about 3 gallons of DEF would be needed for about 100 gallons of fuel plastic containers from 35 to 15,000 gallons, over time, bulk containers began to appear and were located on-site of the operator so that the DEF tank was filled from a bulk dispenser. 
         [0006]    However, storage of DEF began to exhibit problems due to the nature of DEF. For example, DEF freezes around 12° F. and will expand about 7%. As a result, the container expands and there is damage to the hose and pump. Additives should not be added to DEF to reduce the freezing point, as such additives can harm the SRC catalyst. 
         [0007]    As DEF use increased, driven by the Clean Air Act, DEF dispensers were increasingly appearing at fuel islands so that DEF tanks could be refilled while filling diesel fuel tanks. However, given the limited space available at a fuel island, the tanks that would fit on the island had limited capacity. One solution was to stack containers or totes on top of one another so that the containers were arranged vertically to increase the storage capacity while maintaining the same footprint. 
         [0008]    This arrangement was considered desirable given the vertical space between the ground and cover of a fuel island. The space could accommodate  18  wheel trucks. Unfortunately when the container on top needs to be filled, the fill opening has to be much higher than the operator can reach. As a result, a ladder is needed to fill the upper container. Having an operator stand on a ladder in a fuel island, while attempting to use a nozzle and hose to fill the upper container, is not desirable. 
         [0009]    Another often overlooked disadvantage in the stacked configuration is that when a hose from the upper container is disconnected after filling or dispensing, the hose then becomes positioned lower than the upper container and fluid in the hose leaks out on to the ground or other undesirable location. Simply stacking two containers on top of one another is not the solution. 
         [0010]    Another disadvantage with conventional storage containers is they are typically round to increase strength and prevent bulging. However, round containers typically do not properly fit on a fuel island and do not maximize the foot print for storage on a fuel island. Making a container with flat sides is advantageous for the fuel island, but the flat sides tend to bulge when a certain volume is reached so that the container extends over the fuel island. Attempts to strengthen the walls of a flat sided container lead to increased costs. Given the pressure of a full container, making one that is in excess of  10  feet in height results in a reinforced container that is not economical. It would be desirable to have a vertical shape system configured for a fuel island that could be filled completely from an operator at ground level. 
         [0011]    Another difficulty created by the Clean Air Act is to have diesel engines that are used in remote areas to have DEF sources that are portable. For example, farm equipment, construction equipment, diesel engines, and the like. Many of these diesel engines operate in locations that are remote from fuel sources and therefore have high capacity fuel tanks. It would be advantageous to have a vertically stackable DEF source that can increase storage capability without increasing the footprint of the storage unit. 
         [0012]    Additionally, portable DEF supplies also need to be refilled and it would be advantageous to be able to use the same hose, pump, and nozzle to fill the portable DEF source from a bulk container that is used to fill the DEF tank of a diesel engine from a DEF portable supply. It would also be advantageous to be able to refill the bulk container from a mobile DEF supply using the same pump configuration. 
         [0013]    Therefore, it is an object of the present invention to provide for a vertical storage container that can be filled by an operator standing on the ground. 
         [0014]    It is also an object of this invention to provide vertically stacked totes for storage of DEF. 
         [0015]    It is also an object of the present invention to provide for a dispensing/fill assembly that can be used to fill the DEF source from a mobile storage container without duplicating the pump and hoses. 
       SUMMARY OF THE INVENTION 
       [0016]    The objectives of the present invention are accomplished by providing a vertical fluid storage system comprising: a lower container for containing fluid; a lower fill port defined in the top of the lower container; a routing hose having a first section attached between the fill port and a swivel and a second portion attached between the swivel and a top fill hose; an upper container disposed above the lower container having a top fill port on the top of the upper container wherein the fill hose is connected; an upper outlet included in the upper container connected to a gravity hose wherein the gravity hose is connected to a gravity port; and, an intake valve attached to the lower container wherein the intake valve closes to prevent fluid from flowing from the upper container to the lower container when the amount of fluid in the lower container reaches a certain volume. 
         [0017]    The intake valve can be a float valve in one embodiment. A dispensing port can be included in the lower container; a pump can be attached to the dispensing port by a first dispensing hose attached between the dispensing port and the pump; and, a nozzle can be attached to the pump by a second dispensing hose attached between the nozzle and the pump. The pump and first dispensing hose is removably attached to the lower container. 
         [0018]    A spacer can be disposed between the lower and upper containers defining an access area. 
         [0019]    The invention can include an upper container in fluid communications with the lower container; a fill port connected to a top fill hose to transfer fluid from the fill port to the upper container wherein the top fill hose is in fluid communications with the upper container; a top valve in line with the top fill hose for controlling the flow rate of fluid into the upper container; a top fluid level sensor carried by the upper container for sensing the fluid level of the upper container; a gravity port defined in the upper container and in fluid communications with a gravity hose attached to a lower container so that fluid can flow from the upper container to the lower container allowing the lower container to be filled from fluid in the upper container; and, a controller connected to the top valve and the top fluid level sensor so that when the top fluid level sensor determines that the upper container has a predetermined fluid level, the top valve is closed preventing overfilling of the upper container. 
         [0020]    The invention can include a lower fluid level sensor connected to the controller; and, a lower valve in line with the gravity hose and connected to the controller so that when the lower fluid level sensor detects a predetermined fluid level of the lower container, the lower valve is closed and fluid entering the fill port is stored in the upper container. 
         [0021]    The controller can include an electrical junction for receiving power from an external source and supplying power to the controller, top valve and top fluid level indicator. A dispensing port can be included in the lower container as well as a pump attached to the dispensing port by a second dispensing hose attached between the dispensing port and the pump. A nozzle can be attached to the pump by a first dispensing hose attached between the nozzle and the pump. The second dispensing hose can be removably attached to the lower container. 
         [0022]    The invention can include a container cage containing a lower and upper container where the lower and upper container are vertically separated by a spacer; a fill port disposed in a space defined by the spacer; a top fill hose in fluid communications with the fill port and the upper container; a gravity hose connected between the upper container and the lower container; a lower fluid level sensor for determining the level of fluid in the lower container; and, a lower valve in line with the gravity hose so that the lower valve is closed when the lower fluid level sensor determines that there is a predetermined level of fluid in the lower container. 
         [0023]    The controller can be attached to the lower fluid level sensor and the lower valve to prevent fluid from flowing from the upper container to the lower container when the amount of fluid in the lower container reaches a certain volume as detected by the lower level sensor. The invention can include a second upper container in fluid communications with the fill port so that fluid entering the fill port is transferred to the upper container and the second upper container. A second lower container can be in fluid communications with the second dispensing hose so that when fluid can be removed from the lower container and the second lower container by the pump. The gravity hose can be in fluid communications with the lower container and the second lower container. A second fluid level sensor can be attached to the second lower container and the controller; and, a second lower valve can be attached to the controller and in fluid communications with the second lower container. 
         [0024]    The invention can also include a vertical fluid storage system having an first upper container in fluid communications with a first lower container; a second upper container in fluid communications with a second lower container; a fill port connected to a top fill hose to transfer fluid from the fill port to the first and second upper containers wherein the top fill hose is in fluid communications with the first and second upper containers; a first top valve in line with the top fill hose for controlling the flow rate of fluid into the first upper container and a second top valve in line with the top fill hose for controlling the flow rate of fluid into the second upper container; a first top fluid level sensor carried by the first upper container for sensing the fluid level of the first upper container and a second top fluid level sensor carried by the second upper container for sensing the fluid level of the second upper container; a first gravity port defined in the first upper container and in fluid communications with a first gravity hose attached to the first lower container so that fluid can flow from the first upper container to the first lower container allowing the first lower container to be filled from fluid in the first upper container; a second gravity port defined in the second upper container and in fluid communications with a second gravity hose attached to the second lower container so that fluid can flow from the second upper container to the second lower container allowing the second lower container to be filled from fluid in the second upper container; a controller connected to the first top valve, first top fluid level sensor, second top valve and second top fluid sensor so that when the first top fluid level sensor determines that the first upper container has a predetermined fluid level, the first top valve is closed preventing overfilling of the first upper container and when the second top fluid level sensor determines that the second upper container has a predetermined fluid level, the second top valve is closed preventing overfilling of the second upper container; a first dispensing port included in the first lower container; a second dispensing port included in the second lower container; a pump attached to the first and second dispensing ports a second dispensing hose attached between the dispensing ports and the pump; and, a nozzle attached to the pump by a first dispensing hose attached between the nozzle and the pump so that fluid can be pumped from the first and second lower containers. 
         [0025]    The invention can include a first lower fluid level sensor connected to the controller a first lower valve in line with the first gravity hose and connected to the controller so that when the first lower fluid level sensor detects a predetermined fluid level of the first lower container, the first lower valve is closed and fluid entering the fill port is stored in the first upper container. The controller can include an electrical junction for receiving power from an external source and supplying power to the controller, top valve and top fluid level indicator. 
         [0026]    The invention can include an upper container in fluid communications with a first lower container and a second lower container; a fill port connected to a top fill hose to transfer fluid from the fill port to the upper container wherein the top fill hose is in fluid communications with the upper container; a first top valve in line with the top fill hose for controlling the flow rate of fluid into the upper container; a top fluid level sensor carried by the upper container for sensing the fluid level of the upper container; a first gravity port defined in the upper container and in fluid communications with a first gravity hose attached to the first lower container and a second gravity hose attached to the second lower container so that fluid can flow from the upper container to the first and second lower containers allowing the first and second lower containers to be filled from fluid in the upper container; a controller connected to the top valve and top fluid level sensor so that when the top fluid level sensor determines that the upper container has a predetermined fluid level, the top valve is closed preventing overfilling of the upper container; a first dispensing port included in the first lower container; and, a second dispensing port included in the second lower container. 
         [0027]    The invention can include an upper container in fluid communications with a lower container; a fill port connected to a top fill hose to transfer fluid from the fill port to the upper container wherein the top fill hose is in fluid communications with the upper container; a first top valve in line with the top fill hose for controlling the flow rate of fluid into the upper container; a top fluid level sensor carried by the upper container for sensing the fluid level of the upper container; a gravity port defined in the upper container and in fluid communications with a gravity hose attached to the lower container so that fluid can flow from the upper container to the lower container allowing the lower container to be filled from fluid in the upper container; a controller connected to the top valve and top fluid level sensor so that when the first top fluid level sensor determines that the upper container has a predetermined fluid level, the top valve is closed preventing overfilling of the upper container; and, a dispensing port included in the lower container for dispending fluid from the lower container. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0028]    The construction designed to carry out the invention will hereinafter be described, together with other features thereof. The invention will be more readily understood from a reading of the following specification and by reference to the accompanying drawings forming a part thereof, wherein an example of the invention is shown and wherein: 
           [0029]      FIG. 1  is a perspective view of various components of the invention; 
           [0030]      FIG. 2  is a perspective view of various components of the invention; 
           [0031]      FIG. 3  is a front view of various components of the invention; and, 
           [0032]      FIG. 4  is a perspective view of various components of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0033]    Referring to  FIG. 1 , a lower storage assembly  10  is shown having a lower container  12  and a lower cage  14  that receives the lower container. A lower drain assembly  16  is attached to the lower container. The lower drain assembly can include an outlet, valve and handle. A lower base  18  can be included with the lower storage assembly to support the lower storage assembly and to provide sufficient clearance for the lower drain assembly. A lower fill port  20  receives a nozzle or other apparatus to receive fluid from an external source such as another bulk container, mobile source or portable source. When fluid is received by the lower fill valve, the fluid is directed by a routing hose  22  to top fill hose  24 . The top fill hose can be connected to a top fill hose port  25 . The routing hose  22  includes a swivel  26  allowing the first section  22   a  of the routing hose to rotate about the second section  22   b  of the routing hose. When installing or otherwise manipulating the routing hose, the swivel allows the first section to be secured to the lower fill port by a threaded assembly so that when the first section is rotateably attached to the lower fill port, the hose does not kink or otherwise deform undesirably. Further, since the first section rotates independently of the second section, threading the first section on the lower fill port would not disconnect the second section from the top fill hose. 
         [0034]    The top fill hose is attached to the top fill inlet  28  of the upper container  32 . The top fill inlet can include a pressure relief assembly to prevent overfilling or over pressurizing. In one embodiment, a pressure relief valve  30  is included in the top of the upper container. When fluid is received by the lower fill valve, the fluid is under pressure so that the fluid is forced into the top fill hose and into the upper container. The fluid then is gravity fed into the upper outlet  42  and into the attached gravity hose  44  so that the fluid is delivered into the lower container through gravity port  46 . The gravity port can include a fill valve or intake valve  48  that shuts off the gravity port once the lower container reaches a predetermined volume. In one embodiment, the fill valve is a float valve  50 . 
         [0035]    In operation, fluid is delivered to the lower fill port, travels through the routing hose into the top fill hose, fills the upper container, is gravity fed into the upper outlet and into the gravity hose and into the lower container. When the lower container is at a predetermined level, such as nearly full, the fill valve closes and the fluid can no longer flow through the gravity hose. Therefore, the upper container begins to fill. When the upper container is full, pressure in the routing hose increases which can be detected by a fill nozzle and the nozzle can automatically shut off. In one embodiment, the containers are transparent or semi-transparent allowing the operator to see the fluid level in the containers. 
         [0036]    An upper cage  34  can be included to receive the upper container. The upper container and the lower container can be carried by a spacer  36  that is disposed between the two containers. The spacer defines an access area  38  allowing access to the lower fill valve, lower outlet  40  that can be connected to dispensing valve  62  and other components of the invention. 
         [0037]    The lower outlet can include a snorkel  52  so that fluid can be removed from the lower container. The distal end  54  of the snorkel can include a resilient section  56  allowing the snorkel to contact the bottom of the container without permanent deformation. Extensions  58  can be included in the distal end so that if the distal end of the snorkel contacts the bottom of the container, fluid can still flow between the extensions. Opening  60  can be included in the distal end to allow fluid to flow into the snorkel even when the snorkel is contacting the bottom of the container. 
         [0038]    Referring to  FIG. 2 , the fluid enters the lower container at path  64  and travels through routing hose  22  along path  66 . The fluid travels upward through the top fill hose along path  68  and into the top fill inlet. The fluid enters the upper container at  70  and drops to the bottom of the container. The fluid enters the upper outlet and travels through gravity hose  44  along path  72 . The fluid then encounters the fill valve and if the fill valve is closed, the fluid will accumulate in the upper container. If the fill valve is open, the fluid will accumulate in the lower container. 
         [0039]    In one embodiment, a pump  80  can be attached to a pump plate  82  so that the pump and pump plate are removably attached to the lower cage. Nozzle  84  is connected to the pump to dispense fluid from the container. A first dispensing hose  88  connects the nozzle to the pump. In one embodiment, the nozzle is a DEF nozzle. A second dispensing hose  90  is connected between the pump and a dispensing coupling  92 . The pump can be powered by an external power source connected to the pump by the power cables and power cable clamps. In one embodiment, the pump can be contained within a pump housing that can be attached to the pump plate. The pump plate can include a pump bracket  95  that can be used to hang the pump plate on the lower cage. The pump housing  94  can include a nozzle carrier  96  for supporting the nozzle when the nozzle is not in use. 
         [0040]    Referring to  FIG. 3 , the lower storage assembly includes a lower drain assembly  16  allowing fluid to be removed from the lower container  12 . A lower cage  14  receives the lower container. Spacer  36  includes an access area  38  and is disposed between the lower container and upper cage  34  and upper container  32 . In operation, fluid from an external source such as tank, truck tanker and the like, can be attached to a fill port  100 . The external source is then in fluid communications with the fill port. The fill port can be attached to the spacer or otherwise carried by a frame  102 . The fill port can be disposed generally below the upper container and generally above the lower container for ease of access. The frame can include the spacer, upper cage, lower cage or any combination thereof. When fluid enters the fill port, it travels in the top fill hose  24  and is directed from the fill port to the upper container. The top fill hose is connected to a top fill outlet  28  allowing fluid from the fill port to enter the upper container. A top valve  104  can be inline with the top fill hose and can control the flow of liquid into the upper container. The top valve can be in electronic communications with controller  106  that can both receive information from the top valve, transmit information to the top valve and power the top valve. The controller can control the flow rate of fluid into the upper container by actuating the top valve so that only a certain flow rate is accomplished. A top fluid level sensor  108  can determine the fluid level of the upper container and transit the information to the controller. The controller can have computer readable instructions that can determine when the top fluid level sensor detects a fluid level of the upper container and can close the top valve to prevent overfilling of the upper container. When the top fluid level sensor detects that the fluid is at a predetermined level, the top valve can be closed. 
         [0041]    The upper container can include a gravity port connected to a gravity hose  44  allowing fluid to flow from the upper container into the lower container. A lower valve  110  can be in line with the gravity hose and determine the flow rate of fluid from the upper container into the lower container. A lower fluid level sensor  112  can determine if the fluid level of the lower container reaches a certain level and close the lower valve to prevent overfilling of the lower container. When the lower fluid level sensor determines that the fluid level of the lower container is at a predetermined level, the lower valve can be closed. The predetermined levels of fluid can be determined based upon expansion due to temperature to prevent over pressure, maximum volume of containers, clearance level for the various components attached to container and the like. When the lower container valve is closed, fluid entering the fill port that is transferred to the upper container fills the upper container. The flow rate of the lower valve can be larger than the flow rate of the top valve to assist in preventing the overfilling of the upper container. When fluid is removed from the lower container, the lower fluid level sensor can transmit the fluid level to the controller and the lower valve can be actuated by the controller to allow fluid to flow from the upper container to the lower container. In one embodiment, the lower valve can remain open so that when fluid is pumped out of the lower container, the fluid in the upper container is transferred to the lower container. 
         [0042]    Referring to  FIG. 4 , the lower containers are shown with their upper containers removed. One or more lower containers can include an upper container. In this embodiment, a first assembly of a lower container and upper container can be connected to a second assembly of the lower container and an upper container to form multiple vertical storage assemblies. The lower container can include a lower hose connector  118  that connects the second dispensing hose  90  attached to the pump  80  to a first dispensing routing hose  90   a  to a second dispensing routing hose  90 b so that fluid is drawn from the first lower container  12   a  and the second lower container  12   b  without the need for two pumps. The first dispensing coupling  92   a  is connected to the first dispensing routing hose and the second dispensing coupling  92   b  is connected to the second routing dispensing hose. For the upper containers, an upper hose connecter can be used to split and connect the top fill hose to two or more upper containers so that when the fill port receives fluid, it is transferred to two or more upper containers. 
         [0043]    The controller can include relays that are connected to the top valve, top fluid level indicator, lower valve and lower fluid level indicator. An external power connector can be used to provide power to the controller at power junction which can in turn power the pump, top valve, top fluid level indicator, lower valve and lower fluid level indicator. 
         [0044]    While the invention has been described in connection with a preferred embodiment, it is not intended to limit the scope of the invention to the particular form set forth, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims. 
         [0045]    Unless specifically stated, terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. Likewise, a group of items linked with the conjunction “and” should not be read as requiring that each and every one of those items be present in the grouping, but rather should be read as “and/or” unless expressly stated otherwise. Similarly, a group of items linked with the conjunction “or” should not be read as requiring mutual exclusivity among that group, but rather should also be read as “and/or” unless expressly stated otherwise. 
         [0046]    Furthermore, although items, elements or components of the disclosure may be described or claimed in the singular, the plural is contemplated to be within the scope thereof unless limitation to the singular is explicitly stated. The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to,” or other like phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent.