Fluid-level sensing device with encapsulated micro switch

A fluid-level sensing device that uses the interaction of a first magnet attached to the distal end of an external micro switch arm and a second magnet positioned within the distal end of a pivoting float body to close a circuit within the micro switch and create a shut-off signal to stop fluid production. A single housing holds the micro switch and float body, wherein magnetic forces acting through the housing wall between them and other magnet-positioning materials that separate the two magnets cause signal production. After float body deployment, manual reset of the float body is accomplished via its lever-like distal end. The main body of the micro switch, which it is snap-fit into a fixed position within the upper housing chamber for use, is entirely encapsulated in waterproof material to protect it from corrosion. Alternative ways for quick mounting of the housing to a fluid-collecting pan are contemplated.

CROSS-REFERENCES TO RELATED APPLICATIONS

BACKGROUND

1. Field of the Invention

This invention relates to fluid-level sensing devices used to shut off a fluid-producing system in response to rising fluid levels caused by the system that result in a risk of fluid overflow and/or damage to surroundings, specifically to a fluid-level sensing device that is typically connected to the perimeter wall of a fluid collection pan or tray associated with a fluid-producing unit, such as an air conditioning or furnace unit, and is often mounted to, with, or near a drain line connection or drain line connection assembly where it is positioned for float body deployment when rising fluid exceeds a threshold level considered safe. Hereinafter, for simplicity of description alone, the word “pan” will be used to identify a fluid-collecting device used in association with the present invention, without any intent of limitation. The present invention employs the interaction of two magnets to close a circuit in a micro switch and thereby send a shut-off signal to the fluid-producing system to stop its fluid production so that accumulated fluid in the pan monitored by the present invention fluid-level sensing device does not exceed a pre-determined level considered safe. The first magnet is attached to the distal end of an external micro switch arm and the second magnet is positioned within the distal end of a pivoting float body that vertically deploys in response to rising fluid. A single housing with two separate vertically stacked chambers (hereinafter identified as the “upper chamber” and the “lower chamber”) is used to isolate the encapsulated switch in a position directly above the float body, with the magnetic forces between the upper and lower magnets interacting through the central housing wall between them, as well as through the float body's upper surface, the bottom of any magnet-holding cup attached to micro switch external arm, and any other materials used to position and/or retain the two magnets in their usable positions. After float body deployment, manual reset of the float body to its pre-deployment position is accomplished via its lever-like distal end that extends beyond the vertically-extending outer wall of the float/switch housing. Attraction or repulsion forces between the two magnets can be the triggering factor for circuit closure, but repulsion is preferred. The lower open-bottomed chamber in the housing below the micro switch is substantially filled by the buoyant float body. There is no opening through the housing's central wall to allow for communication between the lower open-bottomed float body chamber and the upper open-topped micro switch chamber. Further, the main body of the micro switch is completely encapsulated in waterproof material to protect it from corrosion and ensure reliable and long-term repeat performance. Electrical wiring extending in an upwardly direction from the micro switch connects it to the fluid-producing system for which monitoring is required, so that when the fluid level in a pan to which the present invention is attached exceeds a pre-determined threshold level considered safe, the rising fluid causes the distal end of the float body to pivot in an upwardly direction and increase magnetic interaction between the magnet it supports and the second magnet associated with the distal end of the micro switch arm, which when the threshold level is reached causes a circuit to be closed and results in an electric signal being sent to the fluid-producing system to shut it off and prevent overflow damage to the system, surrounding equipment, nearby objects, and/or adjacent materials. It is also preferred for the lower chamber of the float/switch housing to have one or more air vents that prevent airlock malfunction of the float body. However, in combination or in the alternative, the slot used to guide the lever-like distal end of the float body during its vertical deployment can be configured to serve as an effective air vent. It can also be narrow to avoid the entrance of debris and other non-fluid materials (such as algae or mold) that could interfere with effective and reliable float body performance.

Alternative ways for quick mounting of the present invention housing to a fluid-collecting pan are contemplated, including the use of a quick-mounting shelf area pre-molded into the pan that is configured to facilitate and expedite a drain line connection and placement of the float switch into a level orientation for most reliable long-term operation. Thus, when the present invention float/switch housing is permanently or temporarily associated with a mounting plate having a configuration complementary to that of a shelf area pre-molded into the pan, the act of drain line connection using the shelf-area provides immediate leveling of the float switch body relative to the pan, so that once leveling of the pan is achieved the resulting float deployment trouble-free, reliable, and reproducible without malfunction for long-term use. The lever-like distal end of the float body provides an easy test point for an installer to be certain that float body deployment occurs at the proper fluid level, typically in as little water accumulation as possible. At least one example of the manner in which threshold fluid level adjustment can be accomplished is presented later in this invention disclosure. Applications of the present invention include, but are not limited to, use in air conditioning and furnace condensate collection/overflow prevention applications for shutting off an air conditioning or furnace system when condensate collected in a pan beneath the portion of the system creates a water damage risk by exceeding a pre-established threshold amount, as well as other applications including where rising condensate/fluid beyond a safe threshold limit is undesirable and automated shut-off of the condensate/fluid source is needed or desired to eliminate back-up damage to the condensate producing system or the risk of damage to surrounding objects and structures.

2. Description of the Related Art

When condensates from air conditioning and furnace systems, as well as other condensates, are collected in a pan or tray to avoid contact with surrounding objects and structure, a risk of overflow and/or back-up into the system producing it remains. As a result, fluid-level sensing devices have been employed with collection pans and trays to shut-off the source of condensate flow when the amount of condensate collected exceeds a predetermined threshold level considered safe. However, prior art float switches have many disadvantages, including insubstantial float body shape or construction that reduces buoyancy, switching components having materials or construction with insufficient corrosion resistance, float body positioning that presents a risk of debris interference, float body positioning that presents substantial exposure to collected fluid and a risk of interference from mold and algae growth, float bodies subject to airlock malfunction, float bodies that require the collection of a substantial amount of fluid before their deployment occurs, and/or float bodies not substantially filling the associated float housing wherein prompt float body deployment is sometimes delayed or prevented by its tendency to wobble. Further, installation time of prior art devices can be lengthy when there is guess-work needed by an installer for selecting, mounting, leveling, and otherwise adjusting an appropriately matching and adjusting a float switch and condensate collection pan for correct operation in an intended application, particularly when a hole needs to be drilled in a pan. In addition, maintenance is often required after installation of prior art fluid-level sensing devices to ensure continued stable, reliable, and reproducible float body deployment for electrical shut-off of a fluid-producing unit or system when the accumulated fluid being monitored by the float switch rises beyond a threshold level considered safe. Further, air conditioning condensate collection pans are typically installed in hot attics, and other places where significant temperature fluctuations can occur, and many prior art plastic condensate collection pans have insufficient construction whereby a float switch mounted on the upper edge of the pan's perimeter wall will lean in over a period of time and no longer be maintained in the needed vertical orientation for a prompt and reliable deployment in response to excessive condensate collection in the pan.

The present invention's use of a pivoting buoyant float body in combination with two magnets overcomes deficiencies in the prior art. First, the pivoting float body of the present invention does not have a tendency to wobble, as does a freely-floating body whose vertical movement is guided by a concentric tube or rod inserted centrally through it. Second, the present invention magnets provide rapid circuit closure once the float body begins to deploy, so that a shut-off signal to halt fluid production can be sent with less collected fluid. Third, venting of the present invention float housing substantially reduces airlock formation and since its float body substantially fills the float housing chamber within which it is positioned, interference from debris is minimal. In addition, when the present invention fluid-level sensing device is in fixed association with a drain line connection having a mounting plate, mating it with a complementary configured quick-mounting shelf area in a fluid-collecting pan creates a fast and easy drain line connection, wherein switch installation is accomplished simply as a consequence of the drain line connection being made and the act of drain line connection provides immediate leveling of the float switch relative to the pan, so that once the relatively easy step of leveling the pan is achieved the resulting vertical float body deployment trouble-free, reliable, and reproducible without malfunction during long-term use. Another advantage provided by the present invention fluid-level sensing device over the known prior art is the lever-like distal end of its float body which provides an easily manipulated finger latch to allow post-installation testing by the installer to be certain the present invention fluid-level sensing device is operational and functioning according to need. When a pan with a quick-mounting shelf area is used (particularly one generally trapezoidal in configuration), attachment of the mounting plate to the shelf area also provides a substantial connection that is sturdy and not subject to changes in orientation over time that often occur as a result of sagging or lean in of prior art condensate tray or pan walls. In addition, the present invention sensing device has a sturdy/rugged design and sturdy corrosion-resistant construction. Also, since the lower chamber of the present invention float/switch housing has an open bottom configured to allow condensate collected therein to easily drain once fluid levels subside, its float body is not routinely in contact with collected condensate. Thus, the float body is less likely to become clogged with mold, algae, and/or debris, further protecting it from malfunction.

The closest inventions to the present invention appear to be those disclosed in U.S. Pat. No. 6,140,925 to Lee (2000) and U.S. Pat. No. 6,339,985 to Whitney (2002). The Whitney invention discloses a coffee maker having closure between two chambers achieved by magnetic action, with one of its magnets on the distal end of a pivoting arm. In contrast, the Lee invention discloses a magnetically operated float switch having a float body that is vertically deployable on a central rod, with the rod having a top magnet positioned below a micro switch. However, neither the Lee nor the Whitney inventions disclose a unitary housing with separate isolated vertically-stacked chambers with an open-topped upper chamber configured for holding a corrosion-resistant encapsulated micro switch above a pivoting float body in the open-bottomed lower chamber. Also, the provisions for post-installation testing, quick mounting to a condensate pan, and reducing interference to the float body by mold, algae, and/or debris, which are important to the present invention, are not discussed in the Lee and Whitney disclosures. No other apparatus is known that has the same structure, functions in the same manner, or provides all of the advantages of the present invention.

BRIEF SUMMARY OF THE INVENTION

It is the primary object of this invention to provide a fluid-level sensing device that is easily and promptly attached to a fluid-collecting pan in a desired position of use that places its pivoting float body near the base of the pan's perimeter wall, operates for extended periods of time with little or no post-installation inspection or maintenance, and when properly installed is able to rapidly, reliably, and repeatedly send electrical signals to an associated fluid-producing system to shut it off when only a small threshold amount of fluid has accumulated in the pan. It is a further object of this invention to provide a fluid-level sensing device that is configured for sturdy mounting to a pan wall so that little or no deviation from its originally installed position relative to the pan is experienced during extended periods of use. It is also an object of this invention to provide a fluid-level sensing device that is made from corrosion-resistant materials that resist premature deterioration and malfunction. A further object of this invention is to provide a fluid-level sensing device capable of proper and reliable operation when subjected to temperature extremes. It is also an object of this invention to provide a fluid-level sensing device that can be immediately and easily tested by an installer or maintenance personnel for certainty that the device is properly operational in the intended application. It is a further object of this invention to provide a fluid-level sensing device configured to facilitate its association with the perimeter wall of a fluid-collection pan, shorten installation time, and permit optional adjustment of float body distal end deployment height. It is also an object of this invention to provide a fluid-level sensing device having a rugged construction and being made from materials that do not experience performance loss as a result of exposure to widely fluctuating temperature variations. It is also an object of this invention to permanently or detachably incorporate a fluid-level sensing device as a part of a unitary switch and drain line connection assembly configured for easy and proper installation of the fluid-level sensing device simply as a result of drain line connection. It is a further object of this invention to provide a fluid-level sensing device that provides adequate venting to prevent float body airlock malfunction, facilitates fluid entry into the open-bottomed lower chamber of its float/switch housing, and reduces entry of airborne debris into the lower chamber of the float/switch housing, including the loose insulation fibers typically encountered in attics with some air conditioning applications. It is a further object of this invention to incorporate structure that substantially reduces or avoids lean-in of fluid-collection pan walls at the site of present invention installation and otherwise promotes fast and reproducible shut-off responses directed to an associated fluid-producing unit when the fluid level in the pan exceeds a pre-established threshold level considered safe.

The present invention, when properly made and used, will provide a fluid-level sensing device for use in combination with an associated collection tray or pan (often simply referred to herein as “pan” for simplicity of description and without any intent of limitation) to collect fluid and shut off the source of fluid production when the amount of collected fluid exceeds a pre-established threshold level considered safe to prevent damage to the fluid source and/or its surroundings. Potential applications of the present invention can include the monitoring of condensates collected as a result of air conditioning and furnace system operation (to prevent back-up damage to the system and/or overflow damage to surroundings), as well as the monitoring of other potential fluid risk hazards, such as but not limited to potential hot water heater malfunction. The present invention fluid-sensing device is often provided as a part of a unitary switch/drain-line connection assembly that can be easily handled by an installer to achieve rapid mounting to the perimeter wall of a fluid-collection pan in association with a pre-formed drain line opening in the perimeter wall. Attachment to the drain-line connection assembly can be permanent, temporary, or quick-release. In the alternative, the present invention may be pre-installed during pan manufacture, leaving only a simple and optional float body height adjustment for the installer at the time of pan installation and pan leveling to ensure repeatable and reproducible float body deployment during long-term use whereon little routine inspection or maintenance will be needed.

The present invention comprises a reliable fluid-level sensing device that uses the interaction of a first magnet attached to the distal end of an external micro switch arm and a second (typically larger) magnet positioned within the distal end of a pivoting float body to provide interaction of one to the other so as to trigger the snap action mechanism within the micro switch needed to close a circuit and send a shut-off signal to the fluid-producing unit to stop its fluid production. A single housing is used to place a corrosion-resistant encapsulated micro switch in an open-topped upper chamber in an isolated position above an open-bottomed lower chamber in which a pivoting float body moves in response to rising and falling fluid levels, with the magnetic forces acting through the float/switch housing's central wall, the bottom surface of a magnet-housing cup when used on the external arm of the micro switch, the top surface of the float body, and any other magnet-positioning materials that are placed between the two interacting magnets. After float body deployment takes place that causes tripping of the micro switch, manual reset of the float body is accomplished via its lever-like distal end, which can also be used quickly by an installer as a finger latch to test the float body and make certain that a newly installed fluid-sensing present invention device is fully operational to meet application requirements. Attraction or repulsion forces between the two magnets can be the triggering factor. The open-bottomed lower chamber in the float/switch housing is substantially filled by the buoyant float body. Also, there is no opening in the housing between the lower open-bottomed float body chamber and the upper chamber in which the micro switch is located to prevent direct fluid communication from the lower chamber into the upper chamber. In addition, the main body of the micro switch is completely encapsulated in waterproof material to further protect it from corrosion and enhance its reliability for long-term use, and one or more seals are typically used to secure the micro switch within the upper chamber and reduce the likelihood of fluid entry into the upper chamber from above. Electrical wiring extending in an upwardly direction from the micro switch connects it to the fluid-producing system for which monitoring is required, so that when the fluid level in a pan to which the present invention is attached exceeds a pre-determined threshold level considered safe, the rising fluid causes the distal end of the float body to pivot in an upwardly direction and increase magnetic interaction between the magnet it supports and the second magnet associated with the distal end of the micro switch arm, which when the threshold level is reached causes a circuit to be closed and results in an electric signal being sent to the fluid-producing system to shut it off and prevent overflow damage to the system, surrounding equipment, nearby objects, and/or adjacent materials.

It is also preferred for the float housing to have venting that prevents airlock malfunction of the float body. The slot used to guide the lever-like distal end of the float body during its deployment can be configured to serve as an effective air vent. In addition, several alternative mounting means for fast and secure connection of the present invention float/switch housing to a fluid-collecting pan are contemplated, including but are not limited to, the connection of a substantially trapezoidal-shaped mounting plate between the float/switch housing and a complementary trapezoidal-shaped shelf area pre-molded into the perimeter wall of the fluid collection pan for drain line connection, a quickly-releasable spring tab connection between the float/switch housing and a mounting ring with a depending spring tab housing having a rail plate, the connection of the float/switch housing via a bridge to a substantially trapezoidal-shaped mounting plate complementary in configuration to a trapezoidal-shaped shelf area integrated into the pan wall that permits pre-leveled float/switch housing installation relative to the pan, and a grooved spring tab and fastener connection of the float/switch housing to a spring tab housing with complementary ridges that depends from a substantially trapezoidal-shaped mounting plate or a bridge depending from a substantially trapezoidal-shaped mounting plate. When mounting plate of the present invention has a configuration complementary to that of the shelf area pre-molded into the pan, such as but not limited to the substantially trapezoidal shape mentioned above, the act of drain line connection using the shelf area provides immediate leveling of the float body relative to the pan, so that once leveling of the pan is achieved the resulting float deployment trouble-free, reliable, and reproducible without malfunction during long-term use. Contemplated applications include, but are not limited to, use in air conditioning and furnace system condensate collection/overflow prevention applications for shutting off an air conditioning system or furnace when collected condensate in a pan beneath the portion of the system at risk for fluid damage exceeds a pre-established threshold amount, as well as other applications including where rising condensate/fluid beyond a safe threshold limit is undesirable and automated shut-off of the condensate/fluid source is needed or desired to eliminate back-up damage to the condensate producing system or the risk of damage to surrounding objects and structures.

Further, the connection between present invention switch, when part of an assembly, to a condensate/fluid collecting pan can be easily made using a threaded connector and an O-ring, and/or other sealing means or combination that provides a leak-resistant connection between pan and assembly. The present invention assembly and pan can also each be designed so that a mounting plate configured as a part of the assembly laterally overlaps a support shelf configured as a part of the pan perimeter wall to stably align the assembly in its needed position relative to the perimeter wall and maintain the needed level orientation provided during switch installation for proper and reproducible float body deployment. The support shelf/mounting plate structure provides immediate level orientation of the float body within the assembly when the pan to which it is connected is in a substantially level orientation, and also prevents wobble in the connection between the assembly and the perimeter wall so that the level orientation immediately achieved is maintained during an extended period of use. No additional leveling of the attached assembly, or the movable float body within the float housing member of the assembly, is required by an installer for proper, reliable, and reproducible float body deployment. Also, since the pan to be used with the present invention assembly has a sturdy construction and the assembly connection to the perimeter wall is made near the base of the perimeter wall, not over its upper edge, no leveling adjustment of the float body is anticipated at any time during its long-term use due to perimeter wall sagging or lean-in, even when the pan is installed in attics or other places exposed to temperature extremes. Thus, when the assembly is factory-installed, the only adjustment typically needed at the time of its installation is an optional adjustment of the deployment height for the float body within its float switch housing, to custom set the maximum depth of condensate collection in the pan prior to float body activation. The open bottom of the float body's lower chamber also permits collected condensate within it to easily drain back into the pan, thus eliminating favorable growth conditions for algae and/or mold that might otherwise interfere with or inhibit proper and reliable float body deployment. Protection from the loose insulation fibers and other airborne debris typically encountered in attics, where condensate producing air conditioning air handlers are commonly placed, is achieved by the lack of openings in the present invention housing other than that minimally needed for reliable air venting function to prevent float body airlock, a common malfunction of prior art devices. In most applications, the float body in the present invention assembly will be positioned to react to rising levels of collected condensate before any of it enters the drain line connected to the associated pan. A dam can be optionally used over the bottom part of the opening in the drain line connection member of the assembly to block condensate flow into the drain line and thereby extend the amount of time after the threshold level of condensate collection is reached within the pan before any condensate moves into the connected drain line. Electrical connection between the micro switch in the upper housing chamber and the condensate producing unit supported on the pan is typically through wires extending upwardly from the encapsulated micro switch, but not limited thereto. Thus, the present invention fluid-sensing device is designed for fast and efficient installation, as well as for minimal inspection and maintenance after installation.

The description herein provides preferred embodiments of the present invention but should not be construed as limiting its scope. For example, variations in the size and perimeter configuration of the float body; the type of mounting plate or other mounting means associated with the float/switch housing; the amount of the lever-like distal end of the float body extending beyond the housing for used as a testing finger latch; the configuration of the pivoting connection used between the float body and the lower chamber of the float/switch housing; the length of any bridge used to separate the float/switch housing and a the drain line connection mounting plate; whether the float/switch housing is easily detachable from the bridge or mounting plate; the type of connection used between the float/switch housing and the bridge; and the height and width dimensions of the upper and lower chambers within the float/switch housing, other than those shown and described herein, may be incorporated into the present invention. Thus, the scope of the present invention should be determined by the appended claims and their legal equivalents, rather than being limited to the examples given.

LIST OF COMPONENTS

2—first embodiment of a micro switch unit68encapsulated with waterproof material4—electrical wiring6—non-magnetic lever-like external micro switch arm8—non-magnetic cup10—small magnet associated with micro switch12—buoyant float body14—lever-like distal end of float body1216—proximal end of float body12providing pivoting connection18—bore extending through proximal end16used for insertion of pivot pin3420—hollow area through top surface of float body12configured for housing larger magnet2222—larger magnet associated with float body1224—mounting assembly configured for connection to a drain line26—mounting plate with wrap-around sides5228—unitary housing configured for housing encapsulated micro switch2and float body1230—opening configured for communication with a connected drain line32—upper chamber of unitary housing28configured for holding encapsulated micro switch234—pivot pin for insertion through bore1836—dam configured for partial blockage of drain line opening3038—hex nut with end ridges configured for securing mounting plate26to the perimeter wall of a fluid collection pan9440—seal or o-ring configured for placement between hex nut38and pan9442—plug configured for connection to tailpiece50to block fluid flow from pan94into a connected drain line44—ridges46—end slot in housing28through which the distal end14of float body12extends48—threads50—tailpiece of drain line connection assembly2452—upwardly-tapering wrap-around sides of mounting plate2654—air vents56—lower chamber of float housing2858—slide-on non-metallic cup58, extends arm6for more leverage60—material-saving cutout areas in encapsulated micro switch262—sealing ribs on encapsulated micro switch2, preferably added during manufacture64—protruding alignment guide66—elongated protrusion on encapsulated micro switch2configured for engagement with elongated opening74for easy snap-in connection of encapsulated micro switch2within the upper chamber32of float housing2868—representation of micro switch within encapsulated material70—widened portion of the lower chamber56within unitary housing28that is configured to accommodate the larger/wider shape of the second preferred embodiment of float body12wherein most of the buoyancy of float body12is remote from its pivoting fulcrum72—downwardly widening slot which is located in the front portion of the lower chamber56of unitary housing2874—elongated opening in housing28configured for engagement with the elongated protrusion66on encapsulated micro switch276—alignment notch in the wall of upper chamber32that is configured for engagement with the alignment guide64on encapsulated micro switch278—float cover—typically foam and often has informational markings80—rigid attachment plate of float housing28configured for associating float housing28to a fluid-collecting pan9482—spring tab connected to attachment plate80and box-style attachment member136and used for engagement with grooves on rail plate9284—top surface of float body1286—upright wall of fluid-collecting pan9488—slide adjust plate for use in adjusting the distance between small the magnet10associated with the arm6of encapsulated micro switch2and the larger magnet22within float body12, assists in the post-installation testing of float body12to confirm its proper operation, and is secured to housing28so that end slot46or alternative widened end slot72is accessible through its closed central slot14290—drain connection mount in the third drain line connection assembly having a substantially planar mounting ring configured for association with the drain opening of pan94and connection of float housing2892—grooved rail plate94—fluid collecting pan96—D-ring shaped member of drain connection mount9098—upright member use in drain connection mount90or on one end of bridge100, having one open side configured for securely containing attachment plate80or the plate-like rear surface of box-style attachment member136100—bridge configured for connection between housing28and mounting plate26102—rotatable quick-release release member configured for firmly fixing attachment plate80within upright member98104—knurled exterior of rotatable quick-release member102106—open center of rotatable quick-release member102108—fastener configured for insertion through open center106of rotatable quick-release member102and used with rotatable quick-release member102to firmly fix attachment plate80within upright member98110—nut with ridged exterior112—material-saving cutout area on the top front portion of encapsulated micro switch2114—distal end (test latch) of magnet cover118116—T-shaped slot configured for receipt of attachment plate80118—magnet cover associated with the top surface of float body12120—hex indentation122—front channel in housing28configured for adjustable vertical positioning of slide adjust plate88124—material-saving cutout in top of lower chamber56126—alignment protrusions128—elongated guide rails on the front portion of housing28that are configured for retaining slide adjust plate88against housing28130—non-slip member on slide adjust plate88configured for manual vertical adjustment thereof during its installation on unitary housing28132—informational markings134—hole configured for securing pivot pin34in its usable position within bore18136—box-style attachment member with plate-like rear surface having a spring tab82138—stop at bottom of upright member98for help in positioning attachment plate80within upright member98at an optimal height for an intended application140—enlarged upper piece configured for quick manual release of spring tab82and release of attachment plate80from upright member98142—vertically-extending closed slot centrally through slide adjust plate88144—cut-away area on the top front portion of housing28that is similar in configuration to the material-saving cutout area112on the top front portion of encapsulated micro switch2146—retaining mount within float body12for placing larger magnet22in a fixed position during use148—elongated bar configured for retaining slide adjust plate88within the guide rails128on the front portion of housing28

DETAILED DESCRIPTION OF THE INVENTION

The present invention comprises a micro switch unit68(shown inFIG. 33) encapsulated in waterproof material that makes it corrosion-resistant when placed in or around a fluid environment. When micro switch68is encapsulated, it is identified in the accompanying illustrations and the following text by the number2. In addition, the present invention comprises a float body12configured and positioned for upward deployment in response to rising fluid (not shown), wherein when the upward deployment reaches a threshold level no longer considered safe, it causes activation of the micro switch68so that it will send a shut-off signal to the system or unit (not shown) producing the fluid posing a risk of damage to its surroundings. To place the encapsulated micro switch2in proper relation to the float body for such activation, the present invention also comprises a unitary switch/float housing28configured with two vertically-stacked chambers, an upper chamber32with an open top configured to receive the encapsulated micro switch2and an open-bottomed lower chamber56configured to receive the float body12. Since unitary housing28is configured with no fluid communication between upper chamber32and lower chamber56, when encapsulated micro switch2and float body12are respectively positioned therein, each is physically isolated from the other. Therefore, in order for the upwardly deployable float body12to activate encapsulated micro switch2, magnets are used. The small magnet10associated with the non-magnetic lever-like arm6connected to encapsulated micro switch2is preferably smaller in size than the larger magnet22enclosed within the distal end of float body12. Four unitary housings28are discussed in the following disclosure, a first preferred embodiment shown inFIGS. 2,6, and7, a second preferred embodiment shown inFIGS. 9-11, a third preferred embodiment shown inFIGS. 14-19, and23, and a fourth shown inFIGS. 24-27. In addition, the following disclosure contains reference to four preferred embodiments of drain line connection assemblies for stable mounting of the unitary housing in a fixed location that assist in rapid and secure attachment of the present invention encapsulated micro switch2and float body12in optimal positions for prompt and reliable shut-off signal generation, typically to the upright perimeter wall of a fluid collecting container, such as but not limited to the condensate collection pan94shown inFIG. 15. As their name implies, the drain line connection assemblies used as examples herein of preferred mounting structure for the present invention unitary housing, encapsulated micro switch2, and float body12, also typically provide a means for connecting the fluid collecting container to a drain line. A first preferred embodiment of a drain line connection assembly is shown inFIGS. 2,6, and7, a second preferred embodiment is shown inFIGS. 15-21, a third preferred embodiment is shown inFIG. 23, and a fourth preferred embodiment is shown inFIGS. 26-28.

Many of the preferred embodiments of unitary housing28, encapsulated micro switch2, float body12, and drain line connection assemblies (that include mounting plate with wrap-around sides26, drain connection mount90, mounting plate26with bridge100, and the upright members with their front or back grooved rail plate surfaces92), which are identified hereinabove and in the accompanying illustrations, can be manufactured with little or no modification for interchangeable use with one another in a variety of configurations. Thus, the preferred embodiments disclosed herein are provided only as examples, and should not be considered patentably distinct from one another. Instead, they are merely provided to identify the more important features of the present invention, and it is to be understood that the present invention is capable of having other embodiments and of being practiced and carried out in a variety of other ways. Further, the language employed herein is for the purpose of description and should always be interpreted broadly, rather than being considered as limiting. Thus, the claims appended herein should be regarded as including a multitude of equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

FIGS. 1-7show a first preferred embodiment of the encapsulated micro switch2, a first preferred embodiment of unitary float/switch housing28with an upper chamber32isolated from its lower chamber56, and a first preferred embodiment of drain line connection assembly having a mounting plate26.FIG. 1is shows encapsulated micro switch2with its external non-magnetic lever-like arm6carrying a small magnet10close to its distal end in a cup8. Arm6is shown extending downwardly from the main body of encapsulated micro switch2, with cup8positioned below arm6. The size and shape of cup8is not critical, as long as it has sufficient interior space to hold magnet10. Preferably cup8is made from non-magnetic materials. The size and shape of magnet10is also not critical, nor is the configuration or dimension of arm6as long as arm6positions small magnet10in the proper location relative to the larger magnet22housed within float body12for prompt and reliable shut-off signal generation. InFIG. 1the number20represents the top of a hollow area or other designated space within float body12where larger magnet22is fixed in position for interaction with the smaller magnet10associated with arm6. Although not shown, bonding agents may be used to secure larger magnet22within hollow area20.FIG. 1also shows electrical wiring4extending upwardly from the top surface of encapsulated micro switch2for use in connecting encapsulated micro switch2to a fluid-producing unit or system (not shown), so that unit or system may receive a shut-off signal from the encapsulated micro switch2when a sufficient amount of fluid therefrom collects and poses a risk of damage to the unit/system or surroundings.FIG. 1further shows a float body12located under encapsulated micro switch2in a position that allows the larger magnet22within float body12to interact with the smaller magnet10when the distal end14of the pivoting float body12is vertically deployed in response to rising fluid level beyond a predetermined threshold level considered safe. Distal end14is preferably hollow to enhance buoyancy. An installer (not shown) mounts the unitary housing at the proper elevation so that signal generation by encapsulated micro switch2occurs when the threshold level of collected fluid considered safe in the application is either met or exceeded. Both of the magnets10and22are shown in broken lines, as each would otherwise be hidden from view. Further, broken lines marked by the numerical designation of12bshow float body12in a lower pre-deployment position, while solid lines marked by the numerical designation of12ashow float body12in an at least partially deployed position. The double-headed arrow to the right of the lever-like distal end14of float body12shows its expected direction of movement during deployment and reset.FIG. 1also shows the proximal end16of float body12that provides for its pivotal connection to mounting plate26(seeFIG. 6) via pivot pin34, and the bore18extending through proximal end16that is used for insertion of a pivot pin34(such as but not limited to that shown inFIGS. 6 and 32). As can be seen inFIG. 32, it is preferred for pivot pin34to have a position-locking configuration that with a clip or other common fastener (not shown) helps to maintain it within bore18for reliable and long term deployment of float body12without malfunction. The shape of float body12shown inFIG. 1is not considered limiting and other shapes are also usable with the present invention, such as but not limited to the float body12having an arcuate perimeter that is shown inFIG. 12. It is preferred that float body12have a configuration that allows it to promptly deploy as a result of contact with a very small amount of collected fluid, and for float body to substantially fill lower chamber56.

FIG. 2shows the first preferred embodiment of unitary housing28in the present invention connected via a pivot pin34to the mounting plate26of a first preferred embodiment24of a drain line connection assembly. Both are contemplated for use with the encapsulated micro switch2and float body12shown inFIG. 1. The wide top opening of upper chamber32is visible, as is the opening/slot46through which the lever-like distal end14of float body12extends for use in testing and resetting float body12after deployment into proper position for reuse. Although the size of unitary housing28can vary, for cost effective manufacture it is not contemplated for unitary housing28to be much larger than minimally needed for containing encapsulated micro switch2and float body12in their proper positions for effective and reliable shut-off signal generation. Not marked inFIG. 2, but marked by the number54inFIG. 6,FIGS. 2 and 6show two air vents through the top surface of unitary housing28that exhaust air as float body12deploys, preventing airlock malfunction.FIG. 2further shows the first preferred embodiment24of a drain line connection assembly having upwardly-tapering wrap-around sides52that are configured for mating with a shelf (not shown in this disclosure but visible in other patented products of the inventor herein) molded into the perimeter wall of a fluid collection container. The upwardly-tapering wrap-around sides52create a generally trapezoidal configuration, and when the shelf molded into the fluid collection container to which mounting plate26is mated has a complementary trapezoidal configuration, the unitary housing28with its encapsulated micro switch2pre-positioned within upper chamber32and float body12pre-positioned within lower chamber56is automatically leveled relative to the container, so when the container is leveled after present invention installation, float body12becomes leveled for proper and reliable deployment without further installer action.FIG. 2also shows mounting plate having a dam36for raising the depth of fluid collection before its discharge through opening30can occur. Dam36can be made of break-away construction, so that an installer has two discharge options and can select the one best suited to the individual application. In addition,FIG. 1shows a tailpiece50aligned with opening30and rearwardly extending from mounting plate26. When tailpiece50is connected to a drain line (not shown), it can be used to assist in the discharge of collected fluid from the fluid collection container associated with the present invention should non-routine events occur that lead to rapid and/or excessive fluid collection that would otherwise place surroundings at risk for damage.

FIGS. 3-5show components used in association with tailpiece50and for securely fixing mounting plate26in its usable position against the perimeter wall of a fluid collection container.FIG. 3shows a hex nut38with female threads48used on the outside of a fluid collection container for connection with male threads48(seen inFIG. 7) extending rearwardly from mounting plate26. As hex nut38is tightened, the perimeter wall of the fluid collection container becomes sandwiched between the rear surface of mounting plate26and hex nut38. To prevent leaks around the opening in the fluid collection pan through which the connection of hex nut38to mounting plate26is made, an O-ring, washer, or other seal40is used, similar to that shown inFIG. 4. Seal40is also shown inFIG. 7against the back surface of mounting plate26, with sufficient threads48still exposed to allow the connection of hex nut38that will establish a secure connection between mounting plate26and the perimeter wall of the fluid collection pan when hex nut38is tightened.FIG. 5shows a first preferred embodiment of plug42that can be used to prevent discharge of fluid from a collection pan having an opening but no nearby drain line, and where positioning of the fluid collection pan is also not appropriate for overflow into the surrounding area. Plug42can be used to temporarily seal tailpiece50, or bonded or otherwise secured to tailpiece50to provide a permanent connection thereto.FIG. 6shows all of the components inFIGS. 1-5in assembled configuration, with encapsulated micro switch2inserted through the top opening of upper chamber32and the lever-like distal end14of float12extending through the slot46of unitary housing28. Air vents54and electrical wiring4are also shown inFIG. 6.FIG. 7shows a bottom view of the first preferred embodiment24of a drain line connection assembly with its mounting plate26having wrap-around sides52and unitary housing28having lower chamber56and end slot46.FIG. 7shows lower chamber56having an open-bottomed configuration, and no opening between it and the adjacent upper chamber32(which is not visible inFIG. 7).

FIGS. 8-13show second preferred embodiments of the encapsulated micro switch2, float body12, and unitary float/switch housing28, whileFIGS. 14-20,22-23, and33show third preferred embodiments of the encapsulated micro switch2and unitary float/switch housing28.FIGS. 21 and 23respectively show second and third preferred embodiments of drain line connection assemblies. The third preferred embodiment of unitary housing28differs from the second preferred embodiment primarily in its upper body structure (cutout area144on the front top end vs a housing28of uniform height) and the means of attachment used to secure it to a drain line connection assembly (attachment plate80vs box-style attachment member with plate-like rear surface). The second and third first preferred embodiments both can be connected to the perimeter wall of a fluid collection pan via the drain line mount90shown inFIG. 21or via the mounting plate26and bridge100shown inFIG. 23. A fourth preferred embodiment of unitary float/switch housing28is shown inFIGS. 24-27. It differs from the second and third preferred embodiments in that it combines the grooved rail plate structure92of the upright member98used for connection of the second and third preferred embodiments with the attachment plate80of the second preferred embodiment, and then adds a fastener. Thus, a different drain line connection assembly (seen inFIGS. 26 and 27) is needed for securing it to a fluid collection pan, one having an upright member with complementary grooved rail plate structure92adjacent to the front part of its T-shaped slot116, rather than on the rear interior surface of T-shaped slot116(as is shown inFIGS. 20 and 21).

FIG. 8is an enlarged view of the second preferred embodiment of encapsulated micro switch2used in the present invention to create a shut-off signal to stop fluid production when collected fluid monitored by an associated float body12indicates that threshold fluid levels considered safe have been exceeded.FIG. 8shows the second preferred embodiment of encapsulated micro switch2having a substantially rectangular configuration and a snap-in protrusion66on its upper half, above its sealing ribs62.FIG. 12shows an opposed snap-in protrusion66on the upper half of the opposed side of encapsulated micro switch2. The opposed snap-in protrusions66allow for secure positioning of the encapsulated micro switch2within the upper chamber32of the unitary housing28, and resistance against premature and/or inadvertent removal of encapsulated micro switch2from upper chamber32.FIG. 8also shows the second preferred embodiment of encapsulated micro switch2having an alignment guide64, which inFIG. 11is shown extending through an alignment slot76in the wall of the upper portion of unitary housing28. Alignment guide64is used for fast and easy installer positioning of encapsulated micro switch2within upper chamber32. For comparison purposes, one should note that the third preferred embodiment of encapsulated micro switch2(shown inFIGS. 26 and 27) has two opposed alignment guides64, for engagement with the two vertically-extending alignment slots76shown in the top edges of the third and fourth preferred embodiments of unitary housing28(shown respectively inFIGS. 23 and 24). Also, when compared to the first preferred embodiment of encapsulated micro switch2shown inFIG. 1, the length of the second preferred embodiment appears to have a greater length dimension. This added dimension is used for simpler and more cost effective construction of unitary housing28when a larger lower chamber56is needed to accommodate a larger float body12with greater buoyancy (such as that shown inFIG. 12) that can achieve an even faster fluid shut-off response than is possible with the first preferred embodiment of float switch12shown inFIG. 1. In addition, by looking at the positioning of electrical wiring4inFIG. 1, one can see that the micro switch68within the first preferred embodiment of encapsulated micro switch2substantially fills the defined perimeter therein for encapsulated micro switch2, whereas the generally rectangular perimeter of the micro switch68in the second preferred embodiment of micro switch2inFIG. 8is drawn with broken lines inFIG. 8below electrical wiring4, and one can see that the perimeter of additional encapsulation extends forwardly from the forward edge of micro switch68. As further shown inFIG. 8, the bottom portion (which may also be covered by corrosion-resistant material) of the micro switch68(to which arm6is connected) extends below the remainder of encapsulated micro switch2, visually confirming that the micro switch68within it does not occupy the entire interior portion of encapsulated micro switch2. Thus, since the forward portion of the second preferred embodiment of encapsulated micro switch2is substantially needed as filler material for secure positioning of encapsulated micro switch2within the upper chamber32of a unitary housing28configured for a larger float body12than the one identified in the first preferred embodiment of float body12disclosed herein and shown inFIG. 1,FIG. 8shows several material-saving and cost-reducing cutout areas60shown on the side of the second preferred embodiment of encapsulated micro switch2.FIG. 12shows similarly configured and positioned cutout areas60on the opposed side of encapsulated micro switch2. Some of the cutout areas60may extend through the full width of encapsulated micro switch2, however, the ones adjacent to micro switch68would not. The size, number, location, spaced-apart distances from one to the other, and perimeter configuration of cutout areas60may be different from that shown. It is only critical that cutout areas60be formed to the extent that they provide material benefit without causing any structural deficiency.FIG. 8also shows the arm6extending below encapsulated micro switch2having a non-metallic slide-on cup extension58that lengthens arm6so that the small magnet10within cup58can be appropriately positioned to interact with the larger magnet22placed near the distal end of the larger float body12shown inFIG. 12. Finally,FIG. 8shows horizontally-extending dual ribs62centrally around encapsulated micro switch2, which provide a watertight seal for the top opening of upper chamber32to prevent the entry of fluid into upper chamber32from above.

FIGS. 9-11show the second preferred embodiment of unitary float/switch housing28in the present invention that can be used with the second preferred embodiment of encapsulated micro switch shown inFIG. 8and the larger/wider float body12shown inFIG. 12. WhileFIG. 9shows the second preferred embodiment of unitary housing28empty,FIGS. 10-11show the second preferred embodiment of unitary housing28having an encapsulated micro switch2in upper chamber32and a float body12within lower chamber56(as evidenced by the tip of the lever-like distal end14of float body12extending through the downwardly widening slot72of the second preferred embodiment of unitary housing28.FIGS. 10 and 11both show distal end14in its raised deployed or test position (as identified by the number14a) and its lowered pre-deployment position (as identified by the number14b), with the double-headed arrow inFIG. 10showing the direction of distal end14movement. As shown inFIGS. 9-11, the height dimension of the taller central portion of unitary housing28is substantially uniform, and there is no front cutout area144(as seen in the third and fourth preferred embodiments of unitary housing28, as shown respectively inFIGS. 19 and 25). Further,FIG. 9shows the horizontally elongated openings74near the top edge of housing28that are configured for engagement with the opposed elongated protrusions66on the second preferred embodiment of encapsulated micro switch2(shown inFIG. 8).FIG. 9also shows the vertically-extending alignment slot76on one side of housing28at its top edge, which is configured for engagement with the alignment guide64shown on the second preferred embodiment of encapsulated micro switch2inFIG. 8.FIG. 9-11all show lower chamber56having a widened portion70that is configured to house the larger float body12shown inFIG. 12, as well as air vents54at the front and back of unitary housing28. The larger configuration of float body12places most of its buoyancy remote from its pivoting fulcrum, allowing it to deploy faster in response to small amounts of collected fluid, such as one-fourth of an inch to one-half inch. The shape, number, positioning, and size of air vents54are not critical as long as they fulfill their intended function of preventing airlock malfunction of float body12during its upward deployment to assure repeat and reliable float body12deployment in response to rising fluid. In addition,FIGS. 9 and 10show a removable float cover78that is used to briefly inspect the general surface condition of float body12from above, without moving it from its usable location. If algae or debris is found to be present upon such inspection, suitable maintenance can be done to remove it to ensure that float body12will continue to have reliable repeat upward deployment. Float cover78is preferably made from foam, and although not shown may have information markings on its upper or lower surfaces.FIGS. 9-11also show a vertically-extending attachment plate80connected to the rear portion of the widened portion70of lower chamber56in a position remote from the narrow/thin downwardly-widening slot72at the front portion of unitary housing28. Near the top of attachment plate80and on its rear surface,FIGS. 9-11show a spring tab82, which engages the grooved rail plate92configuration on a drain connection mount90or associated with another drain line connection assembly (such as but not limited to the third preferred embodiment of drain line connection assembly shown inFIG. 23). Preferably, but not limited thereto, spring tab82has a 45-degree lead, so it is able to slide up and down for adjustment in one-tenth of and inch increments.

FIGS. 12 and 13show the second preferred embodiment of encapsulated micro switch2inFIG. 8positioned over a preferred configuration of widened float body12that can be used with the second preferred embodiment of unitary housing28and its widened portion70shown inFIGS. 9-11.FIGS. 12 and 13both show encapsulated micro switch2having several cutout areas60, dual sealing ribs62, a top protrusion66, electrical wiring4extending upwardly from its top surface, a lever-like arm6in an angled and downwardly-extending position below it, a non-metallic slide-on cup extension58on arm6, and a small magnet10positioned within cup extension58. Below encapsulated micro switch2FIGS. 12 and 13both show a widened float body12with a lever-like distal end14and an opposed proximal end16configured to provide the needed pivoting connection for upward shut-off deployment of float body12in response to rising fluid levels and downward reset of float body12into a lowered position after deployment for subsequent deployment. WhileFIG. 12shows the larger magnet22in broken lines within float body12, hidden by top surface84,FIG. 13shows float body12with its top surface84removed and the larger permanent magnet22in solids lines and positioned within a retaining mount146to maintain it in a fixed position during pivoting movement of float body12. Whether top surface85is temporarily or permanently attached to the remainder of float body12is not critical.

FIG. 14shows a third preferred embodiment of a unitary housing28in the present invention having a box-style attachment member136with plate-like rear surface having a spring tab82. Additionally,FIG. 14shows the top of the plate-like rear surface having an enlarged upper piece140configured for quick manual release of spring tab82from the grooved rail plate surface on the rear wall of the upright member98used for connection of unitary housing28to a drain connection mount90or drain line connection assembly having a mounting plate26. Like the second preferred embodiment of unitary housing28, the third embodiment has a widened portion70of lower chamber56. Another difference between the third and second preferred embodiments of unitary housing28is that the third preferred embodiment has a front cutout area144that is not identified inFIG. 14by number since it is not clearly shown, but is clearly shown and marked by the number144inFIG. 19.FIG. 14also shows the third preferred embodiment of the unitary housing28having opposed alignment slots76(identified by the number76inFIGS. 16 and 17), a float cover78that may be removable from widened portion70for float body12inspection, and an external pivoting structure with a locking hole134that can be used with common fastening/locking means (not shown) and the locking configuration disclosed for locking pin34inFIG. 32, to retain pivot pin34in a fixed location during its use for reliable and repeat vertical deployment of float body12. Lastly,FIG. 14shows the slide-on cup58in its preferred position if use within the upper chamber32of unitary housing28. Preferably, slide on cup58is made from non-magnetic materials.

FIGS. 15-21show the third preferred embodiment of unitary housing28(seen inFIG. 14) in association with drain connection mount90, which is shown in most detail inFIG. 21. As shown in the various views disclosed inFIGS. 15-21, drain connection mount90has an upright member98with a grooved rail plate92used for engagement of the spring tab82on the back of the plate-like rear surface of the box-style attachment member136connected to unitary housing28.FIG. 15also shows drain connection mount90having a D-shaped ring member depending from one side of upright member98. As identified inFIG. 22, upright member98has a T-shaped slot116configured for insertion of an attachment plate80or the plate-like rear surface and spring tab82of the box-style attachment member136.FIG. 15shows the enlarged upper piece140used to release the spring tab82on the back side of the plate-like rear surface of box-style attachment member136from its engagement with the grooved rail plate92on the back wall of upright member98. In addition,FIG. 15shows the third preferred embodiment of unitary housing28attached to the upright perimeter wall86of a fluid-collecting pan94, whileFIGS. 16-20show views of the third preferred embodiment of unitary housing28and an attached drain connection mount90from differing angles.FIG. 15also shows unitary housing connected to drain connection mount90, and drain connection mount90attached with two hex nuts38to perimeter wall86. A first hex nut38is shown positioned within pan94, with a second hex nut38being shown positioned against the hidden outside surface of pan94.FIG. 15further shows a tailpiece50aligned with a discharge opening30through perimeter wall86and connected to the hidden outside surface of wall86by the second hex nut38, whereby excess fluid collected in pan94can travel through discharge opening30and exit pan94via tailpiece50extending rearwardly from pan94. Another feature of the third preferred embodiment of unitary housing28shown inFIG. 15is the slide adjust plate88attached to the front end of unitary housing28for use in rapid and easy post-installation testing of float body12to confirm its proper deployment for long term reliable use.FIG. 15also shows the distal end114of the magnet cover118(shown inFIG. 22) extending through the vertically-extending closed slot142centrally through slide adjust plate88. Although not shown, it is contemplated and preferred for closed slot142to be aligned with a downwardly widening slot through the front portion of unitary housing28, similar to the downwardly widening slot72shown inFIG. 24for the fourth preferred embodiment of unitary housing28.

FIGS. 16-21reveal in greater detail the structure and relation to one another of various features in the third preferred embodiment of unitary housing28. The side views ofFIGS. 16 and 17show an encapsulated micro switch2housed within the upper chamber of unitary housing28and the connection of drain connection mount90(collectively upright member98and D-shaped ring member96) between unitary housing28and tailpiece50, which could be temporarily or permanently plugged (perhaps with the plug42shown inFIG. 5), or connected to a drains line (not shown). The front top portions of encapsulated micro switch2and unitary housing28are also respectively shown inFIGS. 16 and 17to have similarly configured material-saving cutout areas112and144(the area designated with the number144is shown inFIGS. 19 and 25).FIGS. 16 and 17further show unitary housing28having a lower chamber with a widened portion70configured to accommodate the shape of a widened float body12, the horizontally-elongated snap-in protrusion66on the upper portion of the encapsulated micro switch2exposed through unitary housing28, the alignment guide64on one side of encapsulated micro switch2positioned within the vertically-extending alignment slot76on the upper edge of unitary housing28, electrical wiring extending upwardly from the top of encapsulated micro switch2, the slide adjust plate88secured against the front portion of unitary housing28. In addition,FIGS. 16 and 17show the box-style attachment member136depending from the rear portion of unitary housing28and the enlarged upper piece140of attachment member136configured for quick manual release of the plate-like rear surface of box-style attachment member136from upright member98. When the enlarged upper piece140is manually engaged to release the spring tab82(shown inFIG. 14) from the grooved rail plate structure92(shown inFIG. 20), unitary housing can be manually lifted in an upward direction to slide the plate-like rear surface of box-style attachment member136from the T-shaped slot116of upright member98.FIGS. 16 and 17further show two hex nuts38and a seal40connecting the D-ring shaped member96(one part of drain connection mount90) to tailpiece50. Seal40is positioned between D-ring shaped member96and tailpiece50. For the convenience of an installer, the present invention could be assembled as shown inFIGS. 16 and 17with encapsulated micro switch2positioned within the upper chamber32of unitary housing28, float switch12within the lower chamber56of unitary housing29and the distal end114of its magnet cover118exposed through the front portion of unitary housing28in a pre-deployment position, the plate-like rear surface of box-style attachment member136secured within the T-shaped slot116of upright member98(one part of drain connection mount90), and the D-ring shaped96of drain connection mount90attached to a tailpiece50via two hex nuts38(capable of being tightened manually without tools) and seal40. Then, upon arrival at a worksite with a fluid connection pan having a drain hole and a need for fluid level monitoring, the installer would merely remove seal40and the adjacent hex nut38from behind D-ring shaped member96, insert tailpiece50through the drain hole in the pan so that the rear surface of the D-ring shaped member96is positioned against the inside surface of the fluid collection pan's upright perimeter wall. Thereafter, the installer would simply have to position seal40over tailpiece50and move it against the outside surface of the fluid collection pan's upright perimeter wall, after which the installer would place hex nut38over tailpiece50and manually tighten its threaded engagement to securely fix unitary housing28in place for long term support by the fluid collection pan's upright perimeter wall. When the installer places the bottom surfaces of D-ring shaped member96and upright member98against the bottom of the fluid collection pan (or at least parallel to it), the float body12within unitary housing28is automatically leveled when the pan itself is leveled. Thus, a time-saving benefit for the installer is derived. The only adjustment of unitary housing28that an installer might need to make to finalize installation is to raise unitary housing28so as to set a different threshold fluid collection depth before float body12deploys and a shut-off signal is sent by encapsulated micro switch2to stop fluid production. Therefore, instead of having to tediously adjust the height of float body12and perhaps remove it from its housing to do so, as was commonly done in the prior art, and installer using the third preferred embodiment of unitary housing28and drain connection mount90can easily adjust the height of float body12by a simple raising of unitary housing28through manual engagement of the enlarged upper piece140to release the spring tab82connected to it from the grooved rail plate structure92on upright member98. Once spring tab82is so released, the installer can raise (or possibly lower) the plate-like rear surface of box-style attachment member136relative to upright member98by manually sliding it up or down within the T-shaped slot116of upright member98. When the desired height for unitary housing28and the float body12positioned within its lower chamber56is reached, the installer simply releases the enlarged upper piece140to cause spring tab82to again become engaged with the grooved rail plate structure92on upright member98. If the newly selected height of float body12is still not optimum in the application, the steps of manually engaging enlarged upper piece140and sliding the plate-like rear surface of box-style attachment member136up or down relative to upright member98can be quickly and easily repeated. Although partially obscured and unmarked inFIG. 16,FIG. 17also shows the pivot pin34through the widened portion70of unitary housing28that is used to allow the pivoting movement of float body12within widened portion70.

FIG. 18shows an encapsulated micro switch2positioned within the upper chamber32of the third preferred embodiment of unitary housing28in the present invention and the electrical wiring4of encapsulate micro switch extending upwardly from its top surface for connection to a fluid-producing system or unit (not shown). Unitary housing28and its widened portion70are positioned in front of upright housing98and the D-ring shaped member96depending from it toward the right (which together form drain connection mount90).FIG. 18also shows a hex nut38positioned in front of D-ring shaped member96. The opening30shown through hex nut38provides fluid communication to a tailpiece50(and perhaps also to a drain line connected to tailpiece50) that directs from the pan to which the present invention is connected any excess fluid that poses a risk of damage to surroundings. In addition,FIG. 18shows slide adjust plate88positioned against the front of unitary housing28and the distal end114of the magnet cover118on float body12exposed through the front portion of unitary housing28in a pre-deployment position.

FIG. 19shows a bottom view of the third preferred embodiment of unitary housing28and float body12substantially filling the widened portion70of lower chamber56. Float body12is held in pivotal connection to unitary housing28via pivot pin34. InFIG. 19, an encapsulated micro switch2is also associated with the upper chamber32of unitary housing28. One of the opposed snap-in protrusions66on encapsulated micro switch2is exposed through a horizontally-extending slot (identified by the number74inFIG. 23) in the upper portion of unitary housing28, withFIG. 19also showing the material-saving cutout area144on the front portion of unitary housing28.FIG. 19further shows the slide adjust plate88attached to the front portion of unitary housing28and its rear portion fixedly secured to the upright portion98of drain connection mount90. The D-ring shaped member96of drain connection mount90depending from upright member98is shown inFIG. 19connected by two hex nuts38and a seal40to tailpiece50. The discharge opening30through tailpiece50permits excess fluid in the pan with which the present invention is associated to exit the pan and be prevented from causing damage to surroundings.

FIG. 20is an exploded view of all components shown inFIGS. 15-19except the unitary housing28and small magnet10, and shows relative component positioning one to the other during use. Encapsulated micro switch2is shown with one of its opposed horizontally-extending snap-in protrusions66, several material-saving cutout areas60, alignment guide64, attached electrical wiring4, and the unmarked top front material-saving cutout area (identified inFIG. 33by the number112). Encapsulated micro switch2is positioned above float body12so that its slide-on non-metallic cup58(holding a hidden small magnet10) is positioned above the larger magnet22in float body12, which is shown in broken lines under the magnet cover118.FIG. 20also shows slide adjust plate88in front of encapsulated micro switch2and float body12, with the distal end (test latch)114of magnet cover118extending through the vertically-extending closed slot142centrally through slide adjust88.FIG. 20also shows slide adjust plate88having two upper non-slip members130configured for manual vertical adjustment of slide adjust plate88during its installation on the front portion of unitary housing28wherein the laterally-positioned and horizontally-extending elongated bars148shown on the front of slide adjust plate88become inserted in the front channel122(shown inFIG. 24) defined by the elongated laterally-positioned guide rails128(shown inFIGS. 24 and 25).FIGS. 24 and 25show the fourth preferred embodiment of unitary housing28having the channel122defined by guider rails128, alignment/adjustment protrusions126, and downwardly widening slot72that becomes aligned with the vertically-extending closed slot142centrally through slide adjust88. Although not otherwise visible in the accompanying drawings, it is contemplated for the portion of third preferred embodiment of unitary housing28behind slide adjust plate88to be configured similarly to that shown inFIG. 24for the fourth preferred embodiment of unitary housing28.FIG. 20also shows the rear portion of float body12to have a proximal end16configured to provide pivoting connection of float body12for vertical deployment in response to riding fluid beyond a threshold level considered safe. The pivot pin34used to pivotally connect the proximal end16of float body12to unitary housing28is also shown inFIG. 20. In addition,FIG. 20shows the drain connection mount90(with its upright member98and its D-ring shaped member96) connected to a tailpiece50via two hex nuts38and a seal40. The grooved rail plate92on the rear wall of the T-shaped slot in upright member98is also identified inFIG. 20. As previously stated, the configurations and relative dimensions of most of the components inFIG. 20can be different from that shown, since a multitude of equivalent constructions are possible for the present invention insofar as they do not depart from its spirit and scope.

FIG. 21shows an enlarged view of the drain connection mount90that is a part of the second preferred embodiment of drain connection mounting assembly shown inFIG. 15. A D-ring shaped member96having an opening30configured for fluid communication with a drain line and laterally depending from an upright member98. The upright member98has a T-shaped slot116and a grooved rail plate92on the back inside surface of slot116, which allows variable vertical adjustment of the float body12according to application need via engagement of the spring tab82on the unitary housing28. While in the accompanying illustrations drain connection mount90is shown used with the second and third preferred embodiments of unitary housing28, use is also contemplated with other preferred embodiments of the present invention as long as the other preferred embodiments have a plate (such as the attachment plate80in FIG.11orFIG. 24) and some structure to engage grooved rail plate92(such as the spring tab82inFIG. 11). Although drain connection mount90can be made from differing types of materials, it should be made corrosion-resistant and rigid so that the orientation of float body12does not change over time and prevent it from proper deployment. Also, the size of the opening30in D-ring shaped member96will vary according to the application, and may be different from that shown. Further, the size of number of grooved rail plate92, the number of grooves in rail plate92, and the configuration of grooves in rail plate92may be different from that shown.

FIG. 22shows a third preferred embodiment of float body12, which is shown in use with the third preferred embodiment of unitary housing28inFIGS. 15-18. When the magnet cover118is removed from float body12, a hollow area20is revealed within float body12sized and configured for holding larger magnet22in a desired position of use. A similar hollow area20was shown inFIG. 1with the first preferred embodiment of unitary housing28. Hollow area20is in contrast to the retaining mount146within the second preferred embodiment of float body12shown inFIG. 13, which is configured for placing larger magnet22in a fixed position within float body12during a deployment response to rising fluid. Magnet cover118fits over the distal end14of float body12, has a distal end of its own (also referred to as test latch)114that is shown inFIG. 20extending through slide adjust plate88. As with the materials used with float body12, the materials used for magnet cover118should be corrosion-resistant and lightweight. Magnet cover118can also be configured to slide or be snap-fit into place on float body12, or be permanent fixed against float body12during manufacture. Further, the materials from which test latch114is made should be rigid for easy finger manipulation to confirm proper height adjustment and deployment of float body12.FIG. 22also shows a preferred configuration of the proximal end of float body12used to accomplish its pivoting movement, however the configuration is not critical and can be replaced by other structure fulfilling the same function.

FIG. 23is a rear view of the third preferred embodiment of present invention unitary float/switch housing28detachably secured to a third preferred embodiment of drain connection mounting assembly via engagement of upright member98to box-style attachment member136. The enlarged upper piece140of box-style attachment member136is also shown inFIG. 23, which is configured for quick release of the spring tab82associated with box-style attachment member136from the grooved rail plate92within the T-shaped slot116of upright member98. Although no encapsulated micro switch2is shown in the upper chamber32of unitary housing28inFIG. 23, it shows the pair of opposed, elongated, and substantially horizontally-extending openings74in unitary housing28, as well as the opposed vertically-extending alignment slots76in the upper edge of unitary housing28, which are used to facilitate placement of encapsulated micro switch2within upper chamber32and long term retention of encapsulated micro switch2in its desired position of use.FIG. 23also shows the lower chamber56of unitary housing28having a widened portion70, the pivot pin34extending through unitary housing28that allows for pivoting deployment of float body12in response to rising fluid (not shown), and the slide adjust plate88secured to the front portion of unitary housing28in a position remote from pivot pin34. Only one of the non-slip members130on slide adjust plate88is visible, although as shown inFIG. 20it is preferred for slide adjust plate88to have two non-slip members130.FIG. 23also shows a bridge100connecting upright member98to a mounting plate26with wrap-around sides52that is configured for rapid and easy positioning over a generally trapezoidal shelf (not shown herein) molded into the upright perimeter wall of a plastic fluid-collecting pan. When an installer slides mounting plate26downwardly over such a shelf molded into an upright fluid collection pan wall, the float body12positioning within the associated unitary housing28becomes leveled relative to the pan, so that when the pan is leveled proper and reliable deployment of float body12can be repeatedly expected. To prevent any inadvertent or other premature release of mounting plate26from a complementarily configured shelf in pan wall, and also for connection of a tailpiece50to the fluid discharge opening (shown by the number30inFIG. 2) in mounting plate26(the supporting pan wall also has an opening30through it, but typically without a dam36),FIG. 23shows a hex nut38tightened against the rear surface of mounting plate26.FIG. 23further reveals a seal40between hex nut38and mounting plate26to prevent unwanted fluid leakage from opening30. Although connection of tailpiece50to a drain line is an option,FIG. 23shows a plug42blocking the distal end of tailpiece50.

FIGS. 24 and 25show a fourth preferred embodiment of present invention unitary float/switch housing28having an attachment plate80with an integrated rail plate92and a hex indentation120configured insertion of a threaded fastener108(such as that inFIG. 31). As shown inFIG. 28, it is contemplated for integrated rail plate92to engage a grooved rail plate92on the front interior surface of at least one side of T-shaped slot of an upright member98. This is in contrast to the engagement of a spring tab82on a non-grooved attachment plate80(as inFIG. 11) with the grooved rail plate92on the rear interior surface of the T-shaped slot116of an upright member98(as shown inFIG. 21). Although no encapsulated micro switch2is shown in the upper chamber32of unitary housing28,FIGS. 24 and 25show the fourth preferred embodiment of unitary housing28having a pair of opposed, elongated, and substantially horizontally-extending openings74in unitary housing28, as well as the opposed vertically-extending alignment slots76in the upper edge of unitary housing28, which are used to facilitate placement of encapsulated micro switch2within upper chamber32and long term retention of encapsulated micro switch2in its desired position of use.FIGS. 24 and 25also show the widened portion70of lower chamber56, the cut-away area144on the top front portion of housing28that is similar in configuration to the material-saving cutout area112on the top front portion of encapsulated micro switch2(shown inFIG. 33), and several alignment protrusions126on the front portion of unitary housing28that in combination with guide rails128assist an installer in fast and accurate placement of a slide adjust plate88relative to downwardly widening slot72that assists in the drainage of widened portion70when fluid levels in an associated collection pan subside. The three vertically-stacked and round alignment protrusions126seen inFIG. 24can also be used to adjust the height of a slide adjust plate88relative to unitary housing2within the front channel122defined by guide rails128. In addition,FIG. 25shows the fourth preferred embodiment of unitary housing28having a material-saving cutout124in the top surface of the lower chamber56which does not provide fluid communicate between lower chamber56and upper chamber32.

FIGS. 26 and 27show the attachment of the fourth preferred embodiment of unitary housing28and its associated components to a fourth preferred embodiment of drain line connection assembly having an upright member98with a front inside grooved rail plate (marked by the number92inFIG. 28) that is connected via bridge100to a mounting plate26. While the configuration of bridge100shown inFIGS. 26 and 27is preferred, variations can occur without diminishing its strength or departing from the spirit and scope of the present invention. WhileFIG. 26shows a front view of unitary housing28in its relation to upright member98, bridge100and mounting plate26,FIG. 27shows a rear view of the same without unitary housing28so to reveal the relation of encapsulated micro switch2, float body12, large magnet22, small magnet10, rotatable quick-release member102, and slide adjust plate88to upright member98. EitherFIG. 26,FIG. 27, or both, show encapsulated micro switch2having electrical wiring4configured for connection to a fluid producing unit, material saving cutout areas60, an elongated protrusion66configured for snap-fit engagement with one of the substantially horizontally-extending elongated openings in the upper portion of unitary housing28(shown inFIGS. 24 and 25) for secure positioning of encapsulated micro switch2within upper chamber32, as well as an alignment guide64configured for insertion into one of the substantially vertically-extending slots76in the upper edge of unitary housing28(also shown inFIGS. 24 and 25) during the installation of encapsulated micro switch2into upper chamber32. Without unitary housing28otherwise obscuring the view,FIG. 27shows non-magnetic lever-like external arm6extending downwardly at an angle from encapsulated micro switch2and having a slide-on non-metallic cup58that holds small magnet10above the larger magnet22under magnet cover118in float housing12.FIGS. 26 and 27both show the distal end (or test latch)114of magnet cover118extending through slide adjust plate88and the non-slip members130used for easy installation of slide adjust plate88against the from portion of unitary housing28, as well as prompt manual vertical adjustment of slide adjust plate88if needed in an application.FIG. 26shows the widened portion70of unitary housing28used to protect float body12during it use to activate signal generation by encapsulated micro switch2, andFIGS. 26 and 27both show preferred positioning of the pivot pin34that allow float body12to vertically deploy and be repeatedly reset for future upward deployment in response to rising fluid. In addition,FIG. 27shows the preferred proximal end16configuration of float body12that permits pivoting engagement with pivot pin34. further with a rotatable quick-release release member and fastener together tightening the grip between the attachment plate and upright member to firmly fix the unitary housing to the mounting plate. At the proximal end of unitary housing28, in a position opposed to slide adjust plate88,FIG. 26shows unitary housing28having an attachment plate80, and attachment plate80secured within an upright member98via a rotatable quick-release member102and a threaded fastener108. To release attachment plate80from a securely fixed positioning within upright member98to adjust the threshold amount of fluid in a collection pan that will cause the upward deployment of float body12and activation of encapsulated micro switch2to send a shut-off signal, an installer or maintenance worker needs only to hand rotate quick-release member102to loosen it, raise or lower attachment plate80relative to upright member98, and then hand tighten quick-release member102. WhileFIGS. 26 and 27show a tailpiece50behind mounting plate26and a plug42secured within the end of tailpiece50, onlyFIG. 27shows the nut110and seal40positioned between tailpiece50and mounting plate26. Nut110is an alternative to the hex nut38shown inFIG. 6, which is also used to secure a mounting plate26to the upright perimeter wall of a fluid collection pan.

FIG. 28is a perspective view of the fourth preferred embodiment of drain line connection assembly having an upright member98with a front inside grooved rail plate92within its T-shaped slot116, a bridge100, and a mounting plate26without a dam16over the lower part of its fluid discharge opening30. Although not visible in this view, it is preferred for a front inside grooved rail plate92to also be positioned laterally on the other side of T-shaped slot116.FIG. 28shows the upwardly tapering wrap-around sides52on mounting plate26that allow it to securely engage a generally trapezoidal-shaped shelf (not shown) molded into the perimeter wall of a fluid collection pan for quick placement of float body12and encapsulated micro switch2in their desired positions during fluid level monitoring use. Although the configuration of the mounting plate26shown inFIG. 28is preferred, other embodiments of mounting plate26can also be used, such as ones having material-saving construction, enhanced strength, or a lack of the chamfered edge (shown but unnumbered inFIG. 28) on the upper front portion of wrap-around sides52. The upwardly tapering wrap-around sides52on mounting plate26allow it to slide easily downward over a shelf having complementary trapezoidal configuration, with gravity providing a constant force that pulls mounting plate26more tightly in place over the mated shelf during long term use rather than providing a force that could lead to its eventual unseating from the shelf where by the proper deployment of the float body12could be disrupted. The length of bridge100may vary, and would depend on the intended application.FIG. 28further shows threads48behind mounting plate26that would be used with a female threaded nut (such as hex nut38or the nut110with ridged exterior shown inFIG. 30) to fix mounting plate26securely in place against the upright perimeter wall of a fluid collection pan. In addition,FIG. 28shows a tailpiece50extending rearwardly beyond threads48, which may be detachable from mounting plate26or permanently secured to it. Lastly,FIG. 28shows a stop138centrally against the bottom interior rear wall of upright member98within T-shaped slot116, which is used for proper alignment of attachment plate80(or a similar device) within upright member98to proper level and otherwise position float body12for deployment when a threshold fluid level considered safe is reached so that damage to surroundings is avoided.

The components of the present invention shown inFIGS. 29-33have been explained in the discussions hereinabove for other illustrations.FIG. 29is a perspective view of the threaded rotatable quick-release member102that in combination with the fastener108shown inFIG. 31securely fixes the attachment plate80of the fourth preferred embodiment of unitary housing28within upright member98to position unitary housing28in fixed relation to the perimeter wall of a fluid collection pan. The knurled exterior104of quick-release member102makes its manual rotation by an installer easier and non-slip.FIG. 29also shows female threads configured for engagement with those on the fastener108shown inFIG. 31and the open center106of quick-release member102. During the use of fastener108to fix quick-release member102against the front of upright member98, the hex-shaped head of fastener108is housed within the hex indentation120shown on attachment plate80inFIG. 24. By insetting the hex-shaped head of fastener108within hex indentation120, the hex-shaped head of fastener108does not interfere with the insertion or removal of attachment plate80from the T-shaped slot116of upright member98. Further,FIG. 30shows an alternative configuration of nut110used in the fourth preferred embodiment of the drain line connection assembly to fix mounting plate26securely against the perimeter wall of a fluid collection pan. Previously, the hex nut38inFIG. 3was shown in use for the same purpose. In addition,FIG. 32shows the locking hinge pin34preferred in many embodiments of the present invention for pivoting movement of the float body12during its vertical deployment, whileFIG. 33shows the third preferred embodiment of encapsulated micro switch2having a material-saving cutout area112on its top surface, electrical wiring4rearward from cutout area112, dual horizontally-extending sealing ribs62configured for preventing fluid from entering upper chamber32, a hidden micro switch68positioned below electrical wiring4, non-magnetic lever-like external arm6extending downwardly from micro switch68, and a small magnet10secured within a preferably non-magnetic cup8to arm6. InFIGS. 17 and 28, the third preferred embodiment of encapsulated micro switch2is shown in use with the type of unitary housing28having a material-saving cutout area144in its front/top portion, immediately behind and above an attached slide adjust plate88.