Abstract:
A float switch assembly and maintenance port accessory each made from plastic and impervious to corrosion that are connected in-line to a fluid discharge line, but which are also adaptable to auxiliary applications. Improvements over the prior art include a more responsive operation resulting from use of a wide float switch body and a closely fitting inner wall within the float housing that allow for rapid shut-off of the condensate producing system after collection of only a very small amount of fluid, a simple design, the ability to handle a large fluid flow, a small float housing dimension for easy installation, protection of its float switch body from routine fluid flow, a removable bottom cap for rapid maintenance and inspection of its float switch body, a fluid deflecting member and/or design that resists upstream movement of fluids, and an air-lock preventing configuration that permits operation without air vent holes.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS  
       [0001]     None  
       BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     This invention relates to liquid-level float switches for in-line and auxiliary use, specifically to a system having a float switch assembly of sturdy construction that is primarily contemplated for in-line use with a condensate discharge line in condensate collection applications, but which is also useful in auxiliary and other applications, to send a shut-off signal to the fluid-producing system connected to the discharge line into which the float switch assembly is installed, so as to terminate the introduction of new fluid into the discharge line at the first sign of discharge line blockage (by algae, rust, mold, debris, etc.), and thereby prevent damage to the fluid-producing system as a result of fluid back-up and/or overflow. The present invention has a tubular member and a float housing that is either centered under, or off-set to one side, which is positioned relative to the tubular member so that the bottom of float switch body prior to deployment is lower than the bottom of the tubular member. Further, the housing of the present invention is configured to separate the float switch body from the fluid routinely flowing through the tubular member so as to maintain a high level of reliability of response when a blockage occurs. It is of simple design and can handle a large volume of fluid flow before its float switch body is affected. Both commercial and residential applications are contemplated. The present invention also includes a maintenance port accessory that can be connected into the same fluid discharge line with the float switch assembly. The maintenance port accessory can be mounted in vertically-extending or horizontally-extending orientations, upstream or downstream from the float switch assembly, as the application requires, and it has an internal structure that facilitates the flow of all fluids traveling through it away from the fluid-producing system to which it is connected. It also discourages cleaning agents from moving upstream and into the fluid-producing system. For the internal structure to be effective in directing fluid flow, its larger/wider end is positioned downstream during horizontal orientation, with a reverse positioning being required for vertical orientation. For lowered manufacturing cost, as well as ease in adding cleaning agents to the condensate discharge line to which it is connected, it is preferred that the same type of large cap used to seal the open bottom end of the float housing is also used to seal the threaded connections on the maintenance port accessory. For air conditioning condensate collection, the most preferred embodiment of the present invention is typically small in dimension and when one end of its tubular member is capped off or otherwise blocked or plugged, it is easily converted to auxiliary use as a redundant overflow prevention system, which is often required by local code in air conditioning applications. Thus it is possible for two present invention float switch assemblies to be used with an air conditioning system (as shown in  FIG. 21 ), one installed in-line into the main fluid discharge line, and the other capped on one end and used in an auxiliary/back-up capacity. The present invention float switch assembly has an adjustable float switch body centrally positioned within the float housing with a large surface area for enhanced buoyancy and improved responsiveness that is guided in its vertical movement within the float housing by a vertically-extending shaft connected to either the upper portion of the float housing or the top of the tubular member. The present invention float housing also has an open bottom end that is sealed with an easily removable cap that gives prompt inspection/maintenance access to the float switch body and shaft, an opportunity for an operator to check for the presence of debris/mold/rust/algae in the connected fluid discharge line. The space between an inner wall in the float housing, or male threaded cap, and the float switch body creates a very small volume, so that even a very small amount of fluid therein, such as but not limited to 7.5 ml or 1.5 teaspoons, can cause the float switch body to rise and shut off the source of fluid production.  
         [0004]     2. Description of the Related Art  
         [0005]     When air conditioning condensate and other condensates are collected, there is often a risk of overflow and/or back-up into the system producing it. As a result, liquid-level float switches have been employed in-line and in an auxiliary capacity to shut-off the source of condensate flow when the amount of fluid surrounding it exceeds a predetermined depth. In air conditioning applications, an auxiliary line provides a redundant/back-up source of overflow prevention, which can be branched off from the main condensate collection line or be formed as a separate line connected to the condensing unit, depending upon local code. However, currently known float switches are deficient in many ways and thereby subject to malfunction, less responsive operation, more costly installation, and/or unstable installation. Many prior art float switches tend to be at risk for malfunction since they are in constant contact with the water in the condensate line, and subject to clogging with rust, algae, mold, and other debris during prolonged periods of use. Also, prior art liquid-level float switches tend to have float switch bodies that wobble relative to the shaft with which they are associated, a condition that can lead to less responsive operation or malfunction. In addition, some float switches are at risk for premature malfunction as a result of being made from materials that are not completely corrosion-resistant. In contrast, the present invention is made from plastic that is impervious to corrosion. Its float switch body is wider than those of known prior art float switches for greater water displacement, however, its float housing has a small width dimension so that it can be easily installed in the tight spaces allowed in residential applications for the connection of air conditioner condensate discharge lines. The present invention float housing and float switch body can have complementary cylindrical configurations, or any other configuration that accomplishes the intended purpose, such as but not limited to cross-sectional configurations that are rectangular, hexagonal, and elliptical. In addition, the close positioning of float switch body within the float housing, as well as the positioning of the bottom of the float housing lower than the fluid discharge line to which it is connected, allows less fluid accumulation before the present invention will activate an electrical shut-off signal, for a faster response time than prior art devices. Through use of bonding agents, and/or in combination with one or more optional connectors and/or caps, the float housing can be applied for in-line use, or be installed in auxiliary applications. Since the present invention is small and has a simple design, it is also cost effective to use. Within the next few years, higher rated air conditioning units will be required by law for fuel efficiency. The larger coils provided used will create more condensate. Further, since condensate continues to drip for ten to fifteen minutes after an air conditioning unit has been shut off, it is very important for in-line and auxiliary switches to be responsive to very small amounts of water and be subject to minimal risk of malfunction. The present invention is configured to be responsive to and meet the needs of the higher rated systems, as well as present air conditioning systems. No condensate switch is known with all of the features and advantages of the present invention.  
       BRIEF SUMMARY OF THE INVENTION—OBJECTIVES AND ADVANTAGES  
       [0006]     The primary object of the present invention is to provide a multi-purpose float switch for in-line and auxiliary use to electrically shut-off the source of condensate flow when a blockage occurs in the main condensate discharge line transporting the condensate away from the system generating it. A further object of this invention is to provide a float switch with a compact housing designed for prompt and cost effective installation in the close-fitting areas used to accommodate residential air conditioning air handlers. It is a further object of the present invention to provide a float switch that is sturdy in construction and design for responsive and reliable operation. It is also an objective of the present invention to provide a float switch that is simple in design and can handle a large amount of fluid before its float switch body is affected. A further object of the present invention to provide a float switch that is readily capable of being installed in a level orientation for proper float switch operation. Another object of the present invention is to provide a float switch that will deploy to shut-off the associated fluid-producing system upon the collection of a very small amount of fluid. It is an object of the present invention to provide a float switch that is protected against air-lock without the use of vent openings. A further object of this invention is to provide a float switch that is protected against malfunction when debris is present in the condensate line. In addition, it is a further object of the present invention to provide a float switch that is made from corrosion-resistant materials that resist premature deterioration and malfunction. It is also an object of the present invention to provide a float switch that has cost-effective construction for widespread distribution and use.  
         [0007]     As described herein, properly manufactured and installed, the present invention would provide a float switch assembly of sturdy construction that is primarily contemplated for use in in-line condensate collection applications, but which is also useful in auxiliary and other applications, to terminate the introduction of new fluid into the fluid discharge line to which it is connected at the first sign of a blockage so as to prevent damage from fluid back-up and/or overflow. During in-line installation, the float switch body of the present invention that is used to activate a signal to promptly shut off the fluid-producing system, deploys and upwardly rises when only a small amount of fluid starts to collect in the main discharge line as a result of a full or partial blockage of the main discharge line due to build up of algae, rust, mold, and/or other debris. Similarly, when one end of the present invention tubular member is capped and installed in an auxiliary capacity, it will be positioned to maintain fluid communication with the main discharge line, and when a blockage occurs in the main discharge line causing fluid to be suddenly directed toward the auxiliary float switch body, it will also deploy to activate a shut-off signal in response to only a very small amount of fluid accumulation. For air conditioning condensate collection, the most preferred embodiment of the present invention is typically small and, although not limited thereto, preferred dimensions include a maximum height dimension of approximately two inches, a maximum width dimension less than approximately three inches, and a maximum length dimension of approximately four to six inches. An adjustable float switch body is positioned for its vertical movement within a float housing that is under or adjacent to, and downwardly depends from, a horizontally-extending tubular member so that the bottom end of the float housing is in a position lower than the tubular member. A float switch body is guided for vertical movement by a concentrically positioned shaft secured through the top of the float housing or tubular member, with the amount of float switch body displacement being adjustably defined by an upper lock-nut and a disk-shaped bottom stop that are both connected to the shaft, and which make the float switch body readily adaptable to a wide variety of applications and changing needs. The threaded cap attached to the bottom open end of the float housing gives easy inspection/maintenance access to the float switch body and an opportunity for an operator to check for debris/rust/mold/algae in the connected condensate line. The float switch body has a large surface area for enhanced buoyancy and improved responsiveness during operation, with the float housing having an inner wall closely positioned around the float switch body to separate the float switch body from the main water flow during normal operation and provide an area between the wall and the float switch body of very small volume, so that even a very small amount of fluid can cause the float switch body to rise and shut off the source of fluid production. Although a circular cross-section is one possible configuration for the float switch body and its surrounding float housing, other configurations are also contemplated, such as but not limited to octagonal and a configuration whereby the center portion of the float switch body has a greater height dimension than its circumferential portion. The cap closing the open bottom end of the float housing is preferably threaded and securely sealed with an o-ring to provide a leak-resistant connection. Internally and externally threaded caps are contemplated as a part of the present invention. Further, the large dimension of the tubular member and wider end of the maintenance port accessory permit operation without air vent openings being required to prevent an airlock malfunction. Electrical wires extending through the top of the shaft provide the electrical connection needed with an associated fluid-producing system, so that collection of a very small amount of water (such as but not limited to  7 . 5  ml or  1 . 5  teaspoons) as a result of a blockage in a main fluid discharge line is able to deploy the float switch body and promptly cause a signal to be sent to the fluid-producing system to interrupt its operation. The present invention is typically made from plastic, and thereby impervious to corrosion, which in combination with its sturdy construction avoids premature deterioration.  
         [0008]     Although the description herein provides preferred embodiments of the present invention, it should not be construed as limiting its scope. For example, variations in the height and diameter of the float housing, float switch body, and shaft used; the number of threads used on the upper portion of the shaft for housing connection; the perimeter configuration and dimension of the lock-nut used to tighten the shaft to the housing; the configuration of the connector attached distally to the threaded wider end of the maintenance port accessory; and the number and spacing of protrusions on the outside surface of the bottom cap used to facilitate hand manipulation during installation and removal; in addition to those variations 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. 
     
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS  
       [0009]      FIG. 1  is a front view of a first preferred embodiment of the present invention for use with a fluid discharge line, and which has a float housing adjacent to and depending downwardly from a horizontally-extending tubular member whereby the bottom end of the float housing is positioned lower than the tubular member, a threaded cap attached to the otherwise open bottom end of the float housing, a vertically-oriented shaft centrally within the float housing and having an upper threaded portion that is secured centrally to the top of the float housing by a lock-nut so that the shaft can be used as a guide for vertical movement of a float switch body also positioned centrally within the float housing, but which is hidden from view in this illustration.  
         [0010]      FIG. 2  is a top view of the first preferred embodiment of the present invention.  
         [0011]      FIG. 3  is an end view of the first preferred embodiment of the present invention with a fluid deflecting surface positioned within the tubular member adjacent to the float housing.  
         [0012]      FIG. 4  is a sectional end view of float housing, threaded cap, and the tubular member in the most preferred embodiment of the present invention with the shaft and float switch body positioned centrally within the float housing.  
         [0013]      FIG. 5  is a top view of the o-ring used in the first preferred embodiment of the present invention to provide a watertight connection between the threaded cap and the external threads shown on the bottom end of the float housing.  
         [0014]      FIG. 6  is an exploded end view of float housing, threaded cap, and the tubular member in the first preferred embodiment of the present invention with a shaft for a float switch body positioned centrally within the float housing and the opening for fluid communication between the tubular member and float housing visible.  
         [0015]      FIG. 7  is an end view of a second preferred embodiment of the present invention with a fluid deflecting surface positioned within the tubular member adjacent to the float housing, a float switch body mounted within the float housing, the male threaded cap used for sealing the open bottom surface of the float housing, and the upwardly extending wall used for creating a contained area for fluid collection.  
         [0016]      FIG. 8  is a top view of the second preferred embodiment of the present invention.  
         [0017]      FIG. 9  is a bottom perspective view of the second preferred embodiment of the present invention with an open bottom end with female threads, a flattened top surface, and a central aperture through the top surface.  
         [0018]      FIG. 10  is a top perspective view of the float switch body and male cap of the second preferred embodiment of the present invention with the float switch body poised above the male threaded cap used for sealing the open bottom end of the float housing shown in  FIG. 9 .  
         [0019]      FIG. 11  is a perspective view of a preferred cap configuration used to adapt the second preferred embodiment of the present invention for auxiliary use.  
         [0020]      FIG. 12  is a sectional view of the second preferred embodiment of the present invention with the float switch body within the float housing, the bottom end of which is sealed by a male threaded cap, and tubular member in association with the float housing and positioned so that the bottom end of the float housing is positioned lower than the tubular member.  
         [0021]      FIG. 13  is a perspective view of the most preferred embodiment of the maintenance port accessory of the present invention usable in-line with a fluid discharge line connected to the present invention float switch assembly, with the accessory oriented for horizontal fluid flow and having a threaded wider end and an opposed non-threaded narrower end, with the threaded wider end having a distally secured installation-assisting connector and a capped extension with a large distal opening that outwardly depends from the distal portion of the wider threaded end and is in substantially perpendicular orientation thereto.  
         [0022]      FIG. 14  is a side view of the most preferred embodiment of the maintenance port accessory of the present invention oriented for vertical fluid flow and having a threaded wider end and an opposed non-threaded narrower end, with an installation-assisting connector poised for distal attachment to the threaded wider end and a cap poised for threaded connection to the large distal opening in an extension that outwardly depends in substantially perpendicular orientation from the distal portion of the wider threaded end.  
         [0023]      FIG. 15  is an end view of the most preferred embodiment of the maintenance port accessory of the present invention with a fluid-deflecting internal structure between a threaded wider end and an opposed non-threaded narrower end that facilitates flow of fluid and cleaning agents away from the connected fluid-producing system.  
         [0024]      FIG. 16  is a sectional view of the most preferred embodiment of the maintenance port accessory of the present invention with the fluid-deflecting internal structure between the threaded wider end and the opposed non-threaded narrower end being visible through the non-threaded narrower end.  
         [0025]      FIG. 17  is a side view of two first preferred embodiments and one horizontally-extending maintenance port accessory of the present invention in association with an air conditioner system, with one of the first preferred embodiments capped on its distal end connected to a auxiliary line attached to the air conditioner unit, with the other first preferred embodiment and the maintenance port accessory connected to the main condensate discharge line with the first preferred embodiment connected upstream from the maintenance port accessory.  
         [0026]      FIG. 18  is a side view of one first preferred embodiment and one vertically extending maintenance port accessory of the present invention in association with an air conditioner system, with both connected to the main condensate discharge line extending from the air conditioner and the first preferred embodiment positioned upstream from the maintenance port accessory.  
         [0027]      FIG. 19  is a side view of one first preferred embodiment and one maintenance port accessory of the present invention in association with an air conditioner system, with the first preferred embodiment capped on its distal end connected directly to the air conditioner unit, with the maintenance port accessory connected to the air conditioner&#39;s main condensate discharge line.  
         [0028]      FIG. 20  is a side view of the one first preferred embodiment of the present invention in association with an air conditioner system, with the first preferred embodiment connected II between the air conditioner unit and the main condensate discharge line.  
         [0029]      FIG. 21  is a side view of two first preferred embodiments of the present invention in association with an air conditioner system, with one of the first preferred embodiments capped on its distal end and directly connected to the air conditioner unit in an auxiliary capacity, and the other first preferred embodiment connected to the main condensate discharge line extending from the air conditioner. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0030]      FIGS. 1-6  show a first preferred embodiment of the present invention float switch assembly, while  FIGS. 7-12  disclose a second preferred embodiment of the present invention. The float switch assembly of the present invention is simple in design and can handle a large amount of fluid before its float switch body is affected. In addition,  FIGS. 13-16  show the most preferred embodiment of a maintenance port assembly usable in-line with the float switch assemblies of the present invention when they are installed in a fluid discharge line, and  FIGS. 17-21  illustrate several combinations of the first preferred embodiment, second preferred embodiment, and the maintenance port assembly that can be used in differing applications. However, it is to be understood that many variations in the present invention are possible and also considered to be a part of the invention disclosed herein, even though such variations are not specifically mentioned or shown. Similarly, all of the possible combinations of first preferred embodiment, second preferred embodiment, and the maintenance port assembly are not shown in  FIGS. 17-21 . As a result, a reader should determine the scope of the present invention by the appended claims.  
         [0031]      FIGS. 1-6  show a first preferred embodiment 2 of the present invention shut-off switch, wherein the float switch body  42  is separated from the main condensate flow in tubular member  4 , float switch body  42  is centered within a float switch housing partially off-set from tubular member  4 , with float switch body  42  depending from the top surface of housing  6 , in contrast to second preferred embodiment 30 in which the float switch body  42  depends form the top surface of tubular member  4 .  FIG. 1  shows a first preferred embodiment 2 of the present invention for in-line use with a fluid discharge line (shown in  FIGS. 17-21  by the number  74 ), and which has a float housing  6  adjacent to and depending downwardly from a horizontally-extending tubular member  4  whereby the bottom end of the float housing  6  is positioned lower than the tubular member  4 . Typically, the opposing ends of tubular member  4  have no threads  18 , although a threaded connection is considered within the scope of the present invention. Routinely, and in the absence of a blockage in the main fluid discharge line (sown as number  74  in  FIGS. 17-21 ) to which it is connected, fluid flowing through opening  20  in one end of tubular member  4  exits through the opposing end of tubular member  4 . The circular cross-sectional configurations for tubular member  4  and float housing  6  that are shown in  FIG. 1  are not critical. However, the circular cross-sectional configuration of tubular member  4  is preferred for ease of its connection to existing plumbing lines, most of which are circular in cross-section. Further, irrespective of the cross-sectional configuration of float housing  6 , the float switch body used with it (identified by the number  42  in  FIG. 4 ) must have a complementary configuration that permits deployment of float switch body  42  when only a very small amount of fluid is collected in float housing  6  as a result of a fluid back-up due to a blockage in the connected fluid discharge line  74 .  FIG. 1  also shows a threaded cap  8  attached to the otherwise open bottom end (not shown) of float housing  6  and used to seal it. Cap  8  or other sealing means used should be removable for maintenance and inspection purposes, as well as for replacement of float switch body  42  and shaft  40  when needed, and threaded attachment is preferred. It is also preferred for additional sealing means to be used with cap  8  to seal the open bottom end of float housing  6 , such as but not limited to the o-ring  26  shown in  FIG. 5 . Although not critical, it is further preferred for cap  8  to have outwardly-extending rotation-assisting projections  16  so that when a user grasps the top/outside surface  22  of cap  8  with his or her hand, installation and removal of cap  8  can be easily accomplished by most adults without the use of rotation-assisting tools.  FIG. 1  also shows the upper threaded portion  10  of a vertically-oriented shaft (shown by the number  40  in  FIG. 5 ) extending centrally through the top of float housing  6  and secured in place by a lock-nut  12  and washer  14  so that shaft  40  can be used as a guide for vertical movement of the float switch body  42  positioned centrally within the float housing  6 , as shown in  FIG. 4 . A disk-shaped stop  44  (also shown in  FIG. 4 ) is removably attached to shaft  40  to define the lower boundary for movement of the float switch body  42  within housing  6  in response to changing fluid levels within float housing  6 . Since disk-shaped stop  44  is easily removable from shaft  40 , once cap  8  is removed from the open bottom end of housing  6 , float switch body  42  can be promptly removed for inspection and/or replacement, as needed, and the distance through which float switch body  42  moves during its deployment to activate a shut-off signal for an associated fluid-producing system can be adjusted according to changing needs by reattaching stop  44  in higher or lower positions on shaft  40 . In addition to raising and lowering stop  44  relative to shaft  10 , other means can be used to adjust the maximum vertical displacement of float switch body  42  according to a specific application or need. In the alternative, although not shown, a second stop  44  with the same or different thickness dimension could be used in addition to, or in place of the stop  44  in  FIG. 5 , or the connection of the upper threaded portion  10  of shaft  40  can be altered to adjust the maximum vertical displacement of float switch body  42 . Any combination of the above mentioned vertical displacement adjusting means can also be used. Although not shown in  FIGS. 1-6 , when the present invention is electrically connected to a fluid-generating system, the lead wires would be made to extend upwardly through the open top end of the upper threaded portion  10  of shaft  40 .  FIG. 2  is a top view of the first preferred embodiment 2 of the present invention showing that the upper threaded portion  10  of shaft  40  is centrally connected to the top of float housing  6  by lock nuts  12  and washer  14 .  FIG. 2  also shows threaded cap  8  attached to the bottom end of float housing  6 , rotation assisting projections  16  on cap  8 , and the opposing ends of tubular member  4  having no threads  18 .  FIG. 3  is an end view of first preferred embodiment 2 and having a fluid-deflecting member  24  positioned within tubular member  4  that routinely prevents fluid from entering float housing  6 . As can be seen in  FIG. 6 , an enlarged area  28  above fluid-deflecting member  24  allows fluid communication between tubular member  4  and float housing  6  when a blockage occurs in the associated discharge line  74  to which it is connected. Fluid deflecting member or surface  24  should be sufficiently large to prevent inadvertent splashing of fluid into float housing  6  during routine operation when no back-up of fluid is present in the associated discharge line  74 , but not so large as to impede the routine fluid flow through tubular member  4 .  FIG. 4  shows the float switch body  42  within float housing  6  and tubular member  4  off-set to one side of float housing  6 . Two lock nuts and two washers aid in attaching the upper portion  10  of shaft  40  to float housing  6 . In  FIG. 4 , the top lock nut  12  and washer  14  are not tightly positioned against the top of float housing  6 , which may be the result of modification of the total vertical displacement of float switch body  42  during its deployment.  FIG. 4  shows float switch body in its pre-deployment position, lower than the bottom of tubular member  4 . The opening through tubular member  4  is largely unobstructed, with the exception of fluid-deflecting member  24 . Float switch body  42  substantially fills the interior space within float housing  6  and is prevented from moving downward beyond shaft  40  by a stop-disk  44 .  FIG. 4  further shows cap  8  being attached to float housing  6  an o-ring between housing  6  and cap  8 , and rotation-assisting projections  16  on cap  6  that are used in combination with the outside surface  22  of cap  8  for ease in hand tightening and loosening of cap  8 , as needed. Float switch body  42  is large compared to the interior space within float housing  6  and substantially fills it. However, float switch body  42  does not have to have the cylindrical configuration shown in  FIG. 4  and other shapes are contemplated, such as a generally football-shaped float switch body  42  with a central height dimension that is greater than its circumferential height dimension, or a float switch body  42  that has a cross-sectional configuration of a triangle, ellipse, pentagon, hexagon, octagon, or other regular or irregular curvilinear shape, can be used as long as float housing  6  has a complementary shape that permits float switch body deployment when only a very small amount of fluid is collected in float housing  6 .  FIG. 5  shows the o-ring  26  used in most preferred embodiment 2 to provide a watertight connection between threaded cap  8  and the external threads  18  shown on the bottom end of float housing  6 , as shown in  FIG. 4 . Although not shown, o-ring  26  can also be used in the threaded connections of the maintenance port accessory  56  shown in  FIGS. 13-16 .  FIG. 6  shows first preferred embodiment 2 having tubular member  4  in fluid communication with float housing  6  via enlarged opening  28 , and the fluid deflecting member  24  within tubular member  4  in a position that allows routine travel of fluid (not shown) through the bottom portion of tubular member  4 , while simultaneously providing a threshold fluid depth beyond which fluid will spill over into float housing  6 . When sufficient fluid enters float housing  6 , which typically is only a very small amount of fluid, it causes vertical deployment of the float switch body  42  within housing  6  and activation of a signal that turns off the associated fluid-producing system such as but not limited to the air conditioning system  72  in  FIGS. 17-21 . Fluid-deflecting member  24  is also configured to block cleaning agents introduced into the associated fluid discharge line  74  from easily making their way into float housing  6  and interfering with the proper deployment of float switch body  42 .  FIG. 6  also shows threaded cap  8  separated from the bottom end of float housing  6  to expose threads  17 . A sufficient number of threads  18  should be present to provide a leak-proof closure of the bottom end of float housing  6 . In addition,  FIG. 6  shows lock-nut  12  and washer  14  upon the upper threaded portion  10  of shaft  40 , but not secured against the top of housing  6 , as they would be during normal function. The distal end of the upper threaded portion  10  of shaft  40  extends upwardly beyond housing  6  for the passage of electrical wires (not shown) needed to carry the shut-off signal activated by deployment of float switch body  42  to the fluid-generating system such as the air conditioning system  72  in  FIGS. 17-21 . Although not shown, the configuration of float housing  6  is not limited to the substantially cylindrical shape illustrated in  FIG. 6 , and in the alternative it can have a cross-sectional configuration of a triangle, pentagon, or other regular or irregular curvilinear shape, can be used as long as float switch body  42  has a complementary shape that permits float switch body deployment when only a very small amount of fluid is collected in float housing  6 . Further, although not shown, tubular member  4  can have any cross-sectional configuration, although use of the commonly available cylindrical tubing is preferred for cost considerations. To adapt first preferred embodiment to auxiliary applications, a cap  8  is attached to one of the opposing ends of tubular member  4 , as shown in  FIGS. 17, 19 , and  21 .  
         [0032]      FIGS. 7-12  show a second preferred embodiment 30 of the present invention shut-off switch, wherein the float switch body  42  is also separated from the routine condensate flow (not shown) entering tubular member  4  through opening  20 , however, the float switch body  42  is centered within tubular member  4  with fluid flow being diverted around it by upstanding wall  32  attached to removable male threaded cap  34  above its threads  18 , as shown in  FIG. 10 . Second preferred embodiment 30 also has a simple design and permits a large amount of fluid flow through tubular member  4  before float switch body  42  is affected by the fluid flow. Also, the enlarged space in this and other present invention embodiments allows for operation of float switch body  42  without air lock malfunction or the need for air holes through tubular member  4  to prevent air lock. The upper portion  10  of shaft  40  is connected by two lock nuts  12  and two washers  14  to the top surface of tubular member  4 , in contrast to first preferred embodiment 2 in which float switch body  42  is secured to the top surface of the off-set float housing  6 . The number and type of fasteners used to secure the upper portion  10  of shaft  40  in place during use is not critical in any embodiment of the present invention, whether lock nuts  12  and washers  14  similar to those used in  FIGS. 7 and 8  are used, or not.  FIGS. 7 and 8  show second preferred embodiment 30 with its float housing  6  positioned between its tubular member  4  and male threaded cap  34 , with tubular member  4  directly above float housing  6  and removable male threaded cap  34  directly below float housing  6 . A flattened top area  36  in the upper surface of tubular member  4  provides for the secure tightening of lock nuts  12  to fixedly position shaft  40  centrally within tubular member  4  and float housing  6  for proper and responsive vertical movement of float switch body  42 .  FIGS. 7 and 8  further show male threaded cap  34  having a hexagonal perimeter so that an adult using a hand over the outer surface  22  of cap  34 , or using a rotation-assisting tool such as a wrench (not shown), can easily remove cap  34  to inspect, maintain the proper operation of, and/or replace float switch body  42 , as often as is needed. As shown in  FIGS. 7 and 10 , cap  34  has an upwardly extending wall  32  above threads  18  that is used for creating a contained area (shown in  FIG. 12  by the number  46 ) for fluid collection when a blockage occurs in the main condensate line  74  to which it is connected.  FIG. 9  show the second preferred embodiment 30 having a combined float housing  6  and tubular member  4 , with float housing  6  centered under and depending downwardly from tubular member  4 .  FIG. 9  further shows float housing  6  having an open bottom end with female threads  18 , and tubular member  4  having a flattened top surface  36  with a central aperture  50  therethrough. The amount of threads  18  within float housing  6  should be sufficient to provide a leak-proof seal with male threaded cap  34 , or other plugging or sealing means that provides the same functions of male threaded cap  34 .  FIG. 10  shows float switch body  42  and male cap  34  of the second preferred embodiment 30 of the present invention, with float switch body  42  poised above the male threaded cap  34  that is used for sealing the open bottom end of the float housing  6  illustrated in  FIG. 9 . In  FIG. 10  it can be seen that float switch body  42  is only slightly smaller in diameter than the upstanding wall  32 , so that as fluid accumulates in the space surrounded by wall  32  when a blockage (not shown) in the main condensate discharge line  74  occurs, very little fluid accumulation is needed before float switch body is raised to activate a signal for shutting off the fluid-producing system, such as but not limited to the air conditioner system  72  in  FIGS. 17-21 . The stop-disk  44  shown in  FIG. 12  and used to maintain float switch body  42  on shaft  40  prior to upward deployment, is hidden from view in  FIG. 10 .  FIG. 11  shows a preferred configuration of cap  8  used over one end of tubular member  4  to adapt the second preferred embodiment 30 for auxiliary use, similar to the use of first preferred embodiment 2 in  FIGS. 17, 19 , and  21 . In addition,  FIG. 12  shows the second preferred embodiment 30 having its float switch body  42  in its pre-deployment position lower than the bottom of tubular member  4 . Very little space is present between float switch body  42  and the adjacent upstanding wall  32 . A stop disk  44  prevents float switch body from traveling downward beyond shaft  40 . Since stop  44 , as well as lock nuts  12  and washers  14 , are removable from shaft  40 , shaft  40  and float switch body  42  can be removed from tubular member  4  for maintenance, inspection, and/or replacement, once the male threaded cap  34  that seals the open bottom end of float housing  6  is removed.  FIG. 12  shows male threaded cap  34  secured to the bottom portion of float housing  6  with the aid of o-ring  26 , and cap  34  having a bottom configuration with cut-out areas  54  that conserve material expense and facilitate molded production. Routinely, fluid flowing through the end opening  20  in tubular member  4  is met by upstanding wall  32  and deflected around float switch body  42  in a channel  52 . When the quantity of fluid entering end opening  20  exceeds the height of upstanding wall  32 , typically as a result of a blockage in the main fluid discharge line  74  to which it is connected, fluid will enter the confined space  46  around float switch body  42  where the accumulation of a very small amount of fluid, such as but not limited to  7 . 5 cc or  1 . 5 oz., will cause float switch body  42  to upwardly deploy and cause a shut-off signal to be sent to the fluid-producing system. It is particularly important for the float switch body  42  deployment to occur as a result of only a small amount of fluid collected in air conditioning applications, since the condensate it produces can continue to enter a connected discharge line for as much as 10-15 minutes after the system is turned off. First and second preferred embodiments, respectively 2 and 30 both have a compact housing design for prompt and cost effective installation in the close-fitting areas used to accommodate residential air conditioning air handlers. In addition they have a sturdy construction and design for responsive and reliable operation, and its float switch body  42  is readily capable of being installed in a level orientation for proper and reliable operation. Debris/rust/mold/algae in the condensate line  74  to which it is connected typically will not affect the float switch body  42  of the present invention as it is generally protected during routine operation from the fluid flowing through tubular member  4  by upstanding wall  32  or fluid-deflecting member  24 . In addition, float switch body  42 , float housing  6 , tubular member  4 , shaft  40 , caps  8  and  34 , as well as lock nuts  12  and washers  14  are all made from corrosion-resistant materials that resist premature deterioration and malfunction.  
         [0033]      FIG. 13  shows the most preferred embodiment of the maintenance port accessory  56  of the present invention usable in-line with a fluid discharge line (such as the line  74  in  FIGS. 17-21 ) that is also connected to one or more of present invention float switch assemblies, or other float switches (not shown), with accessory  56  oriented for horizontal fluid flow and having a threaded wider end  66  downstream of an opposed non-threaded narrower end  62 .  FIG. 13  also shows the threaded wider end  66  having a distally secured installation-assisting connector  60  with a hexagonal end configuration  68 , and an extension  58  with an enlarged distal opening (shown by the number  76  in  FIG. 14 ) that outwardly depends from wider threaded end  66 . Extension  58  is not centered within wider threaded end  66 , but located in an off-set position toward its threads  18 . Also, extension  58  is in substantially perpendicular orientation to wider threaded end  66 .  FIG. 13  further shows a threaded cap  8  in place on the distal end of extension  58 , and cap  8  having rotation-assisting projections  16  to assist a hand (not shown) attempting to remove cap  8  by grasping its outside surface  22 . Rotation-assisting projections  16  in all present invention embodiments are non-critical, but preferred. Information markings  64  that indicate the direction of fluid flow when maintenance port accessory  56  is in a horizontally-extending orientation are also shown in  FIG. 13 , and preferred. In contrast,  FIG. 14  shows the most preferred embodiment of the maintenance port accessory  56  oriented for vertical fluid flow and having its threaded wider end  66  above its opposed non-threaded narrower end  62 . An installation-assisting connector  60  is poised for attachment to threaded wider end  66  and a cap  8  is poised for removable threaded connection to the large distal opening  78  in extension  58  that outwardly depends in substantially perpendicular orientation from wider threaded end  66  in a position remote from non-threaded narrower end  62 . Although  FIG. 14  shows a vertical orientation wherein maintenance access to wider threaded end  66  is from its side and fluid flow is substantially vertical,  FIG. 18  shows a different vertical application of maintenance port accessory  56  where the maintenance access to wider threaded end  66  is from its top and fluid flow makes a downward right angle and substantially changes direction from substantially horizontally-extending to vertical.  FIG. 14  further shows information markings  64  that indicate the direction of fluid flow when maintenance port accessory  56  is in a vertically-extending orientation, which are preferred. Although connector  60  with its hexagonal tool-assisting collar  68  can be used with bonding agents to secure the threaded wider end  66  or extension  58  of second preferred embodiment 30 to a fluid discharge line, it is also contemplated for common plumbing connections to also be used.  FIG. 15  looks through the non-threaded narrower end  62  of maintenance port accessory  56  toward its threaded wider end  66 . The hexagonal tool-assisting collar  68  of connector  60  is visible behind threaded wider end  66 . The downward direction of fluid flow from non-threaded narrower end  62  into threaded wider end  66  is evident in  FIG. 15 , which facilitates flow of fluid and cleaning agents away from the connected fluid-producing system, such as but not limited to air conditioning system  72  in  FIGS. 17-21 .  FIG. 15  further shows maintenance port accessory  56  in a substantially horizontally-extending orientation, with cap  8  sealing the enlarged open end  76  of extension  58  via threads  18 , and informational markings on the outside surface of cap  8 . Although  FIGS. 13-16  do not show any surface texture or additional informational markings  64  on threaded wider end  66 , extension  58 , or non-threaded narrower end  62 , it is not contemplated for the informational markings  64  and surface texture in any embodiment of the present invention to be limited to that shown.  FIG. 16  shows the most preferred embodiment of maintenance port accessory  56  with its fluid-deflecting internal structure  70  between its threaded wider end  66  and its opposed non-threaded narrower end  62 .  FIG. 16  also shows extension  58  on the wider threaded end  66  of maintenance port accessory  56  in a position remote from non-threaded narrower end  62 . It is preferred that the positioning of extension  58  be as close to the threads  18  wider threaded end  66 , while still allowing a cap  8  to be attached simultaneously to wider threaded end  66  and the distal end of extension  58 . The closer extension  58  is to non-threaded narrower end  62 , the more opportunity there is for fluids and cleaning agents (not shown) to move past fluid-deflecting internal structure  70  and make their way into non-threaded narrower end  62 . Since maintenance port accessory  56  is in a horizontally-extending position, wider threaded end  66  would be positioned downstream from non-threaded narrower end  62  and fluid flow would move first through non-threaded narrower end  62 . As any fluid passes beyond fluid-deflecting internal structure  70 , the arcuate structure of internal structure  70  would deter casual movement of fluid back toward non-threaded narrower end  62 . Also, where cleaning agents are added through the enlarged opening  78  in extension  58 , fluid-deflecting internal structure  70  would also deter its movement toward non-threaded narrower end  62 , and instead encourage movement through wider threaded end  66 . The informational markings  64  on the outside surface  22  of cap  8  are not critical. The large size of opening  78  in extension  58 , in combination with the enlarged diameter of wider threaded end  66 , allows the addition of cleaning agents through opening  78  without air-lock malfunction and often without the need of a funnel. In horizontally-extending applications the fluid-deflecting internal structure  70  discourages back-flow of cleaning agents (not shown) added through opening  78  from reaching the connected fluid-producing system, while in vertical applications the fluid-deflecting internal structure facilitates splash-free downward flow of cleaning agents added through opening  78 .  
         [0034]     Although the outer surfaces of tubular member  4 , housing  6 , cap  8 , threaded wider end  32 , and narrower non-threaded end  30  are shown in  FIGS. 1-21  to be generally unadorned, with the exception of informational markings  64 , they may have any surface texture or other markings that do not interfere with the intended application. The configuration of connector  60  is not limited to that shown in  FIGS. 13-16 , and connector  60  may have any configuration appropriate to the application that adapts threaded wider end  66  for connection to the fluid discharge line (not shown). Also, for manufacturing ease and to reduce cost, although not limited thereto, it is contemplated for all caps  8  connected to the threads  18  on first preferred embodiment 2, second preferred embodiment 30, and maintenance port accessory  28  to be the same size. Adaptation of first preferred embodiment 2 or second preferred embodiment 30 from its usual in-line application to auxiliary use, can be accomplished by the use of a cap  8  or other conventional sealing or plugging means (not shown) to permanently or temporarily block one end of tubular member  4 . Further, although the relative dimensions of housing  6  and tubular member  4  can be varied from that shown in  FIGS. 1-12 , and the relative dimensions of the components of maintenance port accessory  58  can be varied from that shown in  FIGS. 13-16 , such dimensions are not critical as long as each is sufficiently large to fulfill its intended function without undue material waste.  
         [0035]      FIGS. 17-21  show several examples of present invention use with an air conditioning system, with the combined shut-off switch and float housing being used in both in-line and auxiliary applications. However, it is contemplated for other installation configurations to also be possible using varying combinations of first preferred embodiments 2, second preferred embodiments 30, maintenance port accessories  56 , caps  8  and  34 , and connectors such as but not limited to connector  60  with its hexagonal base  68  that facilitates tool-assisted connection.  FIG. 17  shows two first preferred embodiments 2 and one horizontally-extending maintenance port accessory  56  of the present invention in association with an air conditioner system  72 . One of the first preferred embodiments 2 has a cap  8  on the distal end of its tubular member (shown in  FIG. 1  by the number  4 ), with the opposing end of tubular member  4  being connected to a auxiliary line  76  attached to air conditioner unit  72 . The tubular member  4  of the other first preferred embodiment 2 and the maintenance port accessory  56  are connected to the main condensate discharge line  74 , with first preferred embodiment 2 connected upstream from maintenance port accessory  56 . In most applications it is preferred for first preferred embodiment 2 to be connected upstream from maintenance port accessory  56 . Although not shown, it is contemplated for the tubular member  4  of the first preferred embodiment 2 and maintenance port accessory  56  to be secured to air conditioner unit  72 , auxiliary line  76 , and/or main condensate discharge line  74  using conventional plumbing connection means. As shown in  FIG. 2 , the external threads  18  (shown in  FIG. 14 ) on maintenance port accessory  56  can be used to aid the secure connection between maintenance port accessory  56  and main condensate discharge line  74 , or, as shown in  FIG. 1  the secure connection between maintenance port accessory  56  and main condensate discharge line  74  can be achieved by means other than external threads  18 .  FIG. 18  shows one first preferred embodiment 2 and one vertically extending maintenance port accessory  56  of the present invention in association with an air conditioner system  72 , with both connected to the main condensate discharge line  74  extending from the air conditioner system  72  and the first preferred embodiment 2 positioned upstream from the maintenance port accessory  56 .  FIG. 19  shows one first preferred embodiment and one maintenance port accessory  2  of the present invention in association with an air conditioner system  72 , with the first preferred embodiment 2 having a cap  8  on the distal end of its tubular member  4  and its other end connected directly to the air conditioner system  72 , and further with the maintenance port accessory  56  connected to the air conditioner&#39;s main condensate discharge line  74 .  FIG. 20  shows one first preferred embodiment 2 of the present invention in association with an air conditioner system  72 , with the first preferred embodiment 2 having one of the ends of its tubular member connected directly to the air conditioner system  72  and the main condensate discharge line  74  connected to the other end of its tubular member  4 .  FIG. 21  shows two first preferred embodiments 2 of the present invention in association with an air conditioner system  72 , with one of the first preferred embodiments 2 having a cap  8  on the distal end of its tubular member  4  and the other end of its tubular member  4  directly connected to the air conditioner system  72  in an auxiliary capacity. The tubular member of the other first preferred embodiment 2 in  FIG. 21  is connected to the main condensate discharge line  74  that extends from the air conditioner system  72 .  
         [0036]     The materials from which the first preferred embodiment 2, second preferred embodiment 30, and maintenance port accessory  58  are made can vary, but must be impervious to corrosion. Preferably for cost considerations, although not limited thereto, it is contemplated for housing  6 , float switch body  42 , stop  44 , shaft  40 , lock-nuts  12 , and washers  14  to all be made from plastic. Resistance to UV radiation is not necessarily a contemplated feature of the present invention, unless dictated by the application. Manufacture of the present invention first preferred embodiment 2, second preferred embodiment 30, and the associated but optional maintenance port accessory  58  could be accomplished by blow molding, injection molding, assembly of pre-formed individual components, or a combination thereof, with the choice of manufacturing being determined by the anticipated purchase cost to consumers and the expected duration of use without maintenance, parts replacement, or repair. Although size of the present invention is not critical, for many condensate collection applications, the width and height dimensions of the combined housing  6  and bottom cap  8  would be less than three inches. Embodiments of the present invention can be used for residential or commercial applications, and in new construction as well as retrofit applications.  
         [0037]     Prior to use of the most preferred embodiment 2 of the present invention float switch assembly for an in-line installation in a main fluid discharge line  74 , float switch body  42  would be positioned on shaft  40  so that electrical wires (not shown) extend upwardly beyond its upper threaded portion  10 . Preferably, the upper threaded portion  10  of shaft  42  would then be inserted through the central opening in the top surface of housing  6  with the two lock-nuts  12  so that the remainder of shaft  40  is vertically extending through housing  6  with float switch body  42  substantially filling the interior space within housing  6 . Washers  14  can also be optionally used in association with lock-nuts  12 . Stop  44  would be fixed to the bottom portion of shaft  40  to adjustably define the lower boundary of float switch body  42  displacement vertically along shaft  40  during use, with adjustment further being possible through the repositioning of lock-nuts  12 . The adjustment and positioning of float switch body  42  would be governed by the application and the depth of fluid needed to cause float switch body  42  to rise and send a signal to the system producing the fluid so as to cause termination of fluid flow through the main discharge line  74  to which housing  6  is connected. Any connector or combination of connectors, such as but not limited to connector  60 , can be used to facilitate the in-line connection of the opposing ends of tubular member  4  to main fluid discharge line  74 . Once housing  6  is in a secured and usable position, the installer or operator would check it for the stable and level positioning required for reliable and uninhibited vertical movement of float switch body  42 , and make any adjustment needed to ensure that float switch body  42  moves freely using shaft  40  as a guide for its up and down movement. It is important to note that in the absence of water or other fluid in housing  6 , float switch body  42  is positioned lower than the bottom of the main fluid discharge line  74 , so that only a very small amount of condensate or other fluid is needed to activate float switch body  42  and cause it to rise to the level needed to activate a fluid terminating signal. The electrical wires (not shown) extending from the upper threaded portion  10  of shaft  40  would then be connected to the system providing the water, condensate or other fluid traveling through the main discharge line  74  in fluid communication with housing  6 . Then, when collected fluid fills housing  6  beyond a pre-determined depth that is considered to be safe to prevent a risk of back-up into the fluid-producing system and indicates at least a partial blockage of main fluid discharge line  74 , the present invention float switch body  42  is lifted by the rising fluid to the height that interrupts the system&#39;s operation and stops the introduction of new fluid into the main discharge line  74 . The inner configuration of the connection of tubular member  4  to housing  6  prevents the creation of an airlock within housing  6  that could potentially interfere with the proper vertical movement of float switch body  42 . Such inner configuration also protects float switch body  42  from the fluid in main fluid discharge line  74  until a blockage occurs in main fluid discharge line  74  causing a portion of the fluid therein to enter housing  6 . Minimal maintenance is contemplated. If housing  4  is made from translucent, transparent, or partially transparent materials, an operator could visibly assess the effective operation of float switch body  42  without removing it from housing  6  for inspection. For adaptation of most preferred embodiment 2 of the present invention float switch assembly for an auxiliary installation (not shown), one of the ends of tubular member  4  would be sealed with a cap  8  or other conventional means (not shown). Other installation and operation of preferred embodiment 2 would be similar to that already noted for in-line applications. Installation of maintenance port accessory  58  would also be similar to that already noted for in-line applications of preferred embodiment 2, with connector  60  or other connector (not shown) being used with wider threaded end  66  according to the application to complete the in-line connection. The non-threaded narrower end  62  of maintenance port accessory  58  would be bonded via conventional means to the fluid discharge line  74 . Maintenance port accessory  58  can be positioned upstream or downstream from first preferred embodiment 2 or second preferred embodiment 30 in its connection to a fluid discharge line  74 . Further, maintenance port accessory  58  is not limited to use only in main fluid discharge line  74  applications, and can be used in auxiliary line  76  or other applications when a need for its presence is recognized.