Abstract:
A reservoir assembly is disclosed including a one-piece integrally formed fluid level switch housing and outlet wherein the switch housing can be rotated 360 degrees about its longitudinal axis to locate the outlet at any desired position. A conventional fitting may be integrally formed at the outlet. The orientation of the outlet may be changed at any time after the manufacturing process.

Description:
RELATED APPLICATION 
   This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/794,394, filed 24 Apr. 2006. 

   BACKGROUND OF THE INVENTION 
   The present invention relates to fluid reservoirs and specifically to reservoir assemblies including switches for making or breaking an electrical signal based upon the fluid level in the reservoir. In many applications, it is desirable to monitor the level of fluid in a reservoir. Furthermore, it is desirable to make or break an electrical signal when the amount of fluid in the reservoir drops to a predetermined level. 
   In the design of prior art reservoir assemblies, it was necessary to determine the position of the reservoir outlet fitting during the assembly of the reservoir assembly. Once positioned in the prior art design, the orientation of the outlet fitting is fixed and can not be changed. This results in the necessity of manufacturing and stocking a variety of reservoir assemblies, each having a different position for the outlet fitting. There exists a need for a reservoir assembly where the position or orientation of the outlet fitting can be easily changed after the reservoir assembly is manufactured thereby eliminating the need to manufacture and stock multiple reservoir assemblies each having a different outlet fitting position. 
   Prior art reservoir assemblies also utilize switch housings made from multiple components that must be securely connected to one another. This is typically accomplished with adhesives, press fits and threaded connections. The various components are also commonly formed from different materials. The resulting switch housing is not only costly to manufacture, but also provides a number of areas where the connection could fail thus leading to a fluid leak. There also exists a need for a one-piece integrally formed switch housing for use in a reservoir assembly. 
   SUMMARY OF THE INVENTION 
   The present invention includes a reservoir defining an interior volume and having opposed upper and lower openings. The upper opening receives a removable fillcap and provides a means for filling the reservoir with a fluid. The lower opening receives a one-piece integrally formed switch housing that serves dual purposes. It provides the fluid outlet and the housing for the fluid level switch. 
   The fluid outlet includes an elongate fitting having an internal passageway leading from the interior of the reservoir to the distal end of the fitting. The fitting may be an integrally formed barbed fitting suitable for the attachment of flexible tubing, a hose or the like. 
   The fluid level switch housing includes a tubular stem member within which is located a metallic reed switch and a float having a magnet integrally formed therein or attached thereto. The tubular stem member includes an integrally formed top and at least one integrally formed flexible tab. The float is slidably engaged with the tubular stem member, and is retained on the stem member by the tab. When the float and magnet assembly drop to a predetermined position along the tubular member, the magnetic forces from the close proximity of the magnet cause the reeds of the reed switch to contact and therefore close the electrical circuit to which the switch is connected. 
   The switch housing is rotatably sealed within the lower reservoir opening thereby allowing the user to rotate the fluid outlet fitting 360 degrees about the longitudinal axis of the switch housing. Unlike the prior art designs whereby the position of the outlet fitting must be determined during the manufacturing process, the fluid outlet of the present invention can be rotated about it axis at any time and to any desired position. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of the reservoir assembly. 
       FIG. 2  is a front elevation view thereof. 
       FIG. 3  is a right side elevation view thereof. 
       FIG. 4  is a cutaway view taken along line  4 - 4  in  FIG. 3 . 
       FIG. 5  is a bottom plan view. 
       FIG. 6  is a perspective view of the preferred embodiment of the reservoir assembly. 
       FIG. 7  is a right side elevation view of the reservoir assembly of  FIG. 6 . 
       FIG. 8  is a cutaway view taken along line  8 - 8  in  FIG. 7 . 
       FIG. 9  is an enlarged view of a portion of  FIG. 8 . 
       FIG. 10  is a bottom plan view of the reservoir assembly of  FIG. 6 . 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENT 
   Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention. 
   Referring now to  FIGS. 1 ,  2 ,  3  and  4  the reservoir assembly of the present invention will be designated generally with the reference numeral  10 . The assembly  10  includes a reservoir  12  having an interior volume  14 , an upper opening  16  and a lower opening  18 . The reservoir  12  can have any shape or size and be constructed from any material. In the preferred embodiment, the reservoir  12  has generally rectangular top, bottom and side walls and is constructed from a suitable plastic material such as polypropylene. A mating thread  20  is formed at the upper opening  16  for receiving a cap  22  having threads  24 . A gasket  26  may be placed between the uppermost end of reservoir  12  and cap  22 . Cap  22  may have a valve located therein, such as a silicone umbrella valve, if desired. 
   Referring specifically to  FIG. 4 , a one-piece integrally formed switch housing  30  is located within the lower opening  18 . The switch housing  30  includes a fluid communication channel or conduit  32 , a barbed fitting  34 , a cylindrical body portion  36 , and a hollow stem portion  38  having a hollow interior chamber  40 . The fluid conduit  32  is in fluid communication with the interior volume  14  of the reservoir  12  and terminates at the distal end of the barbed fitting  34  thereby allowing the fluid contained within the reservoir  12  to flow there through. The integrally formed barbed fitting  34  is of a conventional design to allow for the connection of flexible tubing, hose or the like. 
   An electrical reed switch  42 , having lead wires and conventional connectors  44 , is located within the hollow chamber  40  formed within the stem  38 . After the reed switch  42  is placed within the hollow chamber  40 , a cap  46  having a fluid tight seal is placed on the uppermost end  48  of the stem  38 . Potting compound  52  is introduced into the opposite end  50  to secure the reed switch  42  within the hollow chamber  40  and prevent the introduction of any contaminants into the chamber  40  as well. The lead wires  44  pass through the end  50  and are also sealed in place by the potting compound  52 . 
   An annular float assembly  60  is positioned about the stem  38 . The float assembly includes a float  62  and a magnet  64 . The float  62  is constructed from any suitable material that is buoyant when exposed to the fluid contained within the reservoir  12 . The magnet is attached to the float. When the reservoir  12  is sufficiently full of fluid, the float  62  will be located at its uppermost position, whereby further upward movement is restrained by the cap  46 . As the level of fluid within the reservoir  12  begins to decrease, the position of the float assembly  60  will drop or lower along the stem  38 . At a preselected point, the magnet  64  of the float assembly  60  will be positioned substantially adjacent to the reed switch  42 . The magnetic force generated by the magnet  64  within the close proximity to the reed switch  42  will cause the reed switch  42  to close thereby completing the circuit to which the wire leads  44  are connected. As will be appreciated, it is within the scope of the present invention to utilize a reed switch  42  that is opened by the presence of the magnetic forces generated by the magnet  64  thereby opening the circuit to which the wire leads  44  are connected. 
   The switch housing  30  is held in a fluid tight connection with the reservoir  12  by the use of a seal such as a rubber grommet  70  and retaining mechanism such as an external self-locking retaining ring  76 . The inner diameter  72  of grommet  70  creates a fluid tight seal about the cylindrical body portion  36  of the switch housing  30 . The outer periphery  74  of the grommet  70  fits about the lower opening  18  of the reservoir  12  as shown in  FIG. 4  and again provides a fluid tight seal. This arrangement also allows the user of the reservoir assembly  10  to rotate the switch housing  30  within opening  18  and about the longitudinal axis of the switch stem  38  to position the barbed fitting  34  at any desired location relative to the position of the reservoir  12 . 
   As best shown in  FIG. 5 , once assembled the user can rotate the switch housing  30  360 degrees about the longitudinal axis of the stem  38  to position the barbed fitting  34  in any desired location. A pair of substantially parallel flat surfaces  78  (see also  FIGS. 1 ,  2 , and  3 ) are formed in the switch housing  30  adjacent the integrally formed barbed fitting  34  to allow the placement of a wrench or similar tool (not shown) on the housing  30  to aid with the rotational positioning of the barbed fitting  34 . 
   The reservoir assembly  10  is typically constructed as follows. First, the rubber grommet  70  is placed in lower opening  18 . Then, the switch housing  30  (including the reed switch  42  affixed thereto) is passed through the inner diameter  72  of grommet  70 . Next, the retaining ring  76  is attached to a tool (not shown) that is passed through upper opening  16 . The tool allows the user to position the retaining ring  76  about the cylindrical body portion  36  of the switch housing  30 . The retaining ring  76  is depressed onto the cylindrical body portion  36  until it rests against the grommet  70 . Using another suitable tool (not shown) the float assembly  60  is placed over the stem  38  and the cap  46  is sealed to the uppermost end  48  of the stem  38 . Finally, the threaded cap  22  is placed on the threaded fitting  20  at upper opening  16  and rotated until secure. 
   An alternate embodiment of the reservoir assembly  110  of the present invention is shown in  FIGS. 6 through 10 . The alternate embodiment of the reservoir assembly is similar to the previously described embodiment, but incorporates an alternate cap  122  and an alternate switch housing  130 . 
   As shown in  FIG. 8 , the reservoir assembly  110  includes a reservoir  12  having an interior volume  14 , an upper opening  16 , and a lower opening  18 . As described above, the reservoir  12  can have any shape and be constructed from any material. In the preferred embodiment, the reservoir  12  has generally rectangular top, bottom, and side walls and is constructed from suitable plastic material such as polypropylene. A mating threaded portion  20  is formed at the upper opening  16  for receiving a cap  122  having threads  24 . A gasket  26  may be placed between the uppermost end of reservoir  12  and cap  122 . As shown in  FIGS. 6 and 8 , the cap  122  may have a valve  28  located therein, such as a silicone umbrella valve  28 , if desired. 
   As shown in  FIG. 8 , a one-piece integrally formed switch housing  130  is located within the lower opening  18  of the reservoir  12 . The switch housing  130  includes a fluid communication channel or conduit  32 , a barbed fitting,  34 , a cylindrical body portion  36 , and a hollow stem portion  138  having a hollow interior chamber  40 . The fluid conduit  32  is in fluid communication with the interior volume  14  of the reservoir  12  and terminates at the distal end of the barbed fitting  34  thereby allowing the fluid contained within the reservoir  12  to flow therethrough. The integrally formed barbed fitting  34  is preferably of a conventional design to allow for the connection of flexible tubing, hose, or the like. 
   As shown in  FIG. 8 , the cylindrical body portion  138  has an integrally formed top  80 . The top  80  can be of any shape; however in the preferred embodiment the top  80  is spherically shaped. The cylindrical body  138  is further formed with at least one integral tab  82 . It is contemplated that any number or configuration of tabs  82  could be utilized. In the preferred embodiment, the cylindrical body  138  is formed with two integral tabs  82  (see  FIG. 8 ). The tabs  82  preferably extend radially outwardly from the cylindrical body  138  in diametrically opposed directions. The tabs  82  are preferable resiliently flexible, such that the tabs can be flexed (see  FIG. 9 ) and will return to generally their original position (see  FIG. 8 ). 
   As shown in  FIGS. 8 and 9 , an electrical reed switch  42 , having lead wires and conventional connectors  44 , is located within the hollow chamber  40  formed within the stem  138 . After the reed switch  42  is placed within the hollow chamber  40 , potting compound  52  is introduced into the opposite end  50  to secure the reed switch  42  within the hollow chamber  40  and prevent the introduction of any contaminants into the chamber  40  as well. The lead wires  44  pass through the end  50  and are also sealed in place by the potting compound  52 . 
   As shown in  FIG. 8 , an annular float assembly  60  is positioned about the stem  138 . The float assembly includes a float  62  and a magnet  64 . The float  62  is constructed from any suitable material that is buoyant when exposed to the fluid contained within the reservoir  12 . The magnet  64  is attached to the float  62 . When the reservoir  12  is sufficiently full of fluid, the float  62  will be located at its uppermost position, whereby further upward movement is restrained by the tabs  82 . As the level of fluid within the reservoir  12  begins to decrease, the position of the float assembly  60  will drop or lower along the stem  138 . At a preselected point, the magnet  64  of the float assembly  60  will be positioned substantially adjacent to the reed switch  42 . The magnetic force generated by the magnet  64  within the close proximity to the reed switch  42  will cause the reed switch  42  to close thereby completing the circuit to which the wire leads  44  are connected. As will again be appreciated, it is within the scope of the present invention to utilize a reed switch  42  that is opened by the presence of the magnetic forces generated by the magnet  64  thereby opening the circuit to which the wire leads  44  are connected. 
   As shown in  FIGS. 8 and 9 , the switch housing  130  is held in a fluid tight connection with the reservoir  12  by the use of a seal such as a rubber grommet  70  and retaining mechanism such as an external self-locking retaining ring  76 . The inner diameter  72  of grommet  70  creates a fluid tight seal about the cylindrical body portion  136  of the switch housing  130 . The outer periphery  74  of the grommet  70  fits about the lower opening  18  of the reservoir  12  as shown in  FIG. 8  and again provides a fluid tight seal. This arrangement also allows the user of the reservoir assembly  110  to rotate the switch housing  130  within opening  18  and about the longitudinal axis of the switch stem  138  to position the barbed fitting  34  at any desired location relative to the position of the reservoir  12 . 
   As best shown in  FIG. 10 , once assembled the user can rotate the switch housing  130  360 degrees about the longitudinal axis of the stem  138  to position the barbed fitting  34  in any desired location. A pair of substantially parallel flat surfaces  78  are formed in the switch housing  130  adjacent the integrally formed barbed fitting  34  to allow the placement of a wrench or similar tool (not shown) on the housing  130  to aid with the rotational positioning of the barbed fitting  34 . 
   The reservoir assembly  110  is typically constructed as follows. First, the rubber grommet  70  is placed in lower opening  18 . Then, the switch housing  130  (including the reed switch  42  affixed thereto) is passed through the inner diameter  72  of grommet  70 . Next, the retaining ring  76  is attached to a tool (not shown) that is passed through upper opening  16 . The tool allows the user to position the retaining ring  76  about the cylindrical body portion  36  of the switch housing  130 . The retaining ring  76  is depressed onto the cylindrical body portion  136  until it rests against the grommet  70 . Using another suitable tool (not shown) the float assembly  60  is placed over the stem  138 . As described above, the tabs  82  are flexible, such when the float assembly  60  is pushed onto the stem  138 , the tabs  82  temporarily flex to allow the float assembly  60  to pass over the tabs  82  (see  FIG. 9 ). After the float assembly  60  has cleared the tabs  82 , the tabs  82  return to their original, unflexed position (see  FIG. 8 ). Finally, the threaded cap  122  is placed on the threaded fitting  20  at upper opening  16  and rotated until secure. 
   It is also contemplated that the float assembly  60  could be manually removed from the stem  138  in the event maintenance is required. In order to remove the float assembly  60 , the float is simply pulled upward towards the top  80  of the stem  138 . The tabs  82  will flex to allow the float assembly  60  to be moved past the tabs  82 . When the float assembly  60  has passed the tabs  82 , the tabs  82  will return to their unflexed configuration. It is therefore contemplated that the tabs  82  should be sufficiently rigid such that the normal pressure of the float assembly  60  engaging the tabs  82  during use of the reservoir will not cause the tabs  82  to flex significantly. However, the tabs  82  must also be flexible, such that the tabs  82  can flex under a removal or insertion from applied by the float assembly  60 . 
   The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention.