Patent Publication Number: US-2022227223-A1

Title: Fully-integrated, fluid flow-control module designed for installation within an iso filler neck of a top-fill def tank

Description:
RELATED APPLICATION DATA 
     This is a National Stage Application, under 35 U.S.C. § 371, of International Application No. PCT/2020/033499, filed on May 18, 2020, and which claims benefit of U.S. Provisional Application No. 62/848,684, filed on May 16, 2019. 
    
    
     BACKGROUND OF THE INVENTION 
     Field of the Invention 
     This invention relates, generally, to flow control valve assemblies that are used to protect tanks from being overfilled with fluid. More specifically, this invention relates to ultra-compact pressureless flow-control modules designed for installation within the ISO filler neck of a diesel exhaust fluid supply tank. 
     Description of the Prior Art 
     For many years large machinery fitted with fuel tanks have been equipped with rapid-fill fueling systems to enable rapid filing of large capacity fuel tanks. The existing zfast fill fuel systems rely on an air vent that prevents air from escaping the fuel tank when the required level of fuel has been attained. This causes pressure in the fuel tank to increase to a level that automatic shuts-off a fuel supply nozzle. 
     A major concern of this system is that when the fuel level activates the shut-off for the fuel supply nozzle, the shut-off can be overridden and fuel can continue to be forced into the fuel tank above the normal level. This can cause the fuel tank to rupture from the high pressure attained when filling. 
     U.S. Pat. No. 6,311,723 B1 to David Shipp and Robert Turner, has addressed this problem by devising a flow control valve assembly that prevents the build up of pressure within the fuel tank during and after filing. The flow control valve assembly also prevents the supply fuel nozzle from being overridden thus preventing the possibility of overfilling. U.S. Pat. No. 6,311,723 is hereby incorporated by reference. 
     The control valve assembly of U.S. Pat. No. 6,311,723 uses float valve to determine when the level of fuel in the fuel tank is at a desired level. When the desired level of fuel has been attained, the float valve is used to block the flow of fuel through a bleed pipe to stop the flow of fuel through a control valve. An open breather is provided within the fuel tank to allow gas to escape from the fuel tank during filling to prevent the fuel tank rupturing. 
     Another problem associated with prior-art flow control valves is that they are typically used in bottom-filled tanks. This requires that the float assembly be located inside the tank near the top thereof, while the flow control valve is located near the bottom of the tank near where the fuel nozzle couples to the receiver. In order for the float assembly to control the flow control valve, a small-diameter bleed line is used to couple the flow control valve assembly—that is near the bottom of the tank—to the float assembly that is near the top of the tank. The bleed line can be routed either internal or external to the tank, depending on the design of the unit. The use of such a two-piece assembly precludes the use of such a device in smaller tanks. 
     What was needed is a fully-integrated flow control assembly that mounts at the top of the fuel tank. In such a fully-integrated unit, the float assembly and the flow control valve assembly are both installed within the tank near the top thereof. Only an inlet/vent head protrudes from the top of the tank. Installing the fully-integrated assembly is much simpler than installing the separate float and control valve assemblies, as there is no need to make a connection between the two devices. 
     The aforementioned problems were solved, as evidenced by the issuance of U.S. Pat. No. 9,983,598, to Robert Charles Cooley (inventor of the present application), titled FULLY-INTEGRATED FLOW-CONTROL VALVE ASSEMBLY FOR TOP-FILLED FUEL TANKS. This flow-control valve, which is designed for internal mounting near the top of a fuel tank, is suitable for use with liquids, such as petroleum fuels, that do not freeze. 
     The International Organization for Standardization (ISO) is a non-governmental international entity based in Geneva, Switzerland having a membership comprising national standards organization from 162 nations. The ISO has published over 22309 International Standards covering almost myriad aspects of technology and manufacturing. 
     What is needed is a fully-integrated, flow-control valve assembly for top-filled tanks that will switch between on and off states even when the fuel inlet is supplied with fuel under pressure. 
     SUMMARY OF THE INVENTION 
     This invention provides a fully-integrated flow-control module for top-fill diesel exhaust fluid (DEF) tanks. The module is designed to fit within a filler neck of a DEF tank that conforms to ISO (International Organization for Standardization) Standard 22241-4:2009(E). The flow-control module includes a breather cap that locks the flow-control module to an adapter cap that is secured to the mouth of the ISO filler neck. A breather assembly, which allows bi-directional flow of air in an out of the tank in which the flow-control module is installed, is installed in the side of the breather cap. The breather cap screws onto the externally-threaded top of a retainer bushing. A receiver socket screws into the top of the retainer bushing, which is also threaded internally. A receiver fitting screws into the receiver socket. The retainer bushing screws onto an upper portion of a pipe nipple that has a center flange with opposed flat spots that can be engaged by a spanner wrench. The top of a main valve body screws onto a bottom portion of the pipe nipple. A spring-biased valve piston, which is controlled by a bleed path within a bleed and float body, opens and closes to control fluid flow into the DEF tank. A fluid level float is mounted on a control rod. A threaded nut retains the float on the control rod. Both the float and the control rod move up and down in response to fluid levels within the DEF tank. 
     The valve piston incorporates a pair of O-ring seals, one of which is installed near the piston crown to prevent fluid from leaking around the piston when it is in the closed position. The other O-ring seal, which is installed on the piston skirt, prevents fluid from leaking around the piston skirt so that DEF fluid can enter the bleed circuit only through a bleed aperture in the center of the piston crown. Until fluid level in the DEF tank has reached the level of the fluid level float, DEF fluid can enter the bleed circuit through the bleed aperture. As long as DEF bleed fluid can pass through the bleed aperture, the biasing spring beneath the valve piston provides a biasing force that is insufficient to raise the valve piston to its closed position. Bleed fluid enters a biasing spring chamber beneath the piston crown. A partition, which provides a floor for the biasing spring chamber, allows bleed fluid to escape from the spring chamber only through a bleed tube and enter a lower bleed chamber. A control rod guide insert functions as the floor of the lower bleed chamber. As long as the fluid level float is in its lowest position, DEF bleed fluid can pass from the lower bleed chamber into an upper bleed chamber through an escape port, after which is can flow into the DEF tank via escape apertures in the circumferential wall of the bleed and float body. When fluid level in the DEF tank reaches the fluid level float during a filling operation, the float and the control rod to which it is secured begin to rise. The upper end of the control rod and the upper end of a valve poppet are both rigidly secured to a connector beam. Thus, the valve poppet is also lifted by the rising fluid level float. When the float has risen an amount sufficient for the valve poppet to block the escape port, DEF bleed fluid can no longer enter the bleed circuit. At that point, the biasing spring provides a force sufficient to raise the valve piston to its closed position, thereby raising fluid pressure within the pipe nipple and the receiver fitting. This increase in fluid pressure is sensed by the filling nozzle, which cuts off the flow of fluid into the DEF tank. 
     The retainer bushing has an upper straight internal female thread, a lower straight female thread, an upper straight external male thread, a pair of equiangularly-spaced external lugs at the bottom end thereof, and a pair of flats machined into the external surface of the retainer bushing that are positioned between the lugs and the straight external male thread. A receiver socket is threadably secured to the upper straight internal female thread of the retainer bushing, and a receiver fitting, to which a DEF supply line can be secured, is threadably installed in the receiver socket. With the receiver socket and the receiver fitting removed from the flow control module assembly, the assembly is inserted into a central aperture in an adapter cap that is secured to the filler neck of the DEF tank. The assembly is axially positioned so that lugs on the retainer bushing fit into opposed slots within the adapter cap. Between the opposed recesses are a pair of locking shelves, each with a stop at one end. When the retainer bushing is rotated 90 degrees in a clockwise direction (viewed from the top of the assembly), each lug moves beneath a locking shelf and against a stop. Once the retainer bushing has been rotated through the 90-degree angle, the lugs become trapped within the slots so that the retainer bushing cannot be lifted along its central axis. Once the retainer bushing has been rotated so that its lugs are positioned within beneath the locking shelves, a locking ring that is internally keyed to non-rotatably fit over a pair of flats of the retainer bushing, and which is also equipped a pair of diametrically-opposed downwardly-projecting tangs, each of which is angularly ramped at one end, is slipped over the top of the retainer bushing. The downwardly-projecting tangs fit into the now-vacant slots in the filler neck. The breather cap is then threadably secured to the external male thread on the retainer bushing, thereby securing the tangs of the locking ring within the slots. The retainer bushing with the attached flow control module can only be removed by unscrewing the collar, rotating the locking ring with a pin wrench, which causes the angularly-ramped tangs of the locking ring to self-eject from the slots so that the retainer bushing and the attached assembly can be removed from the filler neck. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a right-side elevational view of the fully-integrated, fluid flow-control module designed for installation within an ISO filler neck of a top-fill DEF tank in a fully-closed configuration, and with a fluid coupler fitting installed at the top thereof; 
         FIG. 2  is an isometric view of the flow-control module of  FIG. 1 ; 
         FIG. 3  is a rear elevational view of the flow-control module of  FIG. 1 , with the fluid coupler fitting removed, in a fully-open configuration; 
         FIG. 4  is a cross-sectional view of the flow-control module of  FIG. 3 , taken through section line  4 - 4 ; 
         FIG. 5  is a rear elevational view of the flow-control module of  FIG. 1 , with the fluid coupler fitting removed, in a fully-closed configuration; 
         FIG. 6  is a cross-sectional view of the flow-control module of  FIG. 1 , taken through section line  6 - 6  of  FIG. 5 ; 
         FIG. 7  is an isometric view of an adapter cap and of a wave damping sleeve, which is held in place by the adapter cap when it is screwed onto the external threads of an ISO filler neck of a DEF tank; 
         FIG. 8  is an exploded isometric view of the collar, the locking ring and the retainer bushing; 
         FIG. 9  is a rear elevational view of the flow control module of  FIG. 1 , installed within the wave damping sleeve and secured to the adapter cap which screws onto the external threads of an ISO filler neck of a DEF tank; 
         FIG. 10  is a cross-sectional view of the assembly of  FIG. 9 , taken through section line  10 - 10  of  FIG. 9 , in a fully-open configuration; 
         FIG. 11  is an isometric view of the valve plunger installed within the receiver fitting, the top of which was visible in  FIG. 2 ; 
         FIG. 12  is a cross-sectional view of the flow control module of  FIG. 1 , in a fully-closed configuration, secured to an adapter cap and installed within a wave damping sleeve; 
         FIG. 13  is an elevational view of a top-fill DEF tank having an ISO filler neck, with the adapter cap threadably secured to the ISO filler neck and the flow-control module secured to the adapter cap; and 
         FIG. 14  is a cross-sectional view of the assembly of  FIG. 10 , taken through section line  14 - 14  of  FIG. 13 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     This invention provides a fully-integrated pressureless flow-control module for top-fill diesel exhaust fluid (DEF) tanks. The module is considered pressureless because a filler nozzle, through which fluid enters the tank, does not cut off fluid flow into the tank in response to the sensing of pressure buildup within the tank. Pressure build up occurs only within the module, and it is this pressure build-up that is sensed by the nozzle and is responsible for the cut-off of fluid flow through the nozzle. The fully-integrated, fluid flow-control module designed for installation within a filler neck of a top-fill diesel exhaust fluid (DEF). The filler neck of the DEF tank conforms to ISO (International Organization for Standardization) Standard 22241-4:2009(E). The new fully-integrated pressureless fluid flow-control module for top-fill diesel exhaust fluid (DEF) tanks will now be described in detail, with reference to the attached drawing figures. It should be understood that although the drawing figures may not be drawn to exact scale, they are, nevertheless, intended to be illustrative of the form and function of the invention. If the item number comprises three digits, the left-most digit indicates the drawing figure number where the item is most completely visible. Likewise, if the item number comprises four digits, then the two left-most digits indicate the drawing figure where the item is most completely visible. 
     Referring now to  FIGS. 1, 2, and 3 , the flow-control module  100  includes a breather cap  101  that locks the flow-control module  100  within the mouth of the ISO filler neck. The breather cap  101  has a pair of diametrically opposed flats  102 -A and  102 -B (not visible in this view), thereby enabling the breather cap  101  to be rotated with a spanner wrench. A barbed connector  103  is anchored in a threaded port in the periphery of the breather cap  101 , which is in communication with the interior of the breather cap  101 . A resilient tube  104  connects the barbed connector  103  to a breather assembly  105 , which allows bi-directional flow of air in an out of the DEF tank in which the flow-control module  100  is installed. The breather cap  101  screws onto the externally-threaded top of a retainer bushing  106 . A receiver socket  107  screws into the top of the retainer bushing  106 , which is also internally threaded. A receiver fitting  108  screws into the receiver socket  107 . A pipe nipple  109  couples the retainer bushing  106  to a main valve body  111 . Only an annular center flange of the pipe nipple  109  is visible in this view. The center flange is equipped with diametrically opposed flats  110 -A and  110 -B (not visible in this view) that can also be engaged by a spanner wrench. The main valve body  111  encloses a spring-biased valve piston  112  which opens and closes to control fluid flow into the DEF tank via fill port  113 . Movement of the valve piston  112  is controlled by fluid pressure beneath the piston crown, which is, in turn, controlled by a bleed path within a bleed/float body  114  that is secured to the main valve body  111 . The bleed/float body  114  is equipped with a plurality of bleed fluid escape ports  115 . The bleed path within the bleed/float body  114  is controlled by the position of a fluid level float  116 , which is, in turn, is controlled by fluid level in the DEF tank. A plurality of airflow ports  119  in the bleed/float body  114 , enables equalization of air pressure within the float chamber as the fluid level float rises within the bleed/float body  114 . A threaded nut  118  secures the fluid level float  116  to a central control rod  117 . Both the fluid level float  116  and the central control rod move up and down in response to changes in fluid levels within the DEF tank. In  FIGS. 1, 2, and 5 , the valve piston  112  is in a closed position, while in  FIG. 3 , the valve piston  112  is in an open position. In  FIG. 3 , an O-ring seal  301  is installed on the valve piston  112  just below the piston crown. This O-ring seal  301  is used to more completely seal the valve seat and prevent leakage of DEF fluid into the DEF tank when the valve piston  112  is in its closed position. In  FIG. 5 , it will be noted that the retainer bushing  106  has a pair of opposed lugs  301 -A and  301 -B, which are employed to lock the flow control module into an adapter cap that is secured to the filler neck of the DEF tank. This will be shown and explained with reference to subsequent drawings. 
     Referring now to the cross-sectional view of  FIGS. 4 and 6 , the function of the internal components of the flow control module  100  will described. As previously mentioned, the breather assembly  105  provides for bidirectional air flow into and out of the DEF tank. As the DEF tank is being emptied and pressure within the tank is less than ambient air pressure, a spring-loaded poppet  401  opens to nearly equalize those pressures. On the other hand, when the tank is being filled, and pressure within the tank is greater than ambient air pressure, a spring-loaded breather piston  402  opens so that the two pressures can nearly equalize. The spring loading on both the poppet  401  and the breather piston  402  prevents absolute equalization of internal and external air pressures. 
     Still referring to  FIGS. 4 and 6 , a locking ring  403 , used to lock the flow control module within the adapter cap, is visible. It function will be explained with reference to subsequent drawings. In these cross-sectional views, it can be seen that the retainer bushing  106  screws onto an upper portion  404  of the pipe nipple  109 , and the top of the main valve body  109  screws onto a bottom portion  405  of the pipe nipple  109 . It will be noted that the center flange of the pipe nipple  109  has an upper annular surface  406 -U that provides a sealing surface for upper O-ring seal  407  and a lower annular surface  406 -L that provides a sealing surface for lower O-ring seal  408 . The use of O-ring seals negates the need for tapered threads on the threaded joints. It will be noted that the valve piston  112  incorporates an O-ring groove  410 , in which the piston O-ring  301  is installed. The valve piston  112  also has a skirt O-ring groove  411  and a skirt O-ring seal  412  installed within O-ring groove  411 . The skirt O-ring seal  411  prevents DEF fluid from leaking around the piston skirt an into the bleed circuit. Thus bleed fluid can enter the bleed circuit only through the bleed aperture  409  that is in the center of the piston crown. Until fluid level in the DEF tank has reached the level of the fluid level float  116 , the valve piston  112  is in the lowered position, and DEF fluid can enter the DEF tank through fill ports  113  and enter the bleed circuit through the bleed aperture  409 . As long as DEF bleed fluid can pass through the bleed aperture  409 , the biasing spring  413  provides a biasing force that is insufficient to raise the valve piston  112  to its closed position. Bleed fluid enters the biasing spring chamber  414  beneath the bleed aperture  409 . A partition  415  provides a floor for the biasing spring chamber  414 , and enables bleed fluid to escape from the chamber  414  and enter a lower bleed chamber  418  only through a bleed tube  416 . A control rod guide insert  417  functions as the floor of the lower bleed chamber  418 . It will be noted that the bleed tube  416  is sandwiched between the partition  415  and the guide insert  417 . As long as the fluid level float is in its lowest position, as shown in  FIG. 4 , DEF bleed fluid can pass from the lower bleed chamber  418  into an upper bleed chamber  419  through an escape port  420 , and then into the DEF tank through the bleed fluid escape apertures  115  in the circumferential wall  421  of the bleed/float body  114 . When fluid level in the DEF tank reaches the fluid level float  116 , the float  116  begins to rise, lifting the control rod  117  and the connector beam  422 . A valve poppet  423  is secured to the connector beam  422 , and it also is lifted by the rising fluid level float  116 . When the float  116  has risen an amount sufficient for the valve poppet  423  to block the escape port  420 , DEF bleed fluid can no longer enter the bleed circuit. At that point, fluid pressure beneath the valve piston  112  increases to a level that the biasing spring  413  provides a force sufficient to raise the valve piston  112  to its closed position, thereby raising fluid pressure within the pipe nipple  109  and the receiver fitting  108 . This increase in fluid pressure is sensed by the filling nozzle, which cuts off the flow of fluid into the DEF tank. In  FIG. 6 , the fluid level float  116  has risen, thereby causing the control rod  117 , the connector beam  422  and the valve poppet  423  to rise and block the escape port  420 . The valve piston  112  has closed in response to the sealing of the escape port  420 . 
     Still referring to  FIGS. 4 and 6 , it will be noted that O-ring seals are used extensively to seal joints. O-ring seal  424  is used to seal the vent cap  101  to the retainer bushing  106 , O-ring seal  425  is used to seal the joint between the main valve body  111  and the bleed/float body  114 . O-ring seal  426  is used on the valve poppet  423  to completely seal the escape port  420  when the valve poppet  423  is in its elevated and closed position. O-ring seals  427 ,  428 ,  429 ,  430  and  431  are used to seal joints in the fluid bleed circuit. 
     Referring now to  FIG. 7 , an adapter cap  702  having internal threads that are designed to threadably engage the external threads of a DEF tank filler neck conforming to ISO Standard 22241-4:2009(E), is shown. A lower portion of the flow-control module  100  fits within a wave damping sleeve  701  that will be secured to the ISO filler neck by the adapter cap  702 . The adapter cap  702  has a central aperture  703 . The adapter cap  702  is equipped with a pair of opposed slots  704 -A and  704 -B. Between the opposed slots  704 -A and  704 -B are a pair of locking shelves  705 -A and  705 -B, each with a stop at one end (only stop  706 -A is visible in this view; stop  706 -B, which is identical to stop  706 -A, is hidden). 
     Referring now to  FIG. 8 , only the breather cap  101 , the locking ring  403  and the retainer bushing  106  are shown in this view. It will be noted that the retainer bushing  106  has a pair of opposed lugs  301 -A and  301 -B. With the receiver socket  107 , the receiver fitting  108 , the breather cap  101  and the barbed connector  103 , the resilient tube  104  and the breather assembly  105  removed from the assembly of  FIGS. 1 through 6 , the flow-control module is inserted, float end first, into the central aperture  703  of the adapter cap  702  which will be threadably secured to the filler neck of the DEF tank (shown in  FIGS. 13 and 14 ). The assembly is axially positioned so that the lugs  301 -A and  301 -B on the retainer bushing  106  fit into opposed slots  704 -A and  704 -B within the adapter cap  702 . When the assembly is rotated 90 degrees in a clockwise direction (viewed from the top of the assembly), each lug  301 -A and  301 -B moves beneath a locking shelf  705 -A and  705 -B, respectively, and against a stop  706 -A and  706 -B, respectively. Before insertion of the assembly into the central aperture  703  of the adapter cap  702 , the assembly can be rotated 180 degrees so that lugs  301 -A and  301 -B engage opposed slots  704 -B and  704 -A, respectively. In other words, either orientation of the assembly works equally well. Once the retainer bushing  106  has been rotated through the 90-degree angle, the lugs  301 -A and  301 -B become trapped within the locking shelves  705 -A and  705 -B so that the retainer bushing and the flow-control module assembly to which it is attached, can no longer be lifted out of the adapter cap  702 . Once the flow-control module assembly has been rotated so that its lugs  301 -A and  301 -B are positioned against the stops  706 -A and  706 -B, the locking ring  403  which is equipped with internal keys  807 -A and  807 -B, that non-rotatably fit over flats  809 -A and  809 -B, respectively, of the retainer bushing  106 , and which is also equipped a pair of diametrically-opposed downwardly-projecting tangs  805 -A and  805 -B, each of which has an angular ramp  806 -A and  806 -B, respectively, at one end thereof, is slipped over the top of the retainer bushing  106 . The downwardly-projecting tangs  805 -A and  805 -B fit into the now-vacant slots  704 -A and  704 -B in the adapter cap  702 . The breather cap  101  and O-ring seal  424  are then slipped over the retainer bushing  106  and the internal female thread  802  of the breather cap  101  is threaded onto the straight external male thread  808  of the retainer bushing  106 , thereby securing the tangs  805 -A and  805 -B of the locking ring  403  within the slots  704 -A and  704 -B. It will be noted that an inner annular downward facing surface  803  of the breather cap  101  presses against an upper circumferential lip  707  of the adapter cap  702 . The retainer bushing  106  with the attached flow control module can be removed by unscrewing the breather cap  101 , which causes the locking ring  403  to rotate counterclockwise and self-eject from the slots  704 -A and  704 -B as each of the angularly-ramped tangs  805 -A and  805 -B contacts a corner of one of the stops  706 -A or  706 -B, thereby enabling the retainer bushing  106  and the flow-control module to which it is secured, to be removed from the adapter cap  702 . 
     Referring now to  FIG. 9 , a lower portion of the flow-control module  100  has been installed within a wave damping sleeve  701 , which will be secured to the ISO filler neck of the DEF tank by the adapter cap  702 . The flow-control module  100  is secured to the adapter cap  702 . 
     Referring now to  FIG. 10 , this cross-sectional view of the installed flow-control module  100  shows both the valve piston  112  and the valve poppet  423  in fully-open positions. It will be noted that a valve plunger  201  within the receiver fitting  108  is urged to a closed configuration by a biasing spring  1001 . The internal threads  1002  of the adapter cap  702  are visible in this view. 
     Referring now to  FIG. 11 , an isometric view of the valve plunger  201  installed within the receiver fitting shows how fluid can flow around it when it is in an open configuration. 
     Referring now to  FIG. 12 , this cross-sectional view of the installed flow-control module  100  is identical to that of  FIG. 10 , but with both the valve piston  112  and the valve poppet  423  in fully-closed positions. 
     Referring now to  FIG. 13 , the flow-control module  100  is shown installed in the ISO filler neck of a DEF tank  1301 . 
     Referring now to  FIG. 14 , this cross-sectional view shows the flow-control module  100  as installed within the ISO filler neck  1401  of the DEF tank  1301 . The adapter cap  702  is designed with internal threads  1002  that engage the external threads  1402  of the DEF tank filler neck  1401 . The wave damping sleeve  701 , which mitigates the effects of the sloshing of DEF fluid within the tank  1300 , slides into the ISO filler neck  1401 . A lower portion of the flow-control module  100  fits within the wave damping sleeve  701 , which has a cylindrical upper extension  1403  that fits within a cylindrical recess  1404  in the adapter cap  702 . An annular flange  1405  near the top of the wave damping sleeve  701  rests on the top of the filler neck  1401 . The adapter cap  702 , when threaded onto the filler neck external threads  1402 , compresses the annular flange  1405  between the mouth of the filler neck  1401  and the adapter cap  702 . 
     Although only a single embodiment of the invention is shown and described herein, it will be obvious to those having ordinary skill in the art that changes and modifications may be made thereto without departing from the scope and the spirit of the invention as hereinafter claimed.