Patent Publication Number: US-7913722-B2

Title: Watercraft fueling apparatus and methods

Description:
TECHNICAL FIELD 
     This disclosure relates to devices and methods of fueling watercraft designed to help prevent the spillage of fuel that might result, for example, from back splash from a fill tube or overfilling a fuel tank. 
     BACKGROUND INFORMATION 
     Fueling watercraft commonly results in a spillage of fuel that can harm marine life, generate a risk of fire, and damage the watercraft. For example, because fuel vapors are heavier than air they can rapidly spread into compartments of the watercraft. These vapors may be ignited upon reaching open flames or by starting the engine(s) or operating an electrical switch. In addition, a sheen of fuel sometimes seen on surface water near watercraft is a contaminant to people in or using the water and has a damaging impact on marine life. For these reasons, such spillage may result in stiff fines assessed to an operator. 
     The causes of spillage are many. By way of example, if the tank is overfilled, fuel may spill out of a fill tube connected to the tank or escape from a vent tube that provides venting for the tank. In addition, sudden movement of the watercraft may cause spillage, such as movement generated by a wave from a passing watercraft or a passenger jumping between the watercraft and a dock. Thus, fueling a watercraft is more challenging than fueling a still vehicle on land. 
     Various devices and methods have been proposed to prevent spillage. For example, the operator may purposefully underfill the fuel tank, e.g., pumping only 25 gallons of fuel knowing the watercraft has a 30-gallon tank. Unfortunately, this may result in reduced range. As another example, the operator may wedge a rag between the nozzle and a fuel port. However, this may not only leave the operator with the task of properly disposing of a contaminated rag, but may also prevent the fuel vapors from properly escaping. Yet another example is the fuel overflow prevention device disclosed in U.S. Pat. No. 5,894,809 to Grigaitis, which discloses a reservoir interposed between a fuel tank vent tube and an air vent port. The reservoir collects overflowing fuel from the fuel tank and returns it to the fuel tank. However, Grigaitis is unable to capture fuel exiting from a top of the fill tube, such as back splash. In addition, fuel may actually exit Grigaitis&#39; air vent port before the operator is aware that the tank is full. 
     SUMMARY OF THE DISCLOSURE 
     According to one embodiment, a fuel fill port on a surface of a watercraft comprises an opening in the fill port, a removable cap covering and sealing said opening, a main fill tube, a catch basin, an overflow tube, and an opening from the catch basin to the main fill tube positioned to permit drainage of the contents of the catch basin into the main fill tube. The main fill tube has an open top end positioned proximate to and below said opening. The main fill tube also has a distal end for connecting to a fuel tank and is sized to accept therein a fuel dispensing nozzle inserted through said opening. The catch basin has an open top positioned below said opening such that back splash of fuel from the main fill tube is collected within the catch basin. The overflow tube is connected between the fuel tank and the catch basin such that excess fuel in the fuel tank is conveyed via the overflow tube into the catch basin. 
     According to another embodiment, a fuel fill port comprises a housing for installation on a surface of a watercraft. The housing has an opening proximate the surface. A cap is removably coupled to the housing for sealing the opening. A fill tube extends through the housing and a first end of the fill tube is sized to accept a fuel dispensing nozzle and a second end of the fill tube is adapted for connection to a fuel tank. A catch basin is defined by a bottom portion of the housing and is positioned relative the opening and the first end of the fill tube such that backflow of fuel from the fill tube collects within the catch basin. A fill vent extends through the housing, and a first end of the fill vent is positioned relative the first end of the fill tube to allow excess fuel from the fuel tank to flow into the catch basin and a second end of the fill vent is adapted for connection to the fuel tank. A passage from the catch basin to the fuel tank guides fuel from the catch basin to the fuel tank. 
     According to still another embodiment, a method fuels a fuel tank of a watercraft through a fill port, which comprises an access opening, a main fill tube connected to a fuel tank having an open top end positioned proximate to and below said opening, a catch basin having an open top and positioned peripherally from said main fill tube, an overflow tube connected between said fuel tank and said catch basin, and a drain opening from said catch basin to said main fill tube. The method for fueling the fuel tank of a watercraft through the fill port involves accepting fuel into said fuel tank via said main fill tube, retaining a back splash of fuel from said main fill tube in said catch basin, draining said back splash of fuel retained in said catch basin into said fuel tank through said drain opening and said main fill tube, venting air displaced in said fuel tank through said overflow tube and externally from said watercraft, transporting any excess of fuel in said fuel tank to said catch basin via said overflow tube, retaining said excess of fuel from said fuel tank in said catch basin, and draining said excess of fuel retained in said catch basin into said fuel tank through said drain opening and said main fill tube. 
     Additional aspects and advantages of this disclosure will be apparent from the following detailed description of preferred embodiments, which proceeds with reference to the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a pictorial view of a watercraft having a fuel fill port according to one embodiment. 
         FIG. 2  is a side view of the fuel fill port of  FIG. 1 . 
         FIG. 3  is a top plan view of a fuel fill port according to another embodiment. 
         FIG. 4  is a flow chart for a method of fueling a watercraft fuel tank, according to one embodiment. 
         FIG. 5  is a partial cross-section of the watercraft and fuel fill port of  FIG. 1  illustrating fuel flow and displaced air flow. 
         FIG. 6  is a partial cross-section of the watercraft and fuel fill port of  FIG. 1  illustrating air flow when a removable cap is installed. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     With reference to the above-listed drawings, this section describes particular embodiments and their detailed construction and operation. The embodiments described herein are set forth by way of illustration only. Those skilled in the art will recognize in light of the teachings herein that variations can be made to the embodiments described herein and that other embodiments are possible. No attempt is made to exhaustively catalog all possible embodiments and all possible variations of the described embodiments. 
     For the sake of clarity and conciseness, certain aspects of components or steps of certain embodiments are presented without undue detail where such detail would be apparent to those skilled in the art in light of the teachings herein and/or where such detail would obfuscate an understanding of more pertinent aspects of the embodiments. 
     As one skilled in the art will appreciate in view of the teachings herein, certain embodiments may be capable of achieving certain advantages, including by way of example and not limitation one or more of the following: (1) preventing spillage of fuel during watercraft fueling; (2) preventing the contamination of waterways resulting from fuel spillage; (3) preventing harm to marine organisms and people caused by spillage; (4) avoiding fines assessed to a watercraft operator resulting from spillage; (5) minimizing the risk of fire due to fuel spillage; (6) avoiding damage to the watercraft based on spillage; (7) providing for increased range of the watercraft by more fully filling a fuel tank; (8) minimizing the risk of confusing the fuel fill port with a water fill port; (9) capturing fuel exiting from a top of a fill tube; and (10) preventing fuel from exiting a vent port. These and other advantages of various embodiments will be apparent upon reading the following. 
       FIG. 1  illustrates a fuel fill port  10  installed on a surface  20  of a watercraft  22 . While fueling, a fuel filler tube  30  transports fuel from the fill port  10  to a tank  40 . An overflow tube  50  allows air and fuel vapors displaced by the fuel to escape via the fill port  10 . In addition, the overflow tube  50  allows excess fuel from the tank  40  to collect in the fill port  10  as further described with reference to  FIGS. 2-6 . After fueling, a cap  60  can cover and seal the fill port  10 . To prevent pressure from building within the tank  40 , the fill port  10  permits air and fuel vapors to escape from the tank  40  via a breather vent line  70  and a breather port  72 . While the breather port  72  is shown installed in a cabin house  80 , the breather port  72  may be installed in other locations, such as the surface  20 , deck  24 , stern  26 , bow  28 , or a port or starboard side of the watercraft  22 . Installing the breather port  72  above the fuel fill port  10  may help prevent fuel from exiting the breather port  72  by allowing the user to see when the tank  40  is full. 
     Referring now to  FIGS. 2 and 3 , the fill port  10  includes a housing  90  for installation on the surface  20 . The housing  90  may be cast molded from metal, such as brass, steel, aluminum, and alloys. Alternatively, the housing  90  may be formed from other materials, such as plastic, and may take shapes other than that shown. In order to seal the housing  90  to the surface  20 , a gasket  92  may be provided. The gasket  92  may be constructed from, for example, elastomer materials such as rubber, neoprene, cork, or polytetrafluorethylene (PTFE).  FIG. 2  illustrates the housing  90  anchored to the watercraft  22  according to one embodiment. A bolt  96  is threaded into the housing  90  to secure the housing  90  to a securing skirt  94 . In addition, other mounting devices and methods may be used, such as a clamp, pin, or rivet. Alternatively, the housing  90  may snap into the securing skirt  94 .  FIG. 3  illustrates the housing  90  secured to the watercraft  22  according to another embodiment. As shown in  FIG. 3 , securing holes  98  are provided through a lip  12  of the fill port  10 . Bolts (not shown) inserted through securing holes  98  help mount the fill port  10  flush to the surface  20 . Other fasteners, such as screws, rivets, and wedge anchors may also be used. 
     The cap  60  is removably coupled to the housing  90  for covering and sealing an opening  100 . In one embodiment, a gasket  62  and a ridge  64  are provided to ensure a tight seal. The gasket  62  may be constructed from elastomer materials such as rubber, neoprene, cork, or polytetrafluorethylene (PTFE). As illustrated in  FIG. 2 , threads  66  are formed on the cap  60  and sized to mate with threads  93  formed on the housing  90 . However, the cap  60  may be coupled to the housing  90  using other methods. For example, one or more pins may be formed on the cap  60  for mating with slots formed in the housing  90  or vice versa. In addition, the cap  60  may be sized to snugly fit within the opening  100  so that friction holds the cap  60  to the housing  90 . The cap  60  may be substantially larger than a water port (not shown) on the watercraft  22 . The size difference helps avoid the hazards and costs associated with inadvertently pouring fuel into a water tank (not shown) in the watercraft  22 . In addition, the cap  60  may include identifying colors or symbols to signify fuel, such as DIESEL FUEL ONLY or GASOLINE ONLY. The cap  60  may be cast molded from metal, such as steel, aluminum, and alloys. Alternatively, the cap  60  may be formed from other materials, such as plastic. 
     In one embodiment, a main fill tube  110  extends through a bottom portion  120  of the housing  90 . The main fill tube  110  may have an open top end  130  positioned proximate to and below the opening  100  and sized to accept a fuel dispensing nozzle (not shown) inserted through the opening  100 . A distal end  140  of the main fill tube  110  is adapted for connection to the tank  40 . For example, threads  142  may be provided and sized to accept various fuel filler tubes  30  and coupling sizes. Additionally, a band clamp (not shown) may be fitted over the fuel filler tube  30  and tightened to secure the fuel filler tube  30  to the main fill tube  110 . Further, the fuel filler tube  30  may be sized to form a friction fit between the fuel filler tube  30  and the main fill tube  110 . The main fill tube  110  may be formed from the same or different material as the housing  90 . A main fill tube cover (not shown) may be hinged to open the top end  130  of the main fill tube  110  to prevent fuel from escaping the main fill tube  110  when the watercraft  22  is in use. 
     A catch basin  150  is defined by the bottom portion  120  of the housing  90  and sidewalls  122  of the housing  90 , according to one embodiment. The catch basin  150  is positioned relative the opening  100  and the open top end  130  of the main fill tube  110  so that backflow or back splash of fuel from the main fill tube  110  collects within the catch basin  150 . For example, the catch basin  150  may have an open top  160  positioned below the opening  100 . The catch basin  150  may be positioned peripherally from the main fill tube  110  and may partially or entirely surround the main fill tube  110 . The amount of fuel that the catch basin  150  holds may depend on several factors, such as the fuel fill rate, human reaction time, and typical back splash volumes. In some embodiments, the catch basin  150  holds between about 8 ounces and about 32 ounces of fuel, but this can vary based upon the application. 
     According to one embodiment, a fill vent  170  extends through the bottom portion  120  of the housing  90  and is substantially parallel to the main fill tube  110 . An open top end  180  of the fill vent  170  may be positioned relative the open top end  130  of the main fill tube  110  to allow excess fuel from the tank  40  to flow into the catch basin  150  via the fill vent  170 . For example, the open top end  180  of the fill vent  170  may be below the open top end  130  of the main fill tube  110 . According to some embodiments, the fill vent  170  is located between about 0.125 and about 0.75 inches below the open top end  130  of the main fill tube  110 , but this can vary based upon the application. In addition, the fill vent  170  may be positioned near a bottom portion  152  of the catch basin  150  and may extend in a direction toward an open top  160  of the catch basin  150 . Alternatively, the fill vent  170  may extend into the catch basin  150  laterally. In one embodiment, a bottom end  190  of the fill vent  170  is adapted for connection to the tank  40 . For example, the fill vent  170  may be in communication with the overflow tube  50  such that excess fuel in the tank  40  is conveyed via the overflow tube  50  into the catch basin  150 . In another embodiment, the overflow tube  50  is connected between the tank  40  and the housing  90  proximate the catch basin  150 , such as through the side wall  122  or the bottom portion  120 . Threads  192  may be provided and sized to accept various overflow tubes  50  and coupling sizes. Alternatively, a band clamp (not shown) may be fitted over the overflow tube  50  and tightened to secure the overflow tube  50  to the fill vent  170 . In addition, the overflow tube  50  may be sized to form a friction fit between the overflow tube  50  and the fill vent  170 . The fill vent  170  may be formed from the same or different material as the housing  90 . The overflow tube  50  may be formed from metals such as steel, brass, iron, or alloys or formed from other materials, such as plastics. 
     In one embodiment, the catch basin  150  is able to guide fuel to the tank  40 . For example, one or more openings  200  may be provided from the catch basin  150  to the main fill tube  110  and positioned to permit drainage of the contents of the catch basin  150  into the main fill tube  110 . The main fill tube  110  in turn can transport the contents to the tank  40  via the fuel filler tube  30 . In another embodiment, one or more openings (not shown) may be provided from the catch basin  150  to fill the vent  170  to permit drainage of the contents of the catch basin  150  into the tank  40  via the overflow tube  50 . The fuel filler tube  30  may be formed from the same or different material as the overflow tube  50 . 
     A breather vent  210  may be positioned within the opening  100  and in communication with the breather port  72  ( FIG. 1 ) to permit air and fuel vapors to flow from the tank  40  externally from the watercraft  22  via the breather port  72  when the cap  60  seals the opening  100 . For example, the breather vent  210  may extend through the housing  90 , such as through the side wall  122  or the bottom portion  120 , and an open top end  212  of the breather vent  210  may terminate proximate the opening  100 . A bottom end  214  of the breather vent  210  may be adapted for connection to the breather port  72 . For example, threads  216  may be provided and sized to accept various breather vent lines  70  and coupling sizes. Alternatively, a band clamp (not shown) may be fitted over the breather vent line  70  and tightened to secure the breather vent line  70  to the breather vent  210 . Further, the breather vent line  70  may be sized to form a friction fit between the breather vent line  70  and the breather vent  210 . The breather vent  210  may be formed from the same or different material as the housing  90 . The breather vent line  70  may be formed from metals such as steel, brass, iron, or alloys or formed from other materials, such as plastics. 
     A back splash cover  220  may be positioned within the catch basin  150  and above the fill vent  170  to prevent excess fuel from escaping from the open top  160  of the catch basin  150 . In one embodiment, the back splash cover  220  is approximately 0.5 inches below the open top end  130  of the main fill tube  110  and approximately 1.0 inches below the open top end  212  of the breather vent  210 . However, the dimensions can vary based upon the application. A breathable material, such as a mesh of metal, plastic, or cloth, may be used to make the back splash cover  220 . However, the back splash cover  220  could also be a solid material with holes (not shown) for drainage formed therein. For example, the back splash cover  220  could be integral with the housing  90 . In addition, the back splash cover  220  could be secured to the housing  90  or resting on a lip formed in the housing  90 . The back splash cover  220  could be made from the same or different material as the housing  90 . 
     With reference to  FIG. 3 , a fuel fill port  10 ′ according to another embodiment has securing holes  98  provided through the lip  12 ′ of the fill port  10 ′. (in  FIG. 3  reference numerals with the prime symbol, e.g.,  10 ′, indicate elements similar to those of the same name in the first embodiment, i.e., the fuel fill port  10 ). The lip  12 ′ may be sized to provide adequate room to accommodate fasteners installed through securing holes  98  and be stiff enough to prevent motion of the fill port  10 ′ relative to the watercraft  22 . As previously described, the main fill tube  110 ′ and the breather vent  210 ′ extend through the back splash cover  220 ′. However, the fill vent  170 ′ is underneath the back splash cover  220 ′. As can be seen by comparing  FIGS. 2 and 3 , the relative positions of the main fill tube  110 ′, the breather vent  210 ′ and the fill vent  170 ′ may vary. For example, the breather vent  210 ′ is shown integrally formed with the sidewall  122  of the housing  90  in  FIG. 2 , but is shown detached from the sidewall  122  of the housing  90  in  FIG. 3 . 
     Referring now to  FIGS. 4 ,  5 , and  6 , a method  400  of fueling the watercraft  22  utilizing the fuel fill port  10  or similar fuel fill port, according to one embodiment, is described. After removing the cap  60 , a nozzle or other fuel dispensing object may be inserted through opening  100  and into the open top end  130  of the main fill tube  110 . At step  405 , the tank  40  accepts incoming fuel  230  from the nozzle via the main fill tube  110 . While fueling the watercraft  22 , the fuel  230  may exit the main fill tube  110  from the open top end  130 . For example, the fuel  230  may reflect off a portion of the main fill tub  110 . In addition, sudden movement of the watercraft  22 , such as that caused by a wave or a passenger jumping off the watercraft  22 , may cause the fuel  230  to splash back from the main fill tube  110 . At step  410 , the catch basin  150  retains back-splash fuel  240  from the main fill tube  110 . For example, the back-splash fuel  240  can pass through the back-splash cover  220  into the catch basin  150 . At step  415 , one or more openings  200  drains the back-splash fuel  240  retained in the catch basin  150  into the tank  40  via the fuel filler tube  30 . 
     Pressure may build in the tank  40  as the fuel  230  enters and causes the displaced air  250  (e.g., air and fuel vapors) to exit the tank  40 . At step  420 , the overflow tube  50  vents the displaced air  250  in the tank  40  into the catch basin  150  and then externally from the fuel fill port  10  and the watercraft  22 . 
     At step  425 , the overflow tube  50  transports the excess fuel  260  from the tank  40  to the catch basin  150 , such as when the tank  40  is overfilled. At step  430 , the catch basin  150  retains the excess fuel  260  from the tank  40 . In one embodiment, the back-splash cover  220  is positioned within the catch basin  150  above the fill vent  170  to prevent the excess fuel  260  from escaping the open top  160  of the catch basin  150 . The back splash cover  220  may be solid or non-porous directly above the fill vent  170 . At step  435 , one or more openings  200  drain the excess fuel  260  retained in the catch basin  150  into the tank  40  via main fill tube  110  and the fuel filler tube  30  or holds it there until the tank  40  can accept it. 
     With reference to  FIG. 5 , when the cap  60  covers and seals opening  100 , pressure may build within the tank  40  and the fuel fill port  10 . For example, the fuel  230  may be colder than the ambient air temperature, especially if the fuel  230  was pumped from an underground storage tank or the fuel  230  cooled overnight. As the fuel  230  adjusts to the ambient air temperature, pressure may build within the tank  40  and the fuel fill port  10 . In addition, as the watercraft  22  moves and jostles the fuel  230  within the tank  40 , the fuel  230  may release vapors that build pressure within the tank  40  and the fuel fill port  10 . The breather vent  210 , the breather vent line  70 , and the breather port  72  vent displaced the air  250  in the tank  40  and the fuel fill port  10  to the environment. 
     The fuel fill port  10  may be used on various watercrafts  22 , such as a yacht, recreational boat, personalized watercraft (e.g., jet-ski™), pleasure craft, jet boat, fishing boat, sail boat, military ship, amphibious landing craft, cruise ship, or shipping vessel. In addition, the fuel fill port  10  may be used on a vehicle, such as a car, motorcycle, train, ship, or aircraft. Further, the fuel fill port  10  may be installed when the watercraft  22  is being fabricated or the fuel fill port  10  may be retrofit into an existing watercraft. While the fuel filler tube  30  and the overflow tube  50  are shown connected directly to the tank  40 , any number of devices, such as a fuel pump, may be installed between the fuel fill port  10  and the tank  40 . 
     The terms and descriptions used herein are set forth by way of illustration only and are not meant as limitations. Those skilled in the art will recognize that many variations can be made to the details of the above-described embodiments without departing from the underlying principles of the invention. The scope of the invention should therefore be determined only by the following claims (and their equivalents) in which all terms are to be understood in their broadest reasonable sense unless otherwise indicated.