Patent Publication Number: US-8967197-B1

Title: Remote actuator device for valve control knob on a tank

Description:
RELATED APPLICATION 
     This application claims priority to, and the benefit of, U.S. Provisional Application No. 61/594,217, filed on Feb. 2, 2012. The entire teachings of the above application are incorporated herein by reference. 
    
    
     BACKGROUND 
     Gas grills utilize fuel tanks (e.g., propane tanks) that are commonly situated in a lower cabinet or other position located below the grilling rack. As such, during operation of gas grills, users frequently must turn on and off the propane tanks, in order to reduce the likelihood of gas leakage when the grill is not in use. This often involves the user&#39;s routinely bending down to turn a knob on a valve that controls flow of the fuel from the fuel tank into the grill (hereinafter referred to as a “valve control knob”). For many grill users, this regular bending motion and reaching around to access the valve control knob is awkward and can cause stress and strain on the back (e.g., lower back) and arms, scraped knees, dirty clothes, as well as other discomforts and inconveniences resulting from reaching around or into a dark, sometimes dirty, cabinet. 
     Some gas grill makers have attempted to solve this problem by providing a secondary valve situated downstream of the valve control knob. The second valve is placed at a convenient location, such as on the front face of the grill. However, many users feel that this safety measure is insufficient, and that additional precaution is needed in the form of physically turning the valve control knob on the fuel tank (e.g., propane tank). Generally, due to the perceived risk of gas leakage, users feel uncomfortable with allowing the valve control knob to remain in an “on” position for an extended period of time during which the gas grill is not being used. As such, current solutions fail to provide a suitable mechanism for physically turning the valve control knob of a fuel tank (e.g., propane tank) of a gas grill between an “on” and an “off” position. 
     SUMMARY 
     There is a need for a device for actuating (i.e., physically moving) the valve control knob of a tank (e.g., a storage tank). The embodiments provided herein are directed toward solutions to address this and other needs, in addition to having other desirable characteristics that will be appreciated by one of skill in the art upon reading the present specification. 
     According to one embodiment, a remote actuator device is provided for a valve control knob on a tank. The remote actuator device includes a sheave formed of an upper flange, a lower flange, and a recess between the upper flange and the lower flange. An outward-facing portion of the lower flange forms a mating member for coupling with the valve control knob on the tank. The remote actuator device further includes a rotatable member configured to be placed at a position distal to the sheave. A looped drive element is situated around the rotatable member and in the recess of the sheave. A control device is coupled to the rotatable member and configured to actuate rotation of the rotatable member. Actuation by the control device of the rotatable member generates a rotation of the sheave capable of turning the valve control knob on the tank. 
     According to further embodiments, the remote actuator device further can include one or more housing elements enclosing one or more of the looped drive element, the sheave, or the rotatable member. The remote actuator device further can include a clamp for securing the sheave to the tank. The rotatable member can include a second sheave formed of an upper flange, a lower flange, and a recess between the upper flange and the lower flange. The looped drive element can include a band, a belt, a rope, a cable, a wire, or a chain. The control device can include a knob fixedly coupled to the rotatable member (e.g., by a stem, an axel, a rod, a pin, etc.). The remote actuator device can include a fastening device for securing the sheave to the tank. The fastening device can include a clamp. 
     According to further embodiments, the remote actuator device further can include a housing containing all or part of the rotating member, a cover containing all or part of the sheave, and a tubular housing member containing all or part of the looped drive element. The housing and the cover can be coupled at least in part by tubular housing member. The remote actuator device further can include one or more attachment mechanisms coupled to the housing. The one or more attachment mechanisms can enable the housing to be attached to, e.g., a grill. The one or more fastening mechanisms can include one or more of: a magnet, a hook, and a strap. The remote actuator device further can include a light source coupled to the housing containing all or part of the rotating member. One or more detection mechanisms further can be included and coupled to the light source for sensing whether the valve control knob is in a closed position or an open position. The light source can be configured to provide a first visual indication when the one or more detection mechanisms detect that the valve control knob is in the closed position and a second visual indication that is different from the first visual indication when the one or more detection mechanisms detect that the valve control knob is in the open position. For example, the first visual indication can include the light source being turned off (i.e., no illumination provided), and the second visual indication can include the light source being turned on (i.e., illumination provided). Alternatively, the first visual indication can include an illumination of a first color of light, and the second visual indication can include an illumination of a second color of light. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
       These and other characteristics of the present invention will be more fully understood by reference to the following detailed description in conjunction with the attached drawings, in which: 
         FIG. 1A  is a side view of an example embodiment of a remote actuator device that includes a sheave coupled by a looped drive element to a rotating element; 
         FIG. 1B  is a top view of the example embodiment of the remote actuator device of  FIG. 1A ; 
         FIG. 2  is a conventional storage tank; 
         FIG. 3  is a bottom view of one example embodiment of the sheave of  FIGS. 1A and 1B ; 
         FIG. 4A  is a side view of an example system in which the remote actuator device of  FIGS. 1A and 1B  is situated above the storage tank of  FIG. 2  for placement thereon; 
         FIG. 4B  is a side view of the system of  FIG. 4A , in which the remote actuator device is almost completely situated on the valve control knob of the storage tank; 
         FIG. 5  is a bottom view of another example embodiment of the sheave of  FIGS. 1A and 1B ; 
         FIG. 6A  is a cross-sectional side view of the example embodiment of the remote actuator device of  FIGS. 1A and 1B  further including one or more housing elements; 
         FIG. 6B  is a side view of the example embodiment of the remote actuator device of  FIG. 6A  that further includes the cover; 
         FIG. 6C  is a top view of the remote actuator device of  FIG. 6A  that further includes the cover; 
         FIG. 7  is a back view of an example system including the remote actuator device of  FIGS. 1A and 1B  situated on the storage tank of  FIG. 2  further with an example embodiment of a clamp situated thereon; 
         FIG. 8A  is a top view of the example system of  FIG. 7 ; and 
         FIG. 8B  is a top view of the example embodiment of the clamp of  FIG. 8A . 
     
    
    
     DETAILED DESCRIPTION 
     An illustrative embodiment described herein relates to a remote actuator device for actuating a valve control knob on a tank (e.g., a storage tank). The remote actuator device generally includes two ends, one of which comprises a sheave and a second of which comprises a rotating member coupled to a control device. The sheave is sized and dimensioned to be placed on the valve control knob of the tank (e.g., storage tank), and the control device is configured to be placed (e.g., mounted) to a convenient location distal to the sheave, e.g., at a location remote from the valve control knob of the tank (e.g., storage tank). The rotating member and the sheave are coupled by a looped drive element, such that the control device can be used to actuate turning motion of the valve control knob from the remote position of the control device. 
     For example, in embodiments where the remote actuator device is used for remotely turning the valve control knob of a fuel tank (e.g., a propane tank), the control device can be placed on the front face of a gas grill at an easily accessible location. This allows the operator or owner of the grill to easily turn the valve control knob of the fuel tank (e.g., propane tank) without having to bend over and reach down to the valve control knob. 
       FIGS. 1 through 8B , wherein like parts are designated by like reference numerals throughout, illustrate example embodiments of a remote actuator device for a valve control knob of a tank (e.g., a storage tank). Although the various embodiments will be described with reference to the examples illustrated in the figures, it should be understood that many alternative forms can be embodied. One of skill in the art will appreciate many different ways to alter the parameters of the embodiments disclosed, such as the size, shape, or type of elements or materials, in a manner still in keeping with the spirit and scope of the present disclosure. 
       FIG. 1A  depicts a side view of a remote actuator device  10  for a valve control knob of a tank.  FIG. 1B  depicts the remote actuator device of  FIG. 1A  from a top view. The remote actuator device  10  includes a sheave  12  formed of an upper flange  14 , a lower flange  16 , and a recess  18  between the upper flange  14  and the lower flange  16 . The remote actuator device  10  also includes a rotatable member  20  that is independent the sheave  12 . As one non-limiting example, the rotatable member  20  can form a second sheave (as depicted in the example embodiment of  FIG. 1 ), which includes an upper flange  22 , a lower flange  24 , and a recess  26  therebetween. 
     The rotatable member  20  and the sheave  12  are coupled to one another by a looped drive element  28 . More specifically, the looped drive element  28  is situated around the rotatable member  20  and in the recess  18  of the sheave  12 . As a few non-limiting examples, the looped drive element  28  can be a band, a belt, a rope, a cable, a wire, a chain, or any other suitable looped drive element capable of generating rotation in the sheave  12  based on actuated rotation of the rotatable member  20 . In the example embodiment of  FIG. 1  which provides that the rotatable member  20  is a second sheave, the looped drive element  28  is situated in the recess  26  of the second sheave. The looped drive element  28  synchronizes rotational motion of the sheave  12  and the rotatable member  20 . Accordingly, rotation of the rotatable member  20  generates rotation of the sheave  12  (e.g., at an equal angular rate or a different angular rate). 
     A control device  30  is coupled to the rotatable member  20  for actuating rotational motion of the rotatable member  20 , and thus also of the sheave  12 . As one non-limiting example, the control device  30  can be a rotatable knob or handle coupled to rotatable member  20  by a shaft  32 , such that rotation of the control device  30  causes the rotatable member  20  to turn. The control device  30  thus can be used to actuate rotational motion of the sheave  12  despite being placed at a position distal to the sheave  12 . 
     The sheave  12  is configured to securely couple with a valve control knob of a tank (e.g., a storage tank).  FIG. 2  depicts one example of a storage tank  34  from a perspective view. The storage tank  34  can be any conventional or suitable storage tank whose contents include a flowable material, such as one or more gasses (e.g., propane, helium, and any other suitable gas), one or more liquids (e.g., water, liquid fuel, etc.), one or more slurries, and/or any other flowable material(s). In illustrative embodiments, the storage tank  34  is a propane tank for use in a gas grill. The storage tank  34  generally includes a valve  36  and a chamber body  44 . In the example embodiment of  FIG. 2 , the valve  36  includes an outlet channel  38 , a stem  40 , and a valve control knob  42  that controls flow of contents from the chamber body  44  to the outlet channel  38 . The valve control knob  42  generally is controlled by a turning motion. 
     Accordingly, to enable coupling between the valve control knob  42  and the remote actuator device  10 , an outward-facing (e.g., downward facing, in the orientation of  FIG. 1 ) portion of the lower flange  16  of the sheave  12  forms a mating member with the valve control knob  42  on the storage tank  34 . For example,  FIG. 3  depicts the sheave  12  from a bottom view. As depicted in the example embodiment of  FIG. 3 , the lower flange  16  includes a protrusion  46  extending downward and having a shape that forms a cavity  48  that substantially conforms to some or all of the shape of the valve control knob  42 . Accordingly, the cavity  48  of the lower flange  16  forms a female mating member configured to receive the valve control knob  42 . 
       FIGS. 4A and 4B  depict the sheave  12  receiving the valve control knob  42  of the storage tank  34 . In  FIG. 4A  the sheave  12  is being lowered toward the storage tank  34 , and in  FIG. 4B  the valve control knob  42  is almost completely received by the lower flange  16 . As depicted in the example embodiments of  FIGS. 4A and 4B , as the sheave  12  is lowered onto the storage tank  34 , the valve control knob  42  enters by the cavity  48 , e.g., with a hand-in-glove fit. Accordingly, once the lower flange  16  of the sheave  12  is placed on the valve control knob  42 , the control device  30  can be used to remotely actuate (e.g., remotely turn) the valve control knob  42 . 
     One of skill in the art will appreciate that the particular design depicted in  FIG. 3  is illustrative and in no way limits the embodiments disclosed herein. Rather, the shape and size of the protrusion  46  cavity  48  can be selected to form a mating member with any valve control knob on any suitable tank (e.g., storage tank). Furthermore, it should be appreciated that the protrusion  46  alternatively can be formed of two or more non-contiguous protrusions that are shaped, sized, and positioned on the lower flange  16  to adequately provide a rotational force against the valve control knob  42 . 
     For instance,  FIG. 5  depicts another example embodiment of the outward-facing portion of the lower flange  16  of the sheave  12 . In the embodiment of  FIG. 5 , the protrusion  46  forms the cavity  48  generally resembling a triangle with rounded ends, for receiving the valve control knob  42  of the storage tank  34  of  FIG. 2 . Situated at the three rounded ends of the triangle shape can be three support cups  50  that dip up (e.g., into the page, as oriented in  FIG. 5 ). The support cups  50  are shaped to receive the ends of the three appendages on the valve control knob  42 . As such, the support cups  50  form walls that tightly fit around the ends of the three appendages on the valve control knob  42  and thus are capable of applying a rotational force against the valve control knob  42 . 
     According to further embodiments, some or all of the remote actuator device  10  can be enclosed in one or more housing elements. For example,  FIGS. 6A ,  6 B, and  6 C depict the remote actuator device  10  with various housing elements from a cross-sectional view, a side view, and a top view, respectively. In the example embodiment of  FIGS. 6A through 6C , the remote actuator device  10  further includes a cover  52  disposed over the upper flange  14 . The cover  52  extends over and is coupled to a cap  54  that can be coupled to a stem  56  extending upward from the upper flange  14 . The cap  54  can be formed of a low-friction material and can effectively server as a washer and bearing for preventing buildup of friction between the stem  56  and the cover  52  or between the upper flange  14  and the cover  52 . The cover  52  can be fixedly coupled with the cap  54  using any suitable mechanism (e.g., adhesives, fastening mechanisms, etc.), as would be readily appreciated by one of skill in the art. 
     The cover  52  can couple with a first end of a flexible, tubular housing member  58 , e.g., via a connection piece  60 . As just one non-limiting example, the tubular housing member  58  can be a hose with a nozzle and the connection piece  60  can be a threaded channel affixed to the cover  52  for receiving the nozzle on the hose. A second end of the tubular housing member  58  can couple with a housing  62  containing the rotatable member  20 , e.g., via a second connection piece  64 . In the example embodiment of  FIGS. 6A through 6C , the housing  62  completely encloses the rotatable member  20 , as depicted. To reduce friction between the housing  62  and the rotatable member  20 , a layer of low-friction material (not shown) can be situated between the housing  62  and the rotatable member. For example, a top washer (not shown) can be situated between the housing  62  and the upper flange  22 , and a bottom washer (not shown) can be situated between the housing  62  and the lower flange  24 . Furthermore, the shaft  32  can pass through a bearing (not shown) in order to reduce frictional forces between the shaft  32  and the housing  62 . To control the tension of the looped drive element  28 , a tensioner, spring, or other tension adjuster (not shown) may be included in the housing  62 , as would be appreciated by one of skill in the art upon reading the present specification. The housing  62  can have a magnetized face  66  (e.g., formed of a magnet, situated above a magnetic insert, etc.) substantially opposite the face of the housing  62  from which the control device  30  extends. The magnetized face  66  can be useful, for example, in mounting the control device  30  at a convenient location distal the valve control knob 42 . Alternatively or additionally, a mounting hook or strap  68  can be included for hanging the control device  30  at such a location. 
     In addition, in some further embodiments, the housing  62  includes a battery compartment (not shown) for receiving a battery and an LED light or other light source ( 82 ) that is powered by the battery. The LED light or other light source can be included for the purpose of alerting an operator of the grill whether the valve  36  is in an open or closed position. Accordingly, one or more detection mechanisms (e.g., flow sensors, pressure sensors, etc.) can be included for determining whether the valve  36  is in an open or a closed position. The one or more detection mechanisms ( 80 ) can be coupled to the LED light or other light source, e.g., in such a way that the one or more detection mechanisms control the LED light or other light source. For example, using one or more circuit elements (e.g., a switch, etc.), the LED light or other light source can be turned off if the one or more detection mechanisms detect that the valve  36  is in a closed position and the LED light or other light source can be turned on if the one or more detection mechanisms detect that the valve  36  is in an open position, as would be appreciated by one of skill in the art upon reading the present specification. 
     As depicted in  FIG. 6C , the tubular housing member  58  can include a divider  70  (e.g., forming a wall) for separating the two sides of the looped drive element  28  and ensuring that the looped drive element  28  does not come into contact with itself during operation. Other separation components are possible. For example, two guide cables could be included within the length of the tubular housing member  58 , each of which can house a different side of the looped drive element  28 . Yet other alternatives are possible, and will be appreciated by one of skill in the art upon reading the present specification. All such embodiments are encompassed by the present disclosure. 
     The remote actuator device  10  further can include a clamp for securing the sheave  12  to the valve control knob  42 . For example,  FIG. 7  depicts a back view of a system including the remote actuator device  10  and such a clamp  72 . As depicted, the clamp  72  can include a handle  74  and an upper appendage  76   a  and a lower appendage  76   b  that clip on to the stem  56  of the sheave  12  and the stem  40  of the storage tank  34 , respectively.  FIG. 8A  further depicts the system of  FIG. 7  from a top view.  FIG. 8B  depicts a top view of the clamp  72  in isolation from the remote actuator device  10 . As can be seen from  FIGS. 8A and 8B , the upper and lower appendages  76   a ,  76   b  of the clamp  72  each includes an indentation  78  for fitting around the stem  56  of the sheave  12  and the stem  40  of the storage tank  34 , respectively. 
     In the example embodiment of  FIGS. 7 and 8A  the remote actuator device  10  is depicted absent the housing elements of  FIGS. 6A through 6C . However, one of skill in the art will appreciate upon reading the present specification that the clamp  72  similarly can be utilized with the remote actuator device  10  when the housing elements of  FIGS. 6A through 6C  are included. For example, the upper appendage  76   a  can clip over the cap  54  and onto the stem  56  of the sheave  12 . 
     The upper flange  14 , the lower flange  16 , and the stem  56  generally can all be one single continuous piece of material (e.g., plastic, metal, and the like). Alternatively, one or more of these pieces can be manufactured separately and adjoined during construction of the remote actuator device  10  (e.g., by adhesives, fasteners, and the like). The cap  54  can be formed of any suitable (e.g., low-friction) material, including plastic, metal, and the like. The cover  52  for the sheave  12  and the housing  62  containing the rotatable member  20  can be any suitable material (e.g., plastic, rubber, metal, and the like). The tubular housing member  58  and/or the divider  70  can be formed of a durable, low-friction material, such as polytetrafluoroethylene. Alternatively or additionally to utilizing a low-friction material, the tubular housing member  58  and/or divider can include a fluoropolymer coating on any inward-facing surfaces that may come into contact with the looped drive element  28 . In the example embodiment of  FIGS. 1 through 8B  in which the control device  30  is a knob, the knob can be constructed of any suitable material (e.g., wood, plastic, rubber, metal, and the like). In general, the materials provided herein are exemplary and in no way limiting of the disclosed embodiments. Rather, one of skill in the art will readily appreciate a wide variety of alternative materials for implementing the remote actuator device  10  upon reading the present specification. All such alternatives and modifications are contemplated within the scope of the disclosure. 
     The illustrative embodiments provided herein offer numerous benefits. For example, using the remote actuator device  10 , owners and operators of gas grills (e.g., which utilize fuel from a propane tank) can more easily turn on and off the propane tank (or other fuel tank) remotely, without having to bend down or reach around or inside an internal cabinet section of the gas grill housing the propane tank (or other fuel tank). Additionally, in embodiments providing an LED light or other light source situated on the housing  62  at a visible location, the LED light or other light source can provide users of the grill with the convenience of knowing with greater certainty that the valve  36  is in an open position or a closed position. This can help reduce doubt in the mind of the user and/or assist in reducing risk of gas leakage when the grill is not in use. One of skill in the art will appreciate numerous other benefits and usages upon reading the present specification. 
     Numerous modifications and alternative embodiments of the present invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the best mode for carrying out the present invention. Details of the structure may vary substantially without departing from the spirit of the present invention, and exclusive use of all modifications that come within the scope of the appended claims is reserved. It is intended that the present invention be limited only to the extent required by the appended claims and the applicable rules of law. 
     It is also to be understood that the following claims are to cover all generic and specific features of the invention described herein, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.