CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

[0001] This application claims priority to and the benefit of U.S. Provisional Patent

Application No. 62/364,199, filed July 19, 2016 and the contents of which are incorporated herein by reference in their entirety.

FIELD

[0002] The present invention relates generally to the field of liquid additives for use in fuel systems.

BACKGROUND

[0003] Certain substances within fuel systems, which may be used within an engine system, may compromise the functionality and integrity of the system. For example, carboxylates (soaping) are a particular concern with Modular Common Rail Systems (MCRS) related fuel systems and can cause premature filter plugging, injector sticking, and pump or engine failures. The cost of repairs due to the carboxylates can be very high, and the frequency and severity of such repairs are likely to worsen as more MCRS-related fuel systems are used.

[0004] In order to prevent the issues and problems caused by the carboxylates and maintain the integrity of the fuel system, automated or manual approaches can be used. However, automated approaches (e.g., using soap filters) can be complicated and complex to implement, and manual approaches (e.g., manually adding additives) may be inaccurate.

[0005] When considering automated approaches, for example, soap filters can be introduced on or near the engine. In order to be effective, additional filters would be needed in addition to the existing stage 1 and 2 filters. However, due to space constraints, adding more filters often will not be feasible or practical. Alternatively, a soap filter could be introduced on the bulk fuel system, but there is no way to guarantee that the soap filter will actually be installed or utilized at the assembly or installation sites.

[0006] Alternative to the soap filter, additives may be introduced into the fuel system to maintain the integrity of the fuel system. For example, it was found that in an example fleet of approximately 120 trucks, there were 30 injector failures over the span of a few months. When additives were introduced into the bulk tanks of the fleet, the fleet stopped having injector failures within a few months. However, once the additives were no longer introduced, the fleet had 42 injector or pump failures over a period of four to six months.

[0007] Additives can be manually added or dispensed by the customer, technician, fueling station personnel, or operator. However, the system for adding additives can be complex and inaccurate, as the operator also has to manually estimate the volume of the fuel and lube, measure the additive in attempt to obtain the correct ratio between additive and fuel, and mix the additive directly into the fuel tank. It also can be difficult to manage the amount of additive required for bulk tanks for multiple engines of varying technology levels. Additionally, manually adding the additive may create an environmental concern since the operator may accidently spill additive on the ground while the operator is adding the additive into the fuel supply.

[0008] Further, even if the volumes are measured, there is no way to ensure that the operator adds the additive in the first place or to control the amount of additive added. For example, the operator may forget to dispense or replenish the additive due to mere oversight. If the operator does remember to replenish the additive, there is no way to ensure that the correct amount of additive is added, resulting in an improper ratio between fuel and additive. Too much additive or additive that is added too frequently may degrade the various parts of the engine due to the highly elevated additive concentrations. Too little additive may compromise integrity of the fuel system (and engine).

[0009] Furthermore, the operator may also accidentally add the incorrect additive to the fuel supply. This mistake may occur in particular when multiple different additives are needed. Since the ratio of additive to fuel depends on which additive is used, the engine may have an incorrect ratio of additive to fuel. For example, 1 part additive to 5000 parts fuel is needed for a diesel fuel and injector cleaner (DFIC), while 1 part additive and 1000 parts fuel is needed for other additives. Use of the incorrect additive may also cause the tank vent inlet to become plugged, which may restrict the engine fuel supply and cause the additive to become semisolid, requiring a heater or coolant lines.

[0010] As another alternative to the above, the fuel supply could be changed to eliminate the carboxylate concerns. However, this change is not always possible in particular regions of the world where there are limited fuel supply choices available. As a further alternative, a pump and electric motor control could be used to "dose" the fuel system over time. However, such a system does not ensure that the correct ratio between fuel and additives.

SUMMARY OF THE INVENTION

[0011] Various embodiments provide for an additive system that includes a holding tank containing a fluid and a dispensing tank containing an additive. The holding tank and the dispensing tank are fluidly connected such that a pressure differential is created between the holding tank and the dispensing tank when the fluid is removed from the holding tank. The pressure differential draws a premeasured amount of the additive from the dispensing tank into the fluid in the holding tank.

[0012] Other embodiments provide for a method of dosing and dispensing additive into a holding tank of an engine. The method includes, during operation of the engine, removing at least a portion of the fluid from the holding tank, creating a pressure differential between the holding tank and a dispensing tank, and drawing a premeasured amount of the additive from the dispensing tank and into the holding tank. The holding tank contains the fluid and the dispensing tank contains additive.

[0013] These and other features, together with the organization and manner of operation thereof, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, wherein like elements have like numerals throughout the several drawings described below. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1 A is a schematic view of an additive system according to one embodiment.

[0015] FIG. IB is a perspective view of the additive system of FIG. 1 A.

[0016] FIG. 2A is a schematic view of an additive system according to another embodiment.

[0017] FIG. 2B is a perspective view of the additive system of FIG. 2A.

[0018] FIG. 3 is a schematic view of a dispensing tank according to one embodiment.

[0019] FIG. 4 is a cross-sectional view of an additive system according to one embodiment.

[0020] FIG. 5 is a cross-sectional view of a dispensing tank according to another

embodiment.

[0021] FIG. 6A is a perspective view of a dispensing tank according to yet another embodiment.

[0022] FIG. 6B is a cross-sectional view of the dispensing tank of FIG. 6A.

[0023] FIG. 7 is a cross-sectional view of a dispensing tank according to still another embodiment.

[0024] FIG. 8 is a flow diagram of an example method of dosing and dispensing additive according to one embodiment.

DETAILED DESCRIPTION

[0025] Referring to the figures generally, the various embodiments disclosed herein relate to an additive system and a fluid additive dosing and dispensing method for simply, easily, and accurately dosing and dispensing additive into a holding tank, which may prevent issues within a fuel system and protect the engine system against contaminants, including, but not limited to, carboxylates. Due to the simplicity of the additive system and the minimal number of components (e.g., the number of components is reduced compared to previous automated systems and methods), the additive system and method described herein are low cost, yet still effective and allow for accurate dosing. Furthermore, the present additive system and method are reliable and simple and ensure that the correct amount of additive is added to the fluid (fuel, for example).

[0026] As described further herein, the additive system includes a holding tank and a dispensing tank. A pressure differential created at the interface between the holding tank and the dispensing tank (e.g., the tank vent inlet of the holding tank) draws additive from the dispensing tank to the holding tank. The predetermined ratio between the size of the dispensing tank compared to the size of the holding tank determines the amount of additive that is moved into the holding tank, thus dispensing a premeasured amount of additive. Accordingly, the correct amount of additive is added to the fluid.

[0027] The present additive system and method can be used within a variety of different industrial applications and may be used with large holding tanks. For example, the present additive system and method may be used with haul trucks, excavators, shovels, or front loaders.

[0028] The present additive system and method are particularly useful within MCRS systems since MCRS systems are particularly sensitive to soaps and the inclusion of additives reduces or eliminates the soap. The present additive system and method may also be useful within vent filters due to contaminant concerns with vent filters. The present additive system and method can be easily and inexpensively integrated with vent filters by providing plumbing into the vent filter system.

[0029] It is understood that the present additive system and method can be used for dispensing any additive into any type of storage tank. For the sake of clarity, a liquid additive (e.g., a fuel additive) for dispensing into a fluid (e.g., fuel) located within a holding tank of a vehicle or automobile is referred to herein.

Additive System

[0030] As shown in FIGS. 1 A-2B and described further herein, an additive system 20 includes a holding tank 50 with fluid 52 and a dispensing tank 30 with additive 32. The holding tank 50 and the dispensing tank 30 are configured such that the dispensing tank 30 dispenses the proper amount of additive 32 into the holding tank 50, where the proper amount of additive 32 depends on the size ratio between the dispensing tank and the holding tank.

Holding Tank

[0031] As shown in FIGS. 1 A and 2A, the holding tank 50 comprises a container or compartment that is configured to hold or contain fluid 52 (e.g., fuel) and is fluidly connected to the dispensing tank 30.

[0032] The holding tank 50 may have an air inlet circuit with an air vent inlet or a tank vent inlet 62 attached to a first portion of the air vent inlet pipe 64. The tank vent inlet 62 allows air 22 to enter into the holding tank 50 as the fluid 52 is disposed (or burned in the case of a vehicle tank). However, due to the connection of the dispensing tank 30 to the air vent inlet pipe 64, additive 32 from the dispensing tank 30 is first drawn into the holding tank 50 through the tank vent inlet 62 before any air 22 enters the holding tank 50 through the tank vent inlet 62. The tank vent inlet 62 may optionally include a filter element (not shown). According to one embodiment, the only air inlet into the holding tank 50 is the tank vent inlet 62.

[0033] The holding tank 50 includes a breather vent outlet 66 with a check valve 68 and an outlet pipe 67. The breather vent outlet 66 may comprise an outward vent that allows air 22 to be released from the holding tank 50 through the outlet pipe 67 as the holding tank 50 is filled, allowing the holding tank 50 to be refilled more quickly. The check valve 68 prevents air from entering into the holding tank 50 and is unidirectional. Accordingly, the holding tank 50 may be quickly filled with fluid 52 or the proper amount of additive 32 from the dispensing tank 30. The holding tank 50 may optionally include a return fluid circuit to direct fluid 52 back into the holding tank 50.

Dispensing Tank

[0034] As shown in FIG. 3, the additive or dispensing tank 30 is configured to hold or contain an additive 32 and is fluidly connected to the holding tank 50. The dispensing tank 30 may optionally be positioned between and fluidly connected to the tank vent inlet 62 and a second portion of the air vent inlet pipe 64. The additive 32 can be dispensed into the holding tank 50 through the tank vent inlet 62 (via the first portion of the air vent inlet pipe 64) or through the return fluid circuit.

[0035] The dispensing tank 30 can be refilled through a variety of different ways. For example, the dispensing tank 30 may have an additive inlet 42 for additive 32 to be poured into the dispensing tank 30 through. According to one embodiment as shown in FIGS. 4-6B, the additive inlet 42 may include a removable cover or cap 44. Accordingly, when the cap 44 is removed, the additive 32 may be poured into the dispensing tank 30 through the additive inlet 42 until the dispensing tank 30 is full. When the dispensing tank 30 is full, the cap 44 can be reinstalled onto the additive inlet 42.

[0036] According to an embodiment shown in FIGS. 6A-6B, the dispensing tank 30 may include a quick disconnect or quick fill port 38 to allow the dispensing tank to be refilled with additive 32 with a pressure "fast fill" method. The additive 32 may flow quickly through the port 38 and fill the dispensing tank 30 when the inner region of the dispensing tank 30 is under a certain or predetermined amount of pressure (in particular negative pressure). The dispensing tank 30 may further include a liquid level shutoff control inside the dispensing tank 30 that automatically stops the flow of additive 32 when the dispensing tank 30 is full. The liquid level shutoff control may function similarly to the mechanisms within a toilet bowl fill stop device or a carburetor float mechanism.

[0037] According to yet another embodiment as shown in FIG. 7, the dispensing tank 30 may include a body portion 37 and a removable additive canister 36. The removable additive canister 36 is configured to contain the additive 32 and be removable from and reattachable to the rest of the dispensing tank 30. For example, the removable additive canister 36 may be directly removable from and reattachable to the body portion 37 of the dispensing tank 30. During servicing, the canister 36 may be removed and either refilled or replaced with a new canister that contains the additive 32. The canister 36 can be made out of a variety of materials, including but not limited to steel, aluminum, or plastic. [0038] The dispensing tank 30 may include an additive outlet 46 connected to the first portion of the air vent inlet pipe 64 of the holding tank 50 and fluidly connected to the holding tank 50. The additive 32 may flow out of the dispensing tank 30 through the additive outlet 46, into the air vent inlet pipe 64, and finally into the holding tank 50.

[0039] As shown in FIGS. 4-5, 6B, and 7, the dispensing tank 30 may include pickup-style inner piping 48 positioned inside the inner region of the dispensing tank 30. The inner piping 48 extends between and provides a fluid path between the additive outlet 46 and a lower portion of the inner region of the dispensing tank 30. For example, according to one embodiment and as shown in FIG. 7, the inner piping 48 may extend into an inner area and to the bottom portion of the removable additive canister 36 (and optionally additionally through an inner area of the body portion 37). The inner piping 48 requires all of the additive 32 to be drawn and removed from the dispensing tank 30 (and moved into the holding tank 50) before any air 22 can move through the additive outlet 46 and into the air vent inlet pipe 64 of the holding tank 50. Accordingly, the additive 32 is completely emptied from dispensing tank 30 and the inner piping 48 ensures that a full dose of additive 32 has been added or provided into the fluid 52 in the holding tank 50.

[0040] According to one embodiment as shown in FIGS. 3-7, the dispensing tank 30 may have a tank vent filter 34 and an air vent inlet 31 to allow atmospheric air 22 to enter into the dispensing tank 30 through the air vent inlet 31 as the additive 32 moves out from the dispensing tank 30 (through the additive outlet 46) and into the holding tank 50. The tank vent filter 34 may throttle the flow of the air 22 such that the air 22 moving through the tank vent filter 34 flows relatively slowly into the dispensing tank 30 through the air vent inlet 31.

[0041] A variety of different types of additives 32 may be used, depending on the need of the engine or vehicle. For example, soap-removing additives may be used in order to remove carboxylates.

[0042] The amount or dose of additive 32 that is added into the fluid 52 in the holding tank 50 depends on the ratio between the size of the holding tank 50 and the size of the dispensing tank 30. Accordingly, the size of the dispensing tank 30 is based on the size of the holding tank 50 and the desired ratio of additive 32 to fluid 52 in order to provide the correct ratio of additive 32 to fluid 52. For example only, a haul truck may require a ratio of 1 : 5000 of additive 32 to fluid 52. The holding tank 50 could be 1000 gallons and the dispensing tank 30 would accordingly be 0.2 gallons in order to supply the correct ratio of additive 32 to fluid 52.

[0043] Optionally, an alarm system may be included with the dispensing tank 30 that places the system in a limp mode (such that the associated engine runs in a reduced level) if no additive 32 is present.

The Holding Tank and the Dispensing Tank

[0044] As shown in FIGS. 1 A-2B, the holding tank 50 and the dispensing tank 30 can be positioned relative to each other in a variety of different configurations. For example, as shown in FIGS. 1 A-1B, the dispensing tank 30 may be mounted to the top of or above the holding tank 50 such that the dispensing tank 30 is higher than the tank vent inlet 62 of the holding tank 50. This configuration may make refilling easier on a genset with belly tank, for example.

Alternatively, as shown in FIGS. 2A-2B, the dispensing tank 30 may be mounted to or on the side of the holding tank 50 such that the dispensing tank 30 is lower than the tank vent inlet 62 of the holding tank 50. This configuration may make refilling easier on a haul truck, for example.

Method of Dosing and Dispensing the Additive

[0045] According to one embodiment as shown in FIG. 8, when the holding tank 50 is full of fluid 52 and the dispensing tank 30 is full of additive 32, the engine can be started (110), which starts to burn the fluid 52 (112) and reduces the fluid level 54 of the fluid 52 within the holding tank 50 (114). As the fluid level 54 within the holding tank 50 decreases (e.g., as the volume of fluid 52 decreases), a pressure differential between the holding tank 50 and the dispensing tank 30 is created (116), which results in or creates a suction or vacuum at the interface (e.g., the tank vent inlet 62 of the holding tank 50) between the holding tank 50 and the dispensing tank 30 (assuming the check valve 68 of the breather vent outlet 66 is functioning properly). This pressure differential (and the resulting suction or vacuum) between the holding tank 50 and the dispensing tank 30 draws on the tank vent inlet 62 and thus draws a premeasured amount of the additive 32 from the dispensing tank 30, through the inner piping 48 (if included in the dispensing tank 30), through the additive outlet 46 of the dispensing tank 30, through the first portion of the air vent inlet pipe 64, and into the holding tank 50 through the tank vent inlet 62 (118) to provide the correct ratio of fluid 52 to additive 32. Once the additive 32 is removed from the dispensing tank 30 and fully dosed and dispensed into the holding tank 50, makeup air 22 from the atmosphere flows through the air vent inlet 31 of the dispensing tank 30, through the dispensing tank 30, through the inner piping 48 (if included in the dispensing tank 30), through the additive outlet 46, through the first portion of the air vent inlet pipe 64, and finally into the holding tank 50 through the tank vent inlet 62 (120).

[0046] According to another embodiment, the dispensing tank 30 is installed on a return fluid line of the return fluid circuit of the holding tank 50 that leads fluid back into the holding tank 50. The additive 32 is added to the holding tank 50 in a similar manner to the above-described embodiment, however, when the engine is restarted, the return fluid flow through the return fluid line will dose the holding tank 50 with additive 32. Every time the holding tank 50 is filled from "empty" and the engine is started, the return fluid in the return fluid circuit introduces the additive into the holding tank by pushing the additive 32 into the holding tank 50, which doses the holding tank 50 with the prescribed amount of additive 32 to obtain the prescribed ratio of additive 32 to fluid 52. The prescribed amount of additive 32 that is dosed into the holding tank 50 depends on the relative size of the holding tank 50 and the dispensing tank 30 (the respective sizes of the holding tank 50 and the dispensing tank 30 are selected depending on the desired "dose ratio" of additive 32).

[0047] In various embodiments, regardless as to whether additive 32 is used within the additive system 20, the engine will still function. Therefore, it is not required to include additive 32, and additive 32 only needs to be included with engines that require additive 32. Accordingly, additive 32 can be used and included on an as-needed basis, depending on the vehicle and only where the engine needs additive 32 (rather than the entire site via a main fuel bulk tank). For example, High Pressure Injection (HPI) Injectors may not require the use of additives 32. [0048] Each time the holding tank 50 is refilled, the dispensing tank 30 may also be refilled at the same time, if additive 32 is desired.

[0049] It is understood that the various components, configurations, and features of the different embodiments of the additive system 20 and additive dosing method may be combined according to the desired use and configuration.

[0050] The term "connected" and the like as used herein mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another.

[0051] References herein to the positions of elements (e.g., "top," "bottom," "above," "below," etc.) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.

[0052] It is important to note that the construction and arrangement of the various exemplary embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention.