RELATED APPLICATIONS

[0001] This application relates to and claims priority benefits from U.S. Provisional Patent Application No. 61/534,605 entitled "Reservoir Assembly," filed September 14, 2011, which is hereby incorporated by reference in its entirety.

FIELD OF EMBODIMENTS OF THE INVENTION

[0002] Embodiments of the present invention generally relate to a reservoir assembly configured to retain a fluid, and, more particularly, to a reservoir assembly configured to sense a level of the fluid retained within the reservoir assembly.

BACKGROUND

[0003] In various applications, reservoirs are used to retain and store fluid that is to be used at a later time. Vehicles, such as automobiles, include various devices that use fluids. For example, a typical automobile includes a reservoir that retains and stores brake fluid used in connection with brake systems. The automobile may also utilize another reservoir for storing windshield wiper fluid. A driver may activate a windshield cleaning operation in which a certain amount of windshield wiper fluid within the wiper reservoir is channeled to or otherwise deposited on the windshield of the automobile.

[0004] Typically, a driver or operator desires to know the level of fluids within various reservoirs or containers. By knowing when the fluids are low, the driver or operator may replenish the fluids. Otherwise, the driver or operator may discover that a particular fluid is depleted without any forewarning.

[0005] Many fluid reservoirs have multiple retaining chambers. Fluid within one chamber may recede to a lower level than another chamber. However, a liquid level may be measured with respect to a chamber retaining the higher level of fluid, which may lead a driver or operator to erroneously believe that there is more fluid within the reservoir. Accordingly, the driver or operator may discover that fluid levels are depleted quicker than expected.

SUMMARY OF EMBODIMENTS OF THE INVENTION

[0006] Certain embodiments provide a reservoir assembly configured to retain a fluid. The reservoir assembly may include a main body having upstanding walls integrally formed with a base defining a retaining chamber configured to retain fluid. A divider wall may separate the retaining chamber into first and second sub- chambers. The reservoir assembly may also include a float member slidably secured to the divider wall. The float member may be configured to float to a lowest level of fluid within the first and second sub-chambers. The float member may include first divider-engaging members that slidably engage a first portion of the divider wall, and second divider-engaging members that slidably engage a second portion of the divider wall. The first portion of the divider wall may be perpendicularly-oriented with respect to the second portion of the divider wall.

[0007] The divider wall may include an upper panel integrally connected to an expanded support extending from the base. The first portion of the divider wall may include interior edges of the upper panel that define a central vertical slot that extends from a top of the upper panel to the expanded support. The second portion of the divider wall may include planar ridges extending outwardly from the expanded support.

[0008] Each of the first and second divider-engaging members may include at least one set of opposed ribs defining a slot therebetween.

[0009] The reservoir assembly may also include a magnetic sensor secured to a portion of the main body. The float member may include a magnet. The magnetic sensor may be configured to sense a magnetic field generated by the magnet. The magnet may be embedded within the float member.

[0010] The reservoir assembly may also include a central processing unit in communication with the magnetic sensor. The magnetic sensor may be configured to output a fluid-level signal to the central processing unit based on movement of the magnet in relation to the magnetic sensor. [0011] The float member may include an upper joint that joins opposed straddling legs having buoyant blocks at distal ends. The float member may be symmetrical about a central vertical axis

[0012] The first divider-engaging members may be proximate a top of the float member. The second divider-engaging members may be proximate a bottom of the float member.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

[0013] Figure 1 illustrates an isometric top view of a fluid reservoir assembly, according to an embodiment.

[0014] Figure 2 illustrates an isometric top internal view of a fluid reservoir assembly, according to an embodiment.

[0015] Figure 3 illustrates a transverse cross-sectional view of a fluid reservoir assembly, according to an embodiment.

[0016] Figure 4 illustrates a top view of a fluid reservoir assembly, according to an embodiment.

[0017] Figure 5 illustrates a bottom view of a fluid reservoir assembly, according to an embodiment.

[0018] Figure 6 illustrates a transverse cross-sectional view of a fluid reservoir assembly when fluid is above an expanded support of a divider wall, according to an embodiment.

[0019] Figure 7 illustrates a transverse cross-sectional view of a fluid reservoir assembly when fluid is proximate top of an expanded support of a divider wall, according to an embodiment.

[0020] Figure 8 illustrates a transverse cross-sectional view of a fluid reservoir assembly when fluid within first and second sub-chambers varies, according to an embodiment.

[0021] Figure 9 illustrates a transverse cross-sectional view of a fluid reservoir assembly when fluid is at a low level within a first sub-chamber and at a top of a divider wall in a second chamber, according to an embodiment. [0022] Figure 10 illustrates an isometric top internal view of a fluid reservoir assembly, according to an embodiment.

[0023] Figure 11 illustrates a transverse cross-sectional view of a fluid reservoir assembly, according to an embodiment.

[0024] Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of "including" and "comprising" and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

[0025] Figure 1 illustrates an isometric top view of a fluid reservoir assembly 10, according to an embodiment. The fluid reservoir assembly 10 includes a main body 12 having upstanding walls 14 integrally formed or otherwise connected to a base 16. The main body 12 may be formed of plastic, metal or the like. A securing protuberance 17, such as a tab, spur, stud, beam, panel, or the like, may extend from a portion of the upstanding walls 14 or the base 16. The securing protuberance 17 may be configured to allow the fluid reservoir assembly 10 to be secured to a frame, panel, or the like, such as within a vehicle.

[0026] The walls 14 and the base 16 define a retaining chamber 18 configured to retain fluid, such as water, wiper fluid, oil, brake fluid, or the like. As shown, the upper end 20 of the main body 12 may be open, thereby allowing fluid to be poured into the retaining chamber 18. Optionally, a cover may be positioned over the main body 12 in order to ensure that fluid within the retaining chamber 18 does not spill out of the fluid reservoir assembly 10. The cover may include an inlet with a removable cap that allows an operator to pour fluid into the retaining chamber 18. Optionally, the cover may simply be configured to move between closed and open positions in order to allow an operator to pour fluid into the retaining chamber 18.

[0027] A divider wall 22 is positioned within the retaining chamber 18 and spans between opposed wall portions 24 and 26. The divider wall 22 separates the retaining chamber 18 into first and second sub-chambers 28 and 30. The divider wall 22 includes a central vertical slot 32 formed therethrough. The central vertical slot 32 may extend from a top of the divider wall 22 to an expanded support that extends from the base 16. As explained below, the divider wall 22 is configured to slidably retain a float member. An upper joint of the float member is configured to be slidably retained within the central vertical slot 32, with straddling legs on either side of the divider wall 22.

[0028] Fluid outlets 34 and 36 are formed through the base 16 within the first and second sub-chambers 28 and 30, respectively. The fluid outlets 34 and 36 may be tubular openings that are configured to allow fluid to pass out of the first and second sub-chambers 28 and 30. The fluid outlets 34 and 36 may include or be operatively connected to valves (not shown) that are selectively engaged between open and closed positions. When in the closed positions, the valves prevent fluid from passing out of the sub-chambers 28 and 30. When opened, the valves allow fluid to pass out of the sub-chambers 28 and 30.

[0029] A magnetic sensor 38 may be secured to a portion of the upstanding walls 14. As shown in Figure 1, the magnetic sensor 38 may be positioned on the wall portion 24 and is generally aligned with a plane occupied by the divider wall 22. However, the magnetic sensor 38 may be positioned at various other portions of the main body 12. The magnetic sensor 38 may be located outside of the retaining chamber 18. Optionally, the magnetic sensor 38 may be positioned within the retaining chamber 18. Also, alternatively, the magnetic sensor 38 may have a portion that extends into the retaining chamber 18 and a portion outside of the retaining chamber 18.

[0030] The magnetic sensor 38 may be any type of sensor configured to detect the presence and/or strength of a magnetic field. The magnetic sensor 38 may be configured to detect changes in a magnetic field. For example, the magnetic sensor 38 may be a non-contact magnetic sensor, such as a Hall effect sensor, a magnetometer, a magnetoresistive sensor, or various other types of magnetic proximity sensors.

[0031] The magnetic sensor 38 may be in communication with a central processing unit (CPU) 40 that receives output signals from the magnetic sensor 38. However, the magnetic sensor 38 may not necessarily be in communication with the CPU 40. The magnetic sensor 38 may be connected to the CPU 40 through a wired or wireless connection. The CPU 40 may detect signals from the magnetic sensor 38 and determine a fluid level within the retaining chamber 18 based on the received signals. The CPU 40 may correlate different output signals received from the magnetic sensor 38 with different fluid levels, for example. The CPU 40 may provide information regarding the fluid level on a display, for example.

[0032] The CPU 40 may include control logic provided on an integrated circuit (IC). The control logic may include various electronic components based on the desired functionality of the CPU 40. The CPU 40 may be any type of processor, microprocessor, integrated circuit, or the like. The instructions on which the CPU 40 operates may be stored on a tangible and non-transitory (for example, not a transient signal) computer readable storage medium, such as a memory. The memory may include one or more computer hard drives, flash drives, RAM, ROM, EEPROM, and the like. Alternatively, one or more of the sets of instructions that direct operations of the CPU 40 may be hard- wired into the logic of the CPU 40.

[0033] Figure 2 illustrates an isometric top internal view of the fluid reservoir assembly 10, according to an embodiment. A float member 42 is slidably secured on the divider wall 22. The float member 42 includes an upper joint 44 integrally connected to opposed straddling legs 46 that straddle the divider wall 22. Buoyant blocks 48 may extend from distal ends of the straddling legs 46. The float member 42 may be integrally formed as a single piece. For example, the float member 42 may be formed of a buoyant material, such as Nitophyl-M, plastic, open or closed-cell foam, rubber, or the like. As shown, the float member 42 may be symmetrical about one or more planes in which the divider wall 22 bisects the float member 42. For example, the float member 42 may be symmetrical about a plane in which the divider wall 22 resides.

[0034] The upper joint 44 includes divider-engaging members 50 extending from front and rear faces. Each divider-engaging member 50 may include opposed ribs, tabs, or the like defining a slot therebetween. Internal edges 52 of the divider wall 22 that define the central vertical slot 32 (shown in Figure 1) are positioned within the slots of the divider-engaging members 50.

[0035] The divider wall 22 includes an upper panel 60 integrally connected to an expanded support 62 extending upwardly from the base 16 of the main body 12. Planar ridges or fins 64 extend outwardly from either side of the expanded support 62. Each buoyant block 48 includes inwardly-directed divider- engaging members 66 (hidden from view in Figure 2), such as opposed ribs, tabs, or the like defining a slot therebetween, that slidably engage the planar ridges 64. As such, the divider-engaging members 50 of the upper joint 44 and the opposed divider- engaging members 66 of the buoyant blocks 48 allow the float member 42 to slide up and down the divider wall 22 in the directions of arrows A. The divider-engaging members 50 of the upper joint 44 slidably engage the upper panel 60 of the divider wall 22, while the opposed divider-engaging members 66 of the buoyant blocks 48 at lower portions of the float member 42 engage the planar ridges 64, which are generally perpendicular to the upper panel 60. The float member 42 engages the divider wall 22 at top and lower ends, with engagement of the divider wall 22 by the top divider-engaging members 50 being orthogonal to the engagement of the divider wall 22 by the bottom divider-engaging members 66. As such, the float member 42 maintains a stable orientation with respect to the divider wall 22 over a full range of sliding movement.

[0036] Figure 3 illustrates a transverse cross-sectional view of the fluid reservoir assembly 10. The float member 42 includes a magnet 70, which may be embedded therein. The magnet 70 may be located in or proximate the upper joint 44 between the straddling legs 46. The magnet 70 produces a magnetic field. The magnetic field is detected by the magnetic sensor 38. As the magnet 70 moves toward and away from the magnetic sensor 38 in the directions of arrows A, the output of the magnetic sensor 38 changes accordingly. The changes in the output of the magnetic sensor 38 may be detected by the CPU 40 (shown in Figure 1) and correlated with different fluid levels.

[0037] As shown in Figure 3, in particular, the divider-engaging members 50 are located at a top of the float member 42, while the divider-engaging members 66 are located at a bottom of the float member 42. The divider-engaging members 50 are aligned with and proximate the upper panel 60 of the divider wall 22, while the divider-engaging members 66 are offset from the plane of the upper panel 60 and spaced equidistant from, and on either side, of the plane of the upper panel 60. As shown, the divider-engaging members 66 are parallel to the planar ridges 64, but perpendicular to the upper panel 60. Conversely, the divider-engaging members 50 are parallel to the upper panel 60, but perpendicular to the planar ridges 64. Accordingly, the float member 42 is stabilized with respect to a vertical axis X of the main body 12, which prevents the float member 42 from laterally shifting, pivoting, or rotating relative to the vertical axis X. That is, the divider-engaging members 50 and 66 ensure that the float member 42 remains upright at all times, no matter the level of fluid within the retaining chamber 18.

[0038] As noted, the divider-engaging members 50 are positioned at a top of the float member 42, while the divider-engaging members 66 are positioned at a bottom of the float member. The vertical distance Di between the divider-engaging members 50 and the divider-engaging members 66 exceeds a distance D ₂ between the vertical axis X and centers of the buoyant blocks 48. It has been found that this relationship allows the float member 42 to slide up and down in the directions of arrows A without binding. In short, locating the divider-engaging members 50 and 66 at opposite ends of the float member 42 provides smoother, more stable movement of the float member 42 with respect to the divider wall 22.

[0039] Figure 4 illustrates a top view of the fluid reservoir assembly 10. The divider-engaging members 50 may include opposed ribs 80 defining a slot 82 therebetween. Internal edges 84 of the upper panel 60 are retained between the ribs 80 within the slot 82. Thus, as shown in Figure 4, the divider-engaging members 50 are aligned with the plane of the upper panel 60. [0040] Figure 5 illustrates a bottom view of the fluid reservoir assembly 10. For the sake of clarity, the base 16 of the main body 12 is not shown in Figure 5. Each divider-engaging member 66 may include opposed ribs 88 defining a slot 90 therebetween. The planar ridges 64 of the expanded support 62 are retained between the ribs 88 within the slots 90. Thus, as shown in Figure 5, the divider-engaging members 66 are aligned with the plane in which the planar ridges 64 reside, which is orthogonal to the plane of the upper panel 60 shown in Figure 4.

[0041] Referring to Figures 4 and 5, more or less divider-engaging members 50 and 66 may be used. Additionally, the float member 42 may include divider-engaging members that engage portions of the divider wall at various other angles.

[0042] Figure 6 illustrates a transverse cross-sectional view of the fluid reservoir assembly 10 when fluid 100 is above the expanded support 62 of the divider wall 22, according to an embodiment. The float member 42 floats with the level of the fluid 100. When the fluid level is high, as shown in Figure 6, a stop 102, such as a wall, beam, bar, arch, or the like, prevents further upward motion of the float member 42. As shown, the stop 102 may be positioned at or proximate the top of the assembly 10. Accordingly, the stop 102 prevents the float member 42 from ejecting from the retaining chamber 18

[0043] Figure 7 illustrates a transverse cross-sectional view of the fluid reservoir assembly 10 when a level of the fluid 100 in both sub-chambers 28 and 30 is at a common height as an upper level 104 of the expanded support 62 of the divider wall 22, according to an embodiment. At the upper level 104, the magnet 70 is distally located from the magnetic sensor 38 because buoyancy forces Bi and B ₂ exerted by and into the buoyant blocks 48 within the first and second sub-chambers 28 and 30, respectively, are sufficient to oppose the weight of the float member 42. That is, the weight of the float member 42 is less than the combined forces B] and B ₂ . The fluid level shown in Figure 7 may be a partial or full fluid level. Because the magnet 70 is distally located from the magnetic sensor 38 as shown at the fluid level 100 of Figure 7, the magnetic sensor 38 does not output a low level signal to the CPU 40 (shown in Figure 1), as the magnet 70 is too far away from the magnetic sensor 38 to trigger such an output. For example, the magnet 70 may be too far away from the magnetic sensor 38 such that the magnetic sensor 38 is unable to detect the presence of a magnetic field. Optionally, the magnetic sensor 38 may be configured to detect the magnetic field of the magnet 70, but detection at the upper level 104 may be correlated with an adequate or sufficient fluid level.

[0044] Figure 8 illustrates a transverse cross-sectional view of the fluid reservoir assembly 10 when fluid 100a and 100b within the first and second sub- chambers 28 and 30, respectively, varies, according to an embodiment. As shown, the float member 42 recedes toward the base 16 based on the lower fluid level 100a within the first sub-chamber 28, even when, as a worst case condition, the fluid level 100b within the second sub-chamber 30 remains at the same heights as the divider wall 22. The float member 42 recedes to the lower level because the combined force of the buoyancy force B ₂ and the reduced buoyancy force Bi is insufficient to overcome the weight of the float member 42. Accordingly, the float member 42 recedes with the lower fluid 100a within the first sub-chamber 28 until the magnet 70 recedes close enough to the magnetic sensor 38 such that the magnetic sensor 38 outputs a low level signal a low level signal to, for example, the CPU 40 (shown in Figure 1). While the lower fluid 100a is shown in the first sub-chamber 28, the lower fluid 100a may be in the second sub-chamber 30, while the higher fluid 100b may be in the first sub-chamber 28. In either case, the float member 42 recedes along with the lower fluid level, whether in the first or second sub-chamber. Further, when the fluid levels are equal in the sub-chambers 28 and 30, the float member 42 floats with respect to the level of the equal fluid levels.

[0045] Figure 9 illustrates a transverse cross-sectional view of the fluid reservoir assembly 10 when fluid 100a is within an established range that would be considered a low level within the first sub-chamber 28, according to an embodiment. As the fluid 100a continues to drop, the float member 42 recedes along with the low fluid 100a, even when the fluid 100b remains at a relatively high level. The magnetic sensor 38 may be configured to output a low fluid signal when the magnet 70 is within a certain distance from the magnetic sensor 38. For example, the magnetic sensor 48 may output a low fluid signal when the upper joint 44 seats on an upper surface of the expanded support 62.

[0046] Figures 10 and 11 illustrate an isometric top internal view and a transverse cross-sectional view, respectively, of a fluid reservoir assembly 200, according to an embodiment. The assembly 200 is similar to the assembly 10. However, the assembly 200 includes a float member 202 having linear, straight, vertical legs 204 that connect an upper joint 206 to buoyant blocks 208. In contrast to the float member 42, the legs 204 are slimmer and generally have less material. A magnet 210 may be pressed into the float member 202, as opposed to being insert- molded with the float member 202. Both the float member 42 and the float member 202 may be plastic or austenitic stainless steel frames and/or molded pieces.

[0047] The float member used with any of the embodiments may be various shapes and sizes. The float member may be symmetrical about a central vertical axis such that portions extend into each sub-chamber at the same depth.

[0048] Referring to Figures 1-11, embodiments provide a reservoir assembly having a float member that is configured to detect a fluid level at a predetermined depth in one sub-chamber, whether or not that fluid level is below the fluid level in another sub-chamber. Embodiments may be used with brake fluid reservoirs, windshield wiper fluid reservoirs, or various other reservoirs in which fluid level detection is desired.

[0049] Given a fluid reservoir with more than one chamber, embodiments or the present disclosure are configured to detect, with one or more sensors, a predetermined range of a low fluid level condition at a predetermined range of depth in one chamber after the fluid level has dropped to a depth that is significantly lower than that of the fluid in a second chamber. For example, the low level condition in one chamber may be detected within a predetermined low level range, independent of the fluid level condition of a second adjacent chamber. Embodiments of the present disclosure are applicable to reservoirs and tanks with more than two adjacent chambers, in which each chamber may have a float attached to the same magnet, for example. [0050] While various spatial and directional terms, such as top, bottom, lower, mid, lateral, horizontal, vertical, front and the like may be used to describe embodiments of the present invention, it is understood that such terms are merely used with respect to the orientations shown in the drawings. The orientations may be inverted, rotated, or otherwise changed, such that an upper portion is a lower portion, and vice versa, horizontal becomes vertical, and the like.

[0051] Variations and modifications of the foregoing are within the scope of the present invention. It is understood that the embodiments disclosed and defined herein extend to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention. The claims are to be construed to include alternative embodiments to the extent permitted by the prior art.

[0052] Various features of the invention are set forth in the following claims.