Fluid level sender assembly and method of making a fluid level sender assembly

1. Field of the Invention

The invention described herein relates to the field of mount assemblies for fluid level senders and methods of making mount assemblies for fluid level senders.

2. Background Art

Fluid level sensors or senders measure fluid levels inside of a fluid tank. A fluid level sender may be mounted on a mount assembly projecting into an interior portion of the fluid tank and may include a flotation device connected to a main body by a rod which pivots with respect to the main body. The mount assembly holds the main body in a position that permits the rod and the floatation device to pivot up and down freely without interference from the walls or other structures of the tank as the fluid level changes. The main body is mounted in a non-movable position and the fluid level sender determines the fluid level based on the angular orientation of the rod with respect to the main body.

The size and shape of fluid tanks vary depending upon their application. Designing, manufacturing and producing different mounts for each different application can be expensive. It is desirable to have a fluid level sender that is mounted on a mount assembly which can be tailored to the dimensions of each specific fluid tank. This invention addresses this and other problems.

In a first aspect of the invention, an apparatus is provided. In at least a first embodiment of the apparatus, a fluid level sender mount assembly for mounting a fluid level sender to a fluid container is disclosed. The assembly comprises a first mounting member that has a chamber with a generally circular cross section. The generally circular cross section has a substantially constant diameter along a length of the chamber. A second mounting member has an elongate docking portion that has an at least partially circular cross section. The generally circular cross section has a substantially constant diameter along a length of the docking portion. The docking portion is sized to slidably fit and rotate within the chamber to permit the second mounting member to be positioned at a plurality of different linear and angular positions with respect to the first mounting member. The docking portion is disposed within the chamber and the second mounting member may be positioned at a desired linear and angular position with respect to the first mounting member. The second mounting member is then affixed to the first mounting member to inhibit relative movement of the first and the second mounting members from the desired linear and angular position. One of the first and the second mounting members may be adapted to be attached to the fluid container such that a portion of each of the first and the second mounting members projects into the fluid container. The other of the first and the second mounting members may be adapted to be attached to the fluid level sender.

In at least one implementation of the first embodiment, the fluid level sender comprises a wire assembly. The chamber is a first chamber that extends through the first mounting member, and the second mounting member has a second chamber. The second chamber may be contiguous with the first chamber to form a tunnel to receive the wire assembly. In at least one variation of this implementation, the second mounting member may be adapted to be attached to the fluid level sender. An end of the wire assembly may include an electrical terminal, and the first mounting member may include an electrical connector to receive the electrical terminal and to transmit an electrical signal from the fluid level sender to a receiver positioned outside of the fluid tank.

In another variation, the first mounting member may be adapted to be attached to the fluid level sender. An end of the wire assembly may include an electrical terminal, and the second mounting member may include an electrical connector to receive the electrical terminal and to transmit an electrical signal transmitted by the fluid level sender to a receiver positioned outside of the fluid tank.

In another variation, the fluid level sender mount assembly may further comprise a mounting plate. The first mounting member may have a first end and a second and the docking portion may be docked with the first end. The mounting plate may be attached to the first mounting member proximate the second end and the mounting plate may be adapted to connect the first mounting member to the fluid tank. The mounting plate may be further configured to permit the wire assembly to pass through the mounting plate. Alternatively, the mounting plate may be attached to the second mounting member at a position spaced apart from the docking portion. The mounting plate may be configured to connect the second mounting member to the fluid tank and to permit the wire assembly to pass through the mounting plate.

In at least another implementation of the first embodiment, the second mounting member may be affixed to the first mounting member by one of a threaded fastener and a crimp.

In another implementation of the first embodiment, the fluid level sender mount assembly may further comprise a fastener that connects the second mounting member to the first mounting member.

In a second embodiment, a fluid level sender assembly is disclosed. The assembly includes a first mounting member having a first chamber having a generally circular cross section. The generally circular cross section has a substantially constant diameter along a substantial length of the chamber. A second mounting member is provided. The second mounting member includes a docking portion that has a generally cylindrical shape and a generally circular cross section. The second mounting member further includes a second chamber that extends through the docking portion. The docking portion is configured to slide telescopically and rotate within the first chamber to allow the second mounting member to be positioned at a plurality of linear and angular positions with respect to the first mounting member. The docking portion is disposed within the first chamber and the second mounting member may be positioned at a desired linear and angular position with respect to the first mounting member. The second mounting member is then affixed to the first mounting member such that the second mounting member is inhibited from moving with respect to the first mounting member out of the desired angular and linear position. A fluid level sender sub-assembly may be attached to one of the first and the second mounting members. The other of the first and the second mounting members may be adapted for attachment to a fluid tank such that a portion of each of the first and the second mounting members and the fluid level sender sub-assembly are disposed inside of the fluid tank.

In at least one implementation of the second embodiment, the fluid level sender sub-assembly may be integral with one of the first and second mounting members.

In at least another implementation of the second embodiment, the fluid level sender may include a wire assembly. The first and the second chambers may form a tunnel to receive at least a portion of the wire assembly. In at least one variation of this implementation, the fluid level sender may be attached to the second mounting member. An end of the wire assembly may include an electrical terminal, and the first mounting member may include a socket to receive the electrical terminal and to transmit an electrical signal from the fluid level sender to a receiver disposed outside of the fluid container. In at least another variation of this implementation, the fluid level sender may be attached to the second mounting member, and the first mounting member may include a plate disposed at an end of the first mounting member that is opposite an end attached to the second mounting member. The plate may be configured to connect the first mounting member to the fluid tank and may be further configured to permit the wire assembly to extend through the plate.

In at least another implementation of the second embodiment, the second mounting member and the first mounting member may be attached to one another by a crimp.

In at least another implementation of the second embodiment, the fluid level sender may further comprise a fastener that affixes the second mounting member to the first mounting member.

In another aspect of the invention, a method of assembling a fluid level sender assembly is provided. The fluid level sender assembled by the method may have having a first support member having first and second ends and a first chamber extending therebetween, a second support member having first and second ends and a second chamber extending therebetween. The second support member may be configured for telescopic connection to the first support member and may be further configured to rotate with respect to the first support member. A fluid level sender may be attached to the second support member. In a third embodiment, the method of assembling the fluid lever send assembly may comprise telescopically connecting the first end of the second support member to the first end of the first support member. The axial position of the second support member with respect to the first support member may be adjusted until the fluid level sender is a desired distance from the second end of the first support member. The first support member may be rotated with respect to the second support member until the fluid level sender is at a desired angular orientation with respect to the first support member. The second support member may be affixed to the first support member to inhibit further axial and angular movement of the second support member with respect to the first support member.

In at least one implementation of the third embodiment, the second support member may be affixed to the first support member by crimping.

In at least another implementation of the third embodiment, the method may further comprise cutting the first support member to a desired length.

In another implementation of the third embodiment, the method may further comprise determining the desired distance between the fluid level sender and the first end of the support member based on internal dimensions of a fluid tank that is to be fitted with the fluid level sender assembly and determining the desired angular orientation of the fluid level sender with respect to the first support member based on the internal dimensions of the fluid tank.

In at least another implementation of the third embodiment, the first support member may further have a plate attached proximate the second end of the first support member. The plate may be configured for attachment to a fluid tank and may have a socket facing the first chamber. The fluid level sender may have a wire assembly having an electrical connector. The method may further comprise inserting the wire assembly through the first and the second chambers and inserting the electrical connector into the socket.