Abstract
A flame mitigation device configured to be located proximate a main container opening of a fuel container having a fuel-receiving chamber, with the main container opening permitting liquid fuel to flow into and out of the fuel-receiving chamber. The flame mitigation device comprises a sidewall defining a plurality of perforations through which the liquid fuel can flow to dispense such liquid fuel from the fuel-receiving chamber when the flame mitigation device is installed within the fuel container. At least a portion of the perforations defined in the sidewall are downwardly sloping perforations, with the downward angle of the downwardly sloping perforations being at least 1 degree below horizontal. And at least 20 percent of the total open area defined by all of said perforations is attributable to downwardly sloping perforations.
Claims
1. A flame mitigation device configured to be positioned proximate a main container opening of a fuel container, the main container opening permitting flow of a liquid fuel into and out of a fuel-receiving chamber of the fuel container, said flame mitigation device comprising: a sidewall defining a plurality of perforations through which liquid fuel can flow when dispensing liquid fuel from the fuel-receiving chamber of the fuel container, wherein said flame mitigation device is formed of a synthetic resin material, wherein said flame mitigation device has an internal volume of at least 2 cubic inches, wherein said flame mitigation device is at least 10 percent open, wherein the average open area of said perforations is not more than 0.05 square inches, wherein at least a portion of said perforations defined in said sidewall are downwardly sloping perforations, wherein a downward angle of said downwardly sloping perforations is at least 1 degree below horizontal, wherein at least 20 percent of the total open area defined by all of said perforations is attributable to downwardly sloping perforations.
2. The flame mitigation device of claim 1, wherein said downwardly sloping perforations extend from an inner surface of said sidewall and slope downwardly to an outer surface of said sidewall.
3. The flame mitigation device of claim 1, wherein the downward angle of said downwardly sloping perforations is at least 30 degrees below horizontal and not more than 65 degrees below horizontal.
4. The flame mitigation device of claim 1, wherein said flame mitigation device comprises one or more wing elements extending from said sidewall, said wings elements configured to compress towards said sidewall as said wing elements pass through the main container opening and expand away from the sidewall after the wing elements have passed through at least a portion of the main container opening.
5. The flame mitigation device of claim 4, wherein said wing elements are configured to inhibit said flame mitigation device from being removed from said fuel container.
6. The flame mitigation device of claim 4, wherein the fuel container includes a neck that defines the main container opening, wherein a distance between a distal end of one wing element and a distal end of an opposing wing element is less than an inner diameter of a portion the neck when said wing elements are compressed and is greater than the inner diameter of the portion of the neck when said wing elements are expanded.
7. The flame mitigation device of claim 1, wherein the plurality of perforations are arranged in one or more sections of arrays.
8. The flame mitigation device of claim 1, wherein said downwardly sloping perforations each include an upper perforation surface, a lower perforation surface, and a pair of side surfaces, where said upper perforation surface and said lower perforation surface each slope downward at an angle of at least 30 degrees below horizontal and not more than 65 degrees below horizontal.
9. The flame mitigation device of claim 1, wherein 100 percent of the total open area defined by said perforations is formed by downwardly sloping perforations.
10. The flame mitigation device of claim 1, wherein said flame mitigation device has an upper end in which an inner diameter is less than 2.5 inches.
11. The flame mitigation device of claim 1, wherein said perforations are configured such that after an amount of liquid fuel has been dispensed from the fuel container and the flame mitigation device is not submerged in liquid fuel held within the fuel-receiving chamber of the fuel container, a quantity of liquid fuel is retained in said perforations.
12. The flame mitigation device of claim 11, wherein the retained quantity of liquid fuel is held in said perforations by intermolecular forces, and wherein the intermolecular forces are sufficient to retain the quantity of liquid fuel in said perforations regardless of the orientation of the flame mitigation device.
13. A fuel container comprising: a hollow tank body defining a fuel-receiving chamber and a main container opening for permitting flow of a liquid fuel into and out of said fuel-receiving chamber; a fuel dispensing assembly coupled to said tank body proximate said main container opening and configured to dispense the liquid fuel from said fuel container; and a fuel retention structure located proximate said main container opening and extending generally downwardly into said fuel-receiving chamber, wherein said fuel retention structure comprises a plurality of perforations through which the liquid fuel must flow to dispense the liquid fuel from said fuel container, wherein said fuel retention structure is configured to retain a quantity of the liquid fuel after said fuel container is tipped or inverted to dispense the liquid fuel therefrom, wherein the retained quantity of the liquid fuel is sufficient to provide a fuel-air mixture proximate to said main container opening that is too rich to support combustion, wherein said fuel retention structure comprises a sidewall defining a plurality of said perforations, wherein at least a portion of said perforations defined in said sidewall are downwardly sloping perforations, wherein a downward angle of said downwardly sloping perforations is at least 1 degree below horizontal, wherein at least 20 percent of the total open area defined by all of said perforations is attributable to downwardly sloping perforations.
14. A method for coupling a flame mitigation device to a fuel container, wherein the fuel container comprises a hollow tank body defining a fuel-receiving chamber and a main container opening for permitting flow of a liquid fuel into and out of the fuel-receiving chamber, wherein said method comprises the steps of: providing the flame mitigation device comprising a sidewall defining a plurality of perforations through which liquid fuel flows when dispensing liquid fuel from the fuel-receiving chamber, and wherein the flame mitigation device further comprises a pair of wing elements extending outwardly from the sidewall; and inserting the flame mitigation device through the main container opening of the fuel container, wherein during said inserting step, the wing elements are compressed adjacent to an outer surface of the flame mitigation device; and securing the flame mitigation device within the main container opening of the fuel container, wherein during said securing step, the wing elements expand away from the outer surface of the flame mitigation device.
15. The method of claim 14, wherein at least a portion of the perforations defined in the sidewall are downwardly sloping perforations having a downward angle of at least 1 degree below horizontal, and wherein at least 20 percent of the total open area defined by all of the perforations is attributable to downwardly sloping perforations.
16. The method of claim 14, wherein the wing elements are configured to inhibit the flame mitigation device from being removed from the main container opening.
17. The method of claim 14, wherein the fuel container includes a neck that defines the main container opening, wherein during said inserting step, a distance between a distal end of one wing element and a distal end of an opposing wing element is less than an inner diameter of a portion the neck, wherein during said securing step, the distance between the distal end of the one wing element and the distal end of the opposing wing element is greater than the inner diameter of the portion the neck,
18. The method of claim 14, wherein the flame mitigation device has an upper end having an inner diameter of less than 2.5 inches.
19. The method of claim 14, wherein the perforations are configured in a manner such that after the liquid fuel has been dispensed from the fuel container and the flame mitigation device is not submerged in liquid fuel contained within the fuel-receiving chamber, a quantity of the liquid fuel is retained in the perforations.
20. The method of claim 19, wherein the retained quantity of the liquid fuel is held in the perforations by intermolecular forces, wherein the intermolecular forces are sufficient to retain the quantity of liquid fuel in the perforations regardless of the orientation of the flame mitigation device.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view of a portable fuel container having a hollow tank body, and a fuel dispensing nozzle mounted to a neck;
[0019] FIG. 2 is an enlarged side elevational view of a neck and opening of a portable fuel container according to the prior art, showing in vertical cross-section a part of the tank body adjacent the neck;
[0020] FIG. 3 is an enlarged, cross-section side elevational view of a neck and opening of a portable fuel container according to one embodiment of the present invention, utilizing an annular neck dam which is inwardly flared to retain fuel proximate the neck and opening;
[0021] FIG. 4 is an enlarged, cross-section side elevational view of neck and opening of a portable fuel container according to another embodiment of the present invention, utilizing an annual neck dam which has a circumscribing and downwardly extending without flaring, and which retains an absorbent sponge-like material;
[0022] FIG. 5 is an enlarged, cross-section side elevational view of a neck and opening of a portable fuel container according to a further embodiment of the present invention, which utilizes and inverted fuel-retaining pocket adjacent the neck and opening;
[0023] FIG. 6 is an isometric view of a vertical section through a portable fuel container as shown in FIG. 1 with the fuel dispensing nozzle removed and showing a plurality of absorbent pads mounted interiorly of the main body for absorbing and retaining fuel within the portable fuel container;
[0024] FIG. 7 is an isometric view of a flash suppressor for integrating inside the neck of a portable fuel container and having a fuel-retaining wall for creating a fuel-retaining pocket proximate the neck and opening of a fuel container;
[0025] FIG. 8 is a plan view of the flash suppressor of FIG. 7 showing an annular rim configured for engaging the inner surface of the neck of the fuel container;
[0026] FIG. 9 is a bottom view of the flash suppressor of FIG. 7 showing perforations in the bottom wall of the flash suppressor for permitting fuel to pass therethrough;
[0027] FIG. 10 is a front elevation view of the flash suppressor of FIG. 7 showing the annular rim in profile and the fuel-retaining wall adjacent the rim, the rear view being a mirror image thereof;
[0028] FIG. 11 is right side elevation view of the flash suppressor of FIG. 7 showing perforations in the sidewall of the flash suppressor below the fuel-retaining wall, the left side elevation being a mirror image thereof;
[0029] FIG. 12 is an enlarged left side elevation view of the flash suppressor of FIG. 7 placed within the neck of a fuel container prior to integration into the neck;
[0030] FIG. 13 is an enlarged left side elevation view showing the interference of the annular rim of the flash suppressor of FIG. 7 with a circumscribing bulge located on the inner surface of the neck of the fuel container prior to integration into the neck;
[0031] FIG. 14 is an enlarged left side elevation view showing the flash suppressor of FIG. 7 integrated into the neck of the container to provide a fuel-retaining pocket adjacent the neck and opening;
[0032] FIG. 15 is a vertical cross-sectional view taken through a fuel container and flash suppressor after integration of the flash suppressor into the fuel container;
[0033] FIG. 16 is an isometric view of a flash suppressor for integrating inside the neck of a portable fuel container having a configuration similar to that of the flash suppressor depicted in FIG. 7, but configured without the fuel-retaining wall, so that fuel retention is accomplished primarily by retaining fuel in the perforations of the flash suppressor;
[0034] FIG. 17 is a top isometric view of a flash suppressor for integrating inside the neck of a portable fuel container having a bottom wall that is shiftable relative the sidewall, illustrating the bottom wall in a closed position;
[0035] FIG. 18 is a bottom isometric view of the flash suppressor of FIG. 17, illustrating the bottom wall in a closed position;
[0036] FIG. 19 is a top isometric view of the flash suppressor of FIG. 17, illustrating the bottom wall in an open position;
[0037] FIG. 20 is an bottom isometric view of a flame mitigation device according to embodiments of the present invention, with the flame mitigation device including downwardly-sloping perforations extending through a sidewall of the flame mitigation device;
[0038] FIG. 21 is an enlarged view of a broken-away top portion of the flame mitigation device from FIG. 20, particularly illustrating the downwardly-sloping perforations extending through the sidewall;
[0039] FIG. 22 is a cross-sectional view taken along the line 22-22 from FIG. 21, and particularly illustrating the downwardly-sloping perforations;
[0040] FIG. 23 is a cross-sectional broken away view of a neck of a fuel container with the flame mitigation device from FIG. 21 being inserted within a main container opening of the fuel container, particularly illustrating the flame mitigation device including wing elements compressed against the sidewall of the flame mitigation device; and
[0041] FIG. 24 is a cross-sectional broken away view of the neck of the fuel container from FIG. 23, with the flame mitigation device being secured within the main container opening of the fuel container by the wing elements expanding away from the sidewall of the flame mitigation device and into engagement with the main container opening.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0042] The following detailed description of embodiments of the invention references the accompanying figures. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those with ordinary skill in the art to practice the invention. The embodiments of the invention are illustrated by way of example and not by way of limitation. Other embodiments may be utilized and changes may be made without departing from the scope of the claims. The following description is, therefore, not limiting. It is contemplated that the invention has general application to validating payment transactions made using payment network systems. However, the scope of the present invention is defined only by the appended claims, along with the full scope of equivalents to which such claims are entitled.
[0043] In this description, references to one embodiment, an embodiment, or embodiments mean that the feature or features referred to are included in at least one embodiment of the invention. Separate references to one embodiment, an embodiment, or embodiments in this description do not necessarily refer to the same embodiment and are not mutually exclusive unless so stated. Specifically, a feature, component, action, operation, etc. described in one embodiment may also be included in other embodiments, but is not necessarily included. Thus, particular implementations of the present invention can include a variety of combinations and/or integrations of the embodiments described herein. Like reference numbers are used to identify the same or similar structures in the different embodiments and views.
[0044] Referring now to the drawings, FIG. 1 shows a portable fuel container 10. The fuel container 10 is shown as an example of the variety of different fuel containers with which the present invention may be employed, it being understood that the present invention is not limited to the particular fuel container 10 as shown herein. The fuel container 10 includes a hollow tank body 12, a collar 14 which is removably mounted to the fuel container 10 and which, in combination with a dispensing spout 16, covers an opening which may be used for filling the fuel container 10 with fuel and from which the fuel contained therein may be selectively dispensed. The dispensing spout 16 of this example is a selectively actuatable dispensing spout biased to a non-dispensing condition, such that the user must operatively depress a button 18 in order to enable fuel to flow from the tank body 12 through the dispensing spout 16 and from a discharge outlet 20. The dispensing spout 16 may be held by the collar 14 which is threadably attached to a neck 22 fluidically communicating with the tank body 12, the external threading on the neck 22 being shown in FIG. 2. In the example shown in FIG. 1, both the dispensing spout 16 and the collar 14 are coupled together whereby unscrewing the collar 14 causes the collar 14 and dispensing spout 16 to be detached from the container as a unit. When the dispensing spout 16 or collar 14 are removed, an opening 24 is revealed which permits filling of the tank body 12 with fuel or, in typically undesired circumstances, through which fuel contained in the tank body 12 may be poured. The size of the opening 24 can be at least at least 2.0, 2.25, 2.75, or 3.0 square inches and/or not more than 10, 8, 6, or 4 square inches. As shown in FIGS. 2-6 and 12-15, a fuel-receiving chamber 25 is presented within the body 12. The fuel-receiving chamber 25 can have a capacity of at least 1 gallon and/or not more than 6 gallons. The fuel container body 12, collar 14 and spout 16 are preferably molded of synthetic resin, such as, for example, polyethylene.
[0045] A typical neck 22 of a portable fuel container 10 is shown in FIG. 2. FIG. 3 illustrates a first embodiment of the apparatus of the present invention. A portable fuel container 10A may be constructed substantially identically to that shown in FIGS. 1 and 2. However, an annular neck dam 26 of synthetic resin material such as polyethylene or polypropylene which is resistant to degradation by exposure to fuel such as gasoline is inserted into the neck 22 proximate the opening 24. As shown in FIG. 3, the annular neck dam 26 may extend around the interior surface of the neck 22 and extends downwardly toward and into the tank body 12. The annular neck dam 26 may be flexible, and flared radially inwardly. Thus, when the portable fuel container 10A is tipped or inverted, fuel 28 (shown by stippling) is retained in a reservoir 30 created by the neck dam 26 adjacent the opening 24 thereby increasing the fuel-air mixture in the vicinity of the neck 22. A generally downwardly facing reservoir opening 31 allows the fuel 28 to enter the reservoir 30 when the fuel container 10A is tipped or inverted and also allows the fuel 28 retained in the reservoir 30 during dispensing to flow back out of the reservoir 30 when the container 10A is returned to its upright position. In certain embodiments of the invention, the reservoir 30 is sized to retain at least 6 milliliters of liquid fuel per gallon of liquid capacity of the container 10. In other embodiments, the reservoir 30 is sized to retain at least 10 milliliters of liquid fuel per gallon of liquid capacity of the container 10.
[0046] FIG. 4 shows an alternate embodiment of the portable fuel container 10B hereof, the portable fuel container 10B being constructed substantially the same as that shown in FIGS. 1, 2 and 3. However in FIG. 4, the annular neck dam 26B is not flared, but rather is substantially configured as a cylindrical tube fitted into the neck 22 and extending downwardly toward and into the tank body 12. An optional pad 32 of porous compressible absorbent material which is sponge-like is provided in the reservoir 30. The annular neck dam 26B may thus serve to retain the pad 32 which as shown may also be annular. Alternatively, the annular neck dam 26B may be omitted, with the pad 32 retained in position by adhesive or mechanical attachment. Fuel 28 may be retained in the reservoir 30 when the portable fuel container 10B is tipped or inverted, thereby increasing the ratio of fuel to air in the vicinity of the neck 22 and opening 24.
[0047] FIG. 5 shows a further alternate embodiment of the portable fuel container 10C hereof. While substantially identical to the portable fuel containers shown in FIGS. 1-4, the wall 34 of the tank body 12 adjacent the neck 22 is configured with an inverted pocket 36. The pocket 36 may be constructed so that it extends completely around and thus surrounds the neck 22, or alternatively as shown in FIG. 5, may be located and configured so that it extends less than 360 around the base 38 of the neck 22. When the portable fuel container 10C is tipped or inverted, fuel 28 will be held in the pocket 36, thereby increasing the ratio of fuel to air in the vicinity of the neck 22.
[0048] FIG. 6 shows a yet further alternate embodiment of the fuel container 10D hereof. FIG. 6 shows the tank body 12D and neck 22D in cross-section, with the opening enclosed but with the understanding that in practice the neck 22D would be open so that fuel could flow into the chamber 25D through an opening in the neck 22D. It is to be understood that the neck 22D would be externally threaded to receive the dispenser 16 shown in FIG. 1, and could have the neck dam or inverted pocket as illustrated in FIGS. 2-5. FIG. 6, however, also shows the use of absorbent pads 40, 42 and 44 attached to the inside surface 46 of the tank body 12D. It is contemplated that only one such absorbent pad would be used per fuel container, but it is possible that a plurality of such pads 40, 42 and 44 could be used simultaneously. While the absorbent pads could be movable or even loose within chamber 25D and still retain sufficient fuel to inhibit an explosion event within the portable fuel container 10D, it is believed that better operating characteristics such as avoiding potential blockages at the opening will be achieved by mounting the pads 40, 42 and 44 to the inside surface 46 using mechanical fasteners or adhesive or bonding the pads to the inside surface 46 of the portable fuel container 10D. Like pad 32, the pads 40, 42 and 44 are preferably porous compressible absorbent material which is sponge-like, for example synthetic resin open-celled foam material. Fuel 28 is thus retained by the pads 40, 42 and 44 to create a mixture too rich for combustion and explosion.
[0049] FIGS. 7 through 15 show a flash suppressor 50 that can be integrated into a portable fuel container 10E. The flash suppressor 50 may have an annular rim 52, a generally cylindrical, conical, or frustoconical suppressor sidewall 54, and a bottom wall 56. The flash suppressor 50 can be injection molded from a synthetic resin material such as polyethylene to be compatible with the tank body. The suppressor sidewall 54 may slightly taper inwardly from its width at the rim 52 to the bottom wall 56 to facilitate molding, for example from between about 0.5 to about 2.5 and most preferably about 1 of taper. The annular rim 52 surrounds an open area into which a gas nozzle may be inserted and may project outwardly from an upper end 58 of the suppressor sidewall 54 a sufficient distance to engage an inner surface of the neck of the portable fuel container into which it is received. The suppressor sidewall 54 may be provided with axially extending ribs 60 along an interior surface 62 of the suppressor sidewall 54. These ribs 60 may extend substantially from the annular rim 52 to the bottom wall 56 to resist wear from the insertion of gasoline nozzles therein or deformation.
[0050] As shown in FIGS. 7, 10-15, the suppressor sidewall 54 can include a circumferentially extending imperforate fuel-retaining wall 64 that retains some of the fuel held in the chamber 25 when the portable fuel container is tipped or inverted to position the opening 24 below the level of fuel held within the chamber 25. The fuel-retaining wall 64 can extend axially downwardly from the upper end 58 of the sidewall 54. In certain embodiments, the fuel-retaining wall 64 extends completely around the circumference of the sidewall and is continuous with the annular rim 52 so that fuel cannot pass between the fuel-retaining wall 64 and the rim 52. The fuel-retaining wall 64 extends axially a sufficient distance to retain a quantity of fuel sufficient to make the fuel-air mixture adjacent the neck too rich for ignition, depending on the capacity of the container. By way of example, the imperforate fuel-retaining wall 64 may extend axially downward from the rim 52 at least about 0.25 inch, at least about 0.5 inch, or at least about 1 inch. The suppressor sidewall 54 may also include a pair of circumferentially spaced axially extending imperforate sections 66 having radially offset (relative to the remainder of the imperforate section) axially spaced circumferentially oriented bands 68 to provide rigidity, and a pair of circumferentially spaced axially extending perforate sections 70 which include an array of perforations 72 sized to permit the flow of fuel, such as liquid gasoline, and air therethrough.
[0051] The suppressor sidewall 54 preferably extends downwardly to position the bottom wall 56 a sufficient distance to permit insertion of a gasoline pump nozzle past the neck 22 and into the area interior of the suppressor sidewall 54. In certain embodiments, the flash suppressor 50 extends at least 0.5, 1, 2, or 3 inches and/or not more than 12, 8, or 6 inches downwardly into the liquid-receiving chamber 25. Further, the flash suppressor 50 can have an internal volume (e.g., the volume of the space defined between the sidewall 54 and above the bottom wall 56) of at least 0.5, 1, 2, or 3 cubic inches and/or not more than 20, 15, 10, or 5 cubic inches.
[0052] The bottom wall 56 of the flash suppressor 50, seen best in FIGS. 8 and 9, may include transverse reinforcement 74 in a generally H shape including downwardly extending transverse flanges 76 and 78 and connecting flange 80. The bottom wall 56 can include a plurality of perforations 72 which are sized to permit fuel such as liquid gasoline and air to flow therethrough. The number of perforations 72 and their size and positioning in the bottom wall 56 and suppressor sidewall are preferably sufficient to permit normal filling of the container at a moderate rate of flow without buildup and overflow of fuel from the container. For example, in certain embodiments, the size and positioning of the perforations 72 in the flash suppressor 50 permit at least 5, 7.5, or 10 gallons per minute of gasoline to flow therethrough under common gasoline filling conditions (e.g., atmospheric pressure and room temperature). In order to permit proper flow of liquid fuel through the flash suppressor 50, the side and lower members (e.g., sidewall 54 and bottom wall 56) can be at least 5, 10, 15, 20, or 25 percent open and/or not more than 80, 70, 60, or 50 percent open, where percent open is the cumulative open area of all the perforations expressed as a percentage of the total internal surface area of the side and lower members of the flash suppressor. Further, each perforation can be sized to present an open area of not more than 0.1, 0.05, 0.025, or 0.015 square inches.
[0053] In certain embodiments, it may be desired for the flash suppressor 50 be permanently attached (i.e., non-removable) to the body 12 by, for example, bonding or welding. One suitable welding technique is to spin-weld the flash suppressor 50 to the body 12 of the portable fuel container 10E. FIG. 12 shows the flash suppressor 50 inserted into the body 12 where the inner surface of the neck 22 is provided with a radially inwardly projecting circumferentially extending bulge 82, but before integration. In FIG. 13, the flash suppressor 50 is pushed downwardly so that the annular rim 52, which may have a beveled edge 84, is in interference with the bulge 82. The rim 52 thus engages the bulge 82, the sizing being complementary such that the rim 52 is sufficiently resilient and preferably able to deflect upon such engagement. The flash suppressor 50 is then rotated relative to the body sufficiently to melt and weld with the bulge 82 to make the flash suppressor unitary with the body 12, thereby creating a seal preventing air and liquid from moving between the annular rim 52 and the neck 22. This unitization of the flash suppressor 50 with the body 12 creates a reservoir 86 or pocket between the body 12, the rim 52 and the imperforate fuel-retaining wall 64 which retains a quantity of fuel therein when the portable fuel container is tipped or inverted.
[0054] FIG. 16 depicts an alternative type of fuel retention structure, i.e., a flash suppressor 100, that employs a plurality of perforations 102 to retain a quantity of liquid fuel at or near the opening of the portable fuel container. After liquid fuel is dispensed from the portable fuel container though the perforations 102 and the container is returned to its upright position, the perforations 102 can retain a sufficient quantity of liquid fuel to make the environment inside the flash suppressor 100 too rich in fuel for combustion to occur. Unlike the flash suppressor 50 depicted in FIG. 7, which includes an imperforate fuel retention wall 64 extending around the top of the sidewall 54, the flash suppressor 100 depicted in FIG. 16 relies primarily, and in certain embodiments exclusively, on the perforations 102 for fuel retention. Although other types of fuel retention structures (e.g., absorptive pads, retention walls, etc.) can be incorporated into or used in conjunction with the flash suppressor 100, in certain embodiments, at least 50, 75, 90, 95, or about 100 weight percent of the liquid fuel retained by the flash suppressor 100 is retained within the perforations 102.
[0055] The dimensions of the flash suppressor 100 depicted in FIG. 16 are chosen to permit adequate fuel flow through the perforations during filling of the fuel container and adequate retention of fuel in the perforations 102 after dispensing fuel from the fuel container through the perforations 102. In certain embodiments, the perforations are configured in a manner such that after the liquid fuel has been dispensed from the container and the fuel retention structure is no longer submerged in the liquid fuel, a quantity of the liquid fuel is retained in the perforations due to intermolecular forces. The intermolecular forces include forces between molecules within the liquid fuel and forces between molecules of the liquid fuel and molecules of the fuel retention structure.
[0056] The perforations 102 of the flash suppressor 100 must provide sufficient open area, as defined previously, to permit fuel to flow adequately through flash suppressor 102 under standard fuel filling conditions without having fuel spill out over the top of the flash suppressor 100. In certain embodiments, the perforations 102 in the sidewall 104 and/or the bottom wall 106 of the flash suppressor 100 can cause the flash suppressor 100 to be at least 5, 10, 15, 20, or 25 percent open and/or not more than 90, 80, 70, 60, or 50 percent open, as defined previously. The total number or perforations in the flash suppressor can be at least 100, 500, 1000, or 2000 and/or not more than 40,000, 20,000, 10,000, or 5,000.
[0057] In certain embodiments, the flash suppressor 100 can have an internal volume of at least 5, 10, 14, or 16 cubic inches and/or not more than 40, 30, 25, or 20 cubic inches. Further, the flash suppressor 100 can have a length (typically measured as the height of the sidewall 104) that allows it to extend at least 2, 3, 4, or 5 inches and/or not more than 12, 10, 8, or 7 inches downwardly into the fuel container.
[0058] The specific configuration (e.g., size, length, and shape) of the perforations 102 in the sidewall 104 and/or end wall 106 of the flash suppressor 100 can affect the ability of the perforations 102 to permit adequate fuel flow therethrough during filling and dispensing, while still permitting adequate fuel retention therein after dispensing. In certain embodiments, the perforations 102 can be sized to present an average perforation open area of at least 0.0005, 0.001, 0.0015, or 0.002 square inches and/or not more than 0.1, 0.05, 0.01, or 0.005 square inches. As used herein, perforation open area means the minimum cross-sectional area of a perforation, measured normal to the direct of extension of the perforation through the wall. As used herein, average perforation open area means the average of all open areas of all perforations in the flash suppressor. The perforations 102 can have an average perforation diameter of at least 0.01, 0.02, 0.03, 0.04, or 0.05 and/or not more than 0.4, 0.2, 0.1, or 0.08 inches. As used herein, perforation diameter means the maximum dimension across a perforation, measured normal to the direct of extension of the perforation through the wall. As used herein, average perforation diameter means the average of all perforation diameters of all perforations in the flash suppressor. The length of each perforation 102 can be determined by the thickness of the walls (i.e., sidewall 104 and/or end wall 106) of the flash suppressor 100. In certain embodiments, the average length of the perforations 102 and/or the average thickness of the sidewall 104 and/or the end wall 106 can be least 0.01, 0.02, 0.04, 0.06, or 0.08 inches and/or not more than 0.25, 0.2, 0.15 or 0.1 inches
[0059] FIGS. 17-19 show a flash suppressor 200 that is similar to the flash suppressor 100 depicted in FIG. 16 in that is does not include an imperforate fuel retention dam near its opening; however, the flash suppressor 200 of FIGS. 17-19 includes a bottom wall 202 that is shiftable relative to the sidewall 204 between an closed position (shown in FIGS. 17 and 18) and an open position (shown in FIG. 19). In certain embodiments, the bottom wall 202 is biased toward the closed position and the bottom wall 202 is configured to be shifted into the open position by contact with a conventional gasoline pump nozzle (not shown) that is inserted though the main opening of the portable fuel container for filling of the container. The bottom wall 202 can automatically shift into the closed position when the fuel pump nozzle is removed from the flash suppressor 200 and the main opening of the portable fuel container. The shiftable bottom wall 202 provides the necessary open area for filling the container with liquid fuel through the flash suppressor 200. In contrast with the flash suppressor 100 illustrated in FIG. 16, liquid fuel does not have to pass through the perforations in the sidewall 204 or the bottom wall 202 of flash suppressor 200 in order to fill the container with fuel. Such a configuration allows the sidewall 204 of the flash suppressor 200 to be much shorter than the sidewall 104 of the flash suppressor 100 depicted in FIG. 16.
[0060] As depicted in FIGS. 17-19 the flash suppressor 200 can include a spring biased hinge 206 coupling the bottom wall 202 to the sidewall 204 and providing for the shiftability and biasing of the bottom wall 202 relative to the sidewall 204. Of course, biasing mechanisms other than the torsion spring depicted in FIGS. 17-19 can be employed to bias the bottom wall 202 toward the closed position
[0061] Referring again to FIGS. 17 and 18, because the end wall 20 of the flash suppressor 200 is closed during dispensing of liquid fuel from the container, the liquid fuel must flow through the perforations in the end wall 202 and/or sidewall 204 in order to dispense liquid fuel from the container. After liquid fuel is dispensed from the container and the flash suppressor 200 is no longer immersed in fuel, flash suppressor 200 retains a quantity of fuel in its perforations that is sufficient to cause the environment in the flash suppressor 200 to be too rich in fuel to support combustion. In order to retain fuel, the perforations of flash suppressor 200 can have substantially the same configuration (e.g., average perforation open area, average perforation diameter, and average perforation length) as the perforations of the flash suppressor 100 depicted in FIG. 16. However, the total number of perforations, internal volume, and sidewall height are substantially less than those of the flash suppressor 100 depicted in FIG. 16.
[0062] In certain embodiments, the total number or perforations in the flash suppressor 200 can be at least 25, 50, 100, or 250 and/or not more than 10,000, 5,000, 2,500, or 1,000. In certain embodiments, the flash suppressor 200 can have an internal volume of at least 2, 4, or 6 cubic inches and/or not more than 200, 15, 12, or 10 cubic inches. Further, the flash suppressor 200 can have a length (typically measured as the height of the sidewall 204) that allows it to extend at least 0.25, 0.5, 0.75 or 1 inch and/or not more than 4, 3, 2, or 1.5 inches downwardly into the fuel container.
[0063] For each of the portable fuel containers 10A, 10B, 10C, 10D and 10E, it is contemplated that provided that 10 ml of gasoline per 1 U.S. gallon (3.785 liters) capacity of the fuel container is retained within the portable fuel container, the fuel-air mixture within the portable fuel container will be too rich to support combustion within the portable fuel container. Moreover, it is believed that approximately 6 ml of gasoline per 1 U.S. gallon (3.785 liters) capacity of the fuel container is retained within the portable fuel container will be too rich to support combustion within the portable fuel container. This is linearly scalable to various sizes of portable fuel containers as defined herein. Thus, for a five-gallon (18.927 liter) capacity portable fuel container, the neck dam alone, the absorbent pads alone, the pocket 36 alone, or the neck dam, pocket and absorbent pad(s) in any combination thereof will hold and retain at least 30 ml or at least 50 ml of gasoline within the portable fuel container 10. Thus, the size of the neck dam 26A or 26B, or the pocket 36, or the reservoir or pocket 86 formed by the body 12, rim 52 and imperforate fuel-retaining 64, or the absorbent pad(s) collectively should be sized corresponding to the volume capacity of the portable fuel container to retain the sufficient amount of fuel, in particular gasoline, described herein.
[0064] For the portable fuel containers 10A, 10B, 10C and 10E, a portion of the fuel 28 dispensed during pouring through the opening is retained immediately proximate the neck 22 and opening 24, thereby increasing the fuel-to-air ratio to a level whereby combustion may not occur. The positioning of the fuel retention structure in the neck proximate the opening 24 helps to inhibit the entry of flame into the chamber 25 of the container because the fuel is retained closely proximate the opening to maintain a too-rich mixture at the opening. For the portable fuel container 10D, the fuel is absorbed by the pads and retained in the chamber 25D within the main body 12D of the portable fuel container 10D to maintain the too rich fuel-air ratio for combustion. The portable fuel container 10E provides, in addition to the increased fuel-air ratio caused by the retention of fuel in the reservoir 86 or pocket, a barrier to the passage of spark or flame attempting to enter the chamber 25 by the suppressor sidewall 54 and bottom wall 56. The method hereof includes the steps of pouring fuel through the opening of a portable fuel container, and retaining a portion of the fuel in a retention member such as an absorbent pad or in a reservoir positioned proximate the opening so as to increase the ratio of fuel to air interiorly of the container, preferably proximate the opening.
[0065] Embodiments of the present invention may also include a flash suppressor in the form of flame mitigation device 300 as illustrated in FIGS. 20-24. In some embodiments, the flame mitigation device 300 may have similar features to those described above with respect to flash suppressor 100. However, it should be understood that flame mitigation device 300 may include any of the features previously-described with respect to flash suppressors 50, 100, and/or 200.
[0066] As shown in FIG. 20, the flame mitigation device 300 may comprise an annular upper rim 310 and a cylindrical sidewall 312 extending down from the annular upper rim 310 to a bottom wall 314. The sidewall 312 may include a plurality of perforations 316 that extend through the sidewall 312. As perhaps best shown in FIG. 22, the perforations 316 may extend from an inner sidewall surface 318 of the sidewall 312 to an outer sidewall surface 320 of the sidewall 312. In some embodiments, one or more of the perforations 316 may be configured to slope downwardly (i.e., downwardly-sloping perforations) through the sidewall 312. Specifically, the perforations 316 may be configured to slope downwardly, with respect to a horizontal reference plane (illustrated by the dashed line in FIG. 22), as the perforations 316 extend from the inner sidewall surface 318 to the outer sidewall surface 320.
[0067] The perforations 316 being configured to slope downwardly can aid in allowing liquid fuel to flow into and out of a fuel container when the flame mitigation device 300 is installed within a main container opening of the fuel container. Specifically, for instance, downwardly-sloping perforations 316 can provide for liquid fuel to pass through the flame mitigation device 300 at a high-enough rate to prevent spillage while the fuel container is being filled at standard gas pump flow rates. In more detail, FIG. 24 illustrates flame mitigation device 300 being installed within a main container opening of a fuel container. As shown, the orientation of the flame mitigation device 300 provides for the openings of the perforations 316 on the inner sidewall surface 318 to be positioned higher on the sidewall 312 than corresponding openings of the perforations 316 on the outer sidewall surface 320. As such, liquid fuel can more easily flow through the flame mitigation device 300 and into the fuel-receiving chamber of the fuel container as the fuel container is being filled (e.g., via a fuel nozzle). Similarly, when the fuel container is tipped to dispense liquid fuel, the angle of the perforations 316 provide for liquid fuel to more easily flow from the fuel-receiving chamber of the fuel container, through the perforations 316, past the flame mitigation device 300, and out of the fuel container. The downwardly sloping perforations 316 can be particularly important for flame mitigation devices 300 having smaller diameters, such as flame mitigation devices having inner diameters, e.g., at an upper end 324 (See FIG. 20) near the annular rim 310, of less than 2.5 inches, less than 2.25 inches, less than 2 inches, less than 1.75 inches, or less than 1.5 inches.
[0068] In some embodiments, the perforations 316 may extend downward at an angle 322 from the inner sidewall surface 318 to the outer sidewall surface 320, as best shown in FIG. 22. The angle 322 of the downwardly sloping perforations 316 may generally be measured relative to a horizontal plane (illustrated by the horizontal dashed line in FIG. 22), which is horizontal when the flame mitigation device 300 is oriented with its upper end 324 directly over its lower end 326 (i.e., when a central, longitudinal axis of the flame mitigation device 30 is vertical). As such, the horizontal plane may be considered parallel to the annular rim 310 and perpendicular to the central, longitudinal axis of the flame mitigation device 30. In certain embodiments, the angle 322 of the downwardly sloping perforations 316 may be at least 1 degree, at least 2.5 degrees, at least 5 degrees, at least 10 degrees, at least 20 degrees, at least 30 degrees, at least 40 degrees, a least 50 degrees, at least 60 degrees, or at least 70 degrees. In certain embodiments the angle 322 of the downwardly sloping perforations 316 may not be more than 85 degrees, not more than 75 degrees, not more than 65 degrees, not more than 55 degrees, not more than 45 degrees, not more than 35 degrees, not more than 25 degrees, not more than 15 degrees, or not more than 5 degrees.
[0069] With reference to FIG. 21, in various embodiments, the perforations 316 may be formed with an upper perforation surface 328, a lower perforation surface 330, and a pair of side perforation surfaces 332, 334. The angle 322 of the perforation 316 may be characterized by the angle formed by either of the upper and/or lower perforation surfaces 328, 330 with respect to horizontal. For example, FIG. 22 shows the lower perforation surface 330 sloping downwardly from the inner sidewall surface 318 to the outer sidewall surface 320 at the angle 322, which is illustrated to be about 45 degrees. In FIG. 22, the upper perforation surface 332 is also sloping downwardly from the inner sidewall surface 318 toward the outer sidewall surface 320 at the angle 322. However, it should be understood that, in some embodiments, only one of the upper and/or lower perforation surfaces 328, 330 may slope downward at the angle 322. Although the perforation surfaces 328, 330, 332, and 334 are illustrated in the drawings as generally flat surfaces, which together form a parallelogram-type shape, it is foreseen that the perforations surfaces 328, 330, 332, and 334 may be curved and may form any suitable shape.
[0070] In some embodiments, each of the perforations 316 included on the flame mitigation device 300 may be downward sloping. In other embodiments, the flame mitigation device 300 may include some perforations that extend generally horizontally, and are, thus, not downward sloping. For example, in certain embodiments, at least 20 percent, at least 30 percent, at least 40 percent, at least 50 percent, at least 60 percent, at least 70 percent, at least 80 percent, at least 90 percent, or 100 percent of the perforations 316 of the flame mitigation device 300 may downwardly sloping. Similarly, in certain embodiments, at least 20 percent, at least 30 percent, at least 40 percent, at least 50 percent, at least 60 percent, at least 70 percent, at least 80 percent, at least 90 percent, or 100 percent of the total open area defined by perforations 316 that are downwardly sloping.
[0071] In some embodiments, as shown in FIG. 20, the perforations 316 may be arranged about the flame mitigation device 300 in sections 336, with each section 336 including an array of perforations 316. In some embodiments, each perforation 316 in a section 336 may extend downward along the same angle 322, while in other embodiments, the downward angle 322 for one or more of perforation 316 in a given section 336 may vary. Because, in some embodiments, the sidewall 312 of the flame mitigation device 300 may be generally cylindrical, the sections 336 may extend arcuately about the sidewall 312. As such, as illustrated in FIG. 20, adjacent sections 336 may be spaced from one another axially by an axial imperforate section 338. Similarly, adjacent sections 336 may be spaced from one another circumferentially by a circumferential imperforate section 340.
[0072] In some embodiments, as shown in FIGS. 20, 23, and 24, the flame mitigation device 300 may further comprising one or more wing elements 342 used to facilitate a secure connection between the flame mitigation device 300 and a fuel container. In more detail, the wing elements 342 may comprise elongated prongs or barbs that are flexibly connected at a proximate end to the sidewall 312. The wing elements 342 may be configured to extend outward from the sidewall 312 (or an outer sidewall surface 320 of the sidewall 312), as shown in FIG. 20, such that a distal end, or free end, of the wing elements 342 may normally be spaced apart from the sidewall 312.
[0073] In general, the wing elements 342 may extend in an upward direction, at an angle 344 with respect to the sidewall 312. The angle 344 at which the wing elements 342 extend relative to the sidewall 312 may be of at least 1 degrees, at least 2.5 degrees, at least 5 degrees, at least 10 degrees, at least 20 degrees, at least 30 degrees, at least 40 degrees, a least 50 degrees, at least 60 degrees, or at least 70 degrees, and/or not more than 85 degrees, not more than 75 degrees, not more than 65 degrees, not more than 55 degrees, not more than 45 degrees, not more than 35 degrees, not more than 25 degrees, not more than 15 degrees, or not more than 5 degrees. In FIG. 20, the wing elements 342 are shown extending upward at an angle 344 of about 30 degrees relative to the sidewall 312.
[0074] Although the figures illustrate that the flame mitigation device 300 includes two wing elements 342, which are positioned on opposite sides of the flame mitigation device 300, it is contemplated that the flame mitigation device 300 may comprise any number of wing elements 342 as may be necessary to secure the flame mitigation device 300 to a fuel container. In some embodiments, the wing elements 342 may be formed of the same material from which the flame mitigation device 300 is formed, such that the wing elements 342 may be integrally formed with the sidewall 312. For example, the wing elements 342 may be formed from a synthetic resin material, such as polyethylene or polypropylene.
[0075] In operation, as illustrated in FIGS. 23 and 24, a user may secure the flame mitigation device 300 to a fuel container 346. Specifically, the flame mitigation device 300 may be secured to a neck 347 of the fuel container 346, with the neck presenting a main container opening 348 through which liquid fuel can be added to or extracted from the fuel container 346. In some embodiments, as shown in FIGS. 23 and 24, the neck 347 may comprise an upper portion 350 having a first inner diameter, and a lower portion 352 having a second inner diameter. The lower portion 352 may, in some embodiments be larger than the upper portion 350, such that the second diameter is greater than the first diameter.
[0076] To secure the flame mitigation device 300 to the fuel container 346, the flame mitigation device 300 can be inserted through the main container opening 348, as presented by the neck 347 of the fuel container 346. As described in more detail below, the wing elements 342 are configured to assist in securing the flame mitigation device 300 within the main container opening 348. To properly insert the flame mitigation device 300 into the main container opening 348, the flame mitigation device 300 should be inserted with its lower end 326 first, such that the wing elements 342 extend in an upward direction. As the flame mitigation device 300 is inserted within the main container opening 348, the wing elements 342 come into contact with an interior surface of the upper portion 350 of the neck 347, which causes the wing elements 342 to compress towards the sidewall 312, as is shown in FIG. 23. In some embodiments, the wing elements 342 will be compressed to a position adjacent to the sidewall 312 as the wing elements 342 pass along the upper portion 350 of the neck 347.
[0077] As shown in FIG. 34, once the flame mitigation device 300 has been sufficiently inserted within the main container opening 348, such that the wing elements 342 have passed beyond the upper portion 350 of the neck 347, the wing elements 342 are free to expand away from the sidewall 312 of the flame mitigation device 300 until the wing elements 342 come into contact with the lower portion 352 of the neck 347. Such expansion is generally made possible due to the larger inner diameter of the lower portion 352 of the neck, as compared with the inner diameter of the upper portion 350 of the neck 347. The wing elements 342 will generally expand outward until they come into contact with the lower portion 352 of the neck 347. In such a position, the flame mitigation device 300 will be secured within the main container opening 348 and inhibited from being removed from the fuel container 346. Specifically, as shown in FIG. 24, the flame mitigation device 300 will be restricted from moving upwards by way of an interference between the free, distal ends of the wing elements 342 and a connection element 358 of the neck 347, with the connection element 358 connecting the upper portion 350 of the neck 347 to the lower portion 352 of the neck. The flame mitigation device 300 may also be restricted from moving downwards by an annular bulge 356 that extends around (i.e., circumscribes) the interior surface of the upper portion 350 of the neck 347. Specifically, such a bulge 356 may interfere with the annular rim 310 of the flame mitigation device 300 so as to prevent the flame mitigation device 300 from falling down within the fuel container 346.
[0078] Embodiments of the flame mitigation device 300 may provide for a wing distance 360, as shown in FIGS. 23 and 34, to be defined as a distance between free, distal ends of opposing wing elements 342. As shown in FIG. 23, when the wing elements 342 are passing along the upper portion 350 of the neck 347, then the wing elements 342 will be in a compressed state, such that the wing distance 360 is less than the inner diameter of upper portion 350 of the neck 347. In contrast, as shown in FIG. 24, after the wing elements 342 have passed beyond the upper portion 350 of the neck 347, the wing elements 342 will expand such that the wing distance 360 is greater than the inner diameter of upper portion 350 of the neck 347. As such, the wing distance 360 of the flame mitigation device 300 in the expanded state is greater than the wing distance 360 of the flame mitigation device 300 in the compressed state.
[0079] It should be understood that the dimensions, values, and/or angles provided above, with reference to the figures may be varied. For example, in certain embodiments, each dimension/angle can be varied by +/10%, +/25%, or +/50%. For example, a dimension of 10 inches in FIG. 20 or 24 provides support for the following claim ranges: 9 to 11 inches (i.e., 10 inches+/10%), 7.5 to 12.5 inches (i.e., 10 inches+/25%), and 5 to 15 inches (i.e., 10 inches+/50%). Further, the upper and lower bounds of the ranges can be use by themselves or together. For example, a range of 7.5 to 12.5 inches provides support for a claimed length of at least 7.5 inches (with no upper end) and a claimed length of not more than 12.5 inches (with no lower end).
[0080] Although the invention has been described with reference to the one or more embodiments illustrated in the figures, it is understood that equivalents may be employed and substitutions made herein without departing from the scope of the invention as recited in the claims.
[0081] Having thus described one or more embodiments of the invention, what is claimed as new and desired to be protected by Letters Patent includes the following:
