TANK-SENSOR SYSTEM AND METHODS FOR PRODUCING THE SAME

Abstract

Provided herein are tank-sensor systems and related manufacturing methods. In at least one aspect, the tank-sensor system includes a tank liner. The tank liner includes a body having a top end, a bottom end, an outer surface, and an inner surface. The tank liner also includes a recessed opening having a recessed portion and an opening. The recessed portion is positioned on the outer surface and the opening is positioned within the recessed portion and defines a through-hole between the outer surface and the inner surface. The tank-sensor system also includes a sensor inserted into the opening and engaging with the recessed portion, and a coating disposed around the outer surface of the tank liner and sealing the recessed opening.

Claims

1. A tank-sensor system, comprising: a tank liner, the tank liner comprising: a body having a top end, a bottom end, an outer surface, and an inner surface; and a recessed opening, the recessed opening comprising a recessed portion and an opening, wherein the recessed portion is positioned on the outer surface and the opening is positioned within the recessed portion to define a through-hole between the outer surface and the inner surface; a sensor inserted into the opening and engaging with the recessed portion; and a coating disposed around the outer surface of the tank liner and at least partially sealing the recessed opening.

2. The tank-sensor system of claim 1, wherein the recessed opening is integrally formed with the body of the tank liner.

3. The tank-sensor system of claim 2, wherein the sensor comprises: a first end having a sensor probe; and a second end having a flange portion and a seal portion.

4. The tank-sensor system of claim 3, wherein the flange portion of the sensor engages with the recessed portion of the recessed opening.

5. The tank-sensor system of claim 3, wherein one or more electrical components extend from the second end of the sensor toward the top end of the body of the tank liner.

6. The tank-sensor system of claim 3, wherein the seal portion of the sensor is a first shape that is complementary to a second shape of the recessed opening.

7. The tank-sensor system of claim 3, wherein the sensor probe of the sensor extends through the opening of the inner surface of the body of the tank liner.

8. The tank-sensor system of claim 5, wherein the coating protects the one or more electrical components.

9. A method for assembling a tank-sensor system, the method comprising: preparing a tank liner, the tank liner comprising: a body having a top end, a bottom end, an outer surface, and an inner surface; and a recessed opening, the recessed opening comprising a recessed portion and an opening, wherein the recessed portion is positioned on the outer surface and the opening is positioned within the recessed portion to define a through-hole between the outer surface and the inner surface, and wherein the recessed opening is integrally formed with the outer surface; inserting a sensor probe into the recessed opening; and applying a coating around the outer surface of the tank liner.

10. The method of claim 9, further comprising: engaging a flange portion of the sensor probe with the recessed portion of the recessed opening; and setting a desirable depth of insertion using the flange portion and a seal portion of the sensor probe.

11. The method of claim 9, further comprising applying one or more alternating layers of binding agents and durable materials to the tank liner.

12. The method of claim 9, wherein applying a coating around the outer surface of the tank liner forms a seal over the recessed opening.

13. The method of claim 9, wherein the recessed opening is integrally formed with the outer surface.

14. The method of claim 9, further comprising applying a finishing material to the inner surface of the tank liner.

15. A method for assembling a tank-sensor system, the method comprising: preparing a tank liner, the tank liner including a body having an outer surface, an inner surface, and a recessed portion positioned on the outer surface; forming a recessed opening in the tank liner; inserting a sensor into the recessed opening; and applying a coating around the outer surface of the tank liner to at least partially seal the recessed opening.

16. The method of claim 15, further comprising machining an opening through the recessed portion to form a through-hole.

17. The method of claim 16, wherein inserting a sensor into the recessed opening further comprises: moving a first end of the sensor from an exterior of the tank liner, through the opening of the recessed opening, and into an interior of the tank liner, and setting a desirable depth of insertion using a flange portion and a seal portion of the sensor.

18. The method of claim 15, wherein applying a coating around the outer surface of the tank liner further comprises applying one or more alternating layers of resin and fiberglass.

19. The method of claim 15, wherein applying a coating around the outer surface of the tank liner protects one or more electrical components extending from the sensor.

20. The method of claim 15, further comprising applying a finishing material to the inner surface of the tank liner.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] FIG. 1 is an isometric view of an exemplary tank-sensor system including an exemplary tank;

[0028] FIG. 2 is a cross-sectional view of the tank of FIG. 1 and an exemplary sensor taken along the line 2-2 of FIG. 1;

[0029] FIG. 3 is a cross-sectional view of the tank of FIG. 1 and an exemplary first sensor and an exemplary second sensor taken along the line 2-2 of FIG. 1;

[0030] FIG. 4A is an isometric view of the sensor of FIG. 2;

[0031] FIG. 4B is a left side elevational view of the sensor of FIG. 4A;

[0032] FIG. 5A is an enlarged, cross-sectional view of an exemplary recessed opening within a tank liner of the tank of FIG. 2;

[0033] FIG. 5B is an additional enlarged, cross-sectional view of the recessed opening of FIG. 5A and the sensor of FIG. 2;

[0034] FIG. 5C is an additional enlarged, cross-sectional view of the recessed opening of FIG. 5A and the sensor of FIG. 2 being positioned within an opening of the recessed opening;

[0035] FIG. 5D is an additional enlarged, cross-sectional view of the recessed opening of FIG. 5A and the sensor of FIG. 2 being further positioned within an opening of the recessed opening;

[0036] FIG. 5E is an additional enlarged, cross-sectional view of the recessed opening of FIG. 5A and the sensor of FIG. 2 installed within the recessed opening;

[0037] FIG. 5F is an additional enlarged, cross-sectional view of the recessed opening of FIG. 5A including the sensor of FIG. 2 installed therein, and an exemplary coating of the tank of FIG. 2;

[0038] FIG. 6 is a flowchart of an exemplary method of manufacturing the tank-sensor system of FIG. 1; and

[0039] FIG. 7 is a flowchart of an exemplary method of assembling the tank-sensor system of FIG. 1.

DETAILED DESCRIPTION

[0040] Before any aspects are described in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings, which is limited only by the claims that follow the present disclosure. The disclosure is capable of other aspects, and of being practiced, or of being carried out, in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of including, comprising, or having and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms mounted, connected, supported, and coupled and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, connected and coupled are not restricted to physical or mechanical connections or couplings.

[0041] The following description is presented to enable a person skilled in the art to make and use aspects of the disclosure. Various modifications to the illustrated aspects will be readily apparent to those skilled in the art, and the generic principles herein can be applied to other aspects and applications without departing from aspects of the disclosure. Thus, aspects of the disclosure are not intended to be limited to aspects shown but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of aspects of the disclosure.

[0042] Additionally, while the following discussion may describe features associated with specific devices or aspects, it is understood that additional devices and/or features can be used with the described systems and methods, and that the discussed devices and features are used to provide examples of possible aspects, without being limited.

[0043] At a high level, aspects of the present disclosure relate to tanks equipped with one or more sensorshereinafter referred to as tank-sensor systemsand methods of manufacturing the same. Tank-sensor systems can be used in residential settings (e.g., homes), where one or more sensors disposed at least partially within an interior of a tank can monitor a quality and/or volume of a fluid (e.g., water, fuel, or the like) within the tank. For instance, a water storage tank-sensor system can be used to store potable water (e.g., for drinking, washing, etc.). The storage tank-sensor system can include a tank having one or more internal sensors that are operatively coupled to a controller designed to increase or decrease the volume of water stored within the tank (e.g., via other components such as pumps, valves, etc.) based on measurements obtained from the one or more sensors. Similarly, in other instances, the one or more internal sensors of the tank can measure parameters or characteristics (e.g., a pH value, a total chlorine value, a free chlorine value, an oxidation-reduction potential) of the water stored in the tank to determine the water quality. In turn, this information can be utilized by a controller associated with the tank such that one or more treatment chemicals can be controllably dosed into the tank based on the determined water quality. Alternative instances of tank-sensor systems can include, but are not limited to, septic tanks, fuel storage tanks, or tanks for any other suitable residential, commercial, or industrial use without departing from the principles of the present disclosure.

[0044] In addition, aspects of the present disclosure relate to improved methods of manufacturing or assembling a tank-sensor system. Prior methods of manufacturing tank-sensor systems involve costly, labor-intensive, and imprecise ways of inserting a sensor into the tank. In particular, prior methods include: (1) preparing a tank liner; (2) applying a coating or laminate to the outer surface of the tank liner; (3) machining an opening through the tank liner and coating or laminate; (4) inserting a fitting into the opening; (5) re-applying the coating or laminate over gaps between the opening and the fitting; and (6) inserting a sensor into the opening. In addition to high costs, prior methods produce tank-sensor systems having partially exposed or protruding sensors which may be undesirable for tight spaces. Thus, the present disclosure relates to an improved method for manufacturing or assembling tank-sensor systems that reduces the need to machine an opening through a completed tank, use a fitting, and/or re-apply coating or laminate over the opening with the sensor mounted therein, thereby allowing the tank-sensor systems to be produced in a less costly and time-consuming manner.

[0045] Turning now to FIGS. 1 and 2, an aspect of an exemplary tank-sensor system 100 and a cross-section thereof are shown. The tank-sensor system 100 can include a tank 102 and one or more sensors 104. Generally, the tank 102 may be provided in the form of a substantially hollow cylinder or a substantially hollow capsule, although the tank 102 may also be provided in other forms and shapes. For example, in other instances, the tank 102 may be provided in the form of polygonal prism shapes such as a rectangular prism, a hexagonal prism, or an octagonal prism. The tank 102 may be configured store one or more fluids that are ultimately provided to an end user.

[0046] The tank 102 may include a tank liner 106, one or more recessed openings 108 and a coating 110. In some aspects, the tank liner 106 may include a body 112 provided in the form of a bottom end 114, a top end 116, an inner surface 118, and an outer surface 120. In some instances, the shape of the body 112 may be substantially the same as the shape of the tank 102. The body 112 may be designed as a storage unit or storage component for one or more fluids. The inner surface 118 may be configured to define an interior cavity 122 of the tank 102 where water, fuel, or other liquids and/or contents can be stored. The tank liner 106 can be formed from any suitable, corrosion-resistant material without departing from the principles of this disclosure. Exemplary manufacturing techniques include, but are not limited to, blow molding or rotational molding (e.g., using plastic resin materials such as polyethylene or polypropylene), and/or welding (e.g., using metallic materials such as stainless steel).

[0047] Each of the one or more recessed openings 108 may include a recessed portion 124 disposed on the outer surface 120 of the tank liner 106 and an opening 126 that extends through the inner and outer surfaces 118, 120 of the tank liner 106, thereby creating a through-hole in the tank liner 106. In some aspects, the opening 126 may be disposed in or proximate to a center area of the recessed portion 124 (see, e.g., FIG. 5A). In some aspects, the one or more recessed openings 108 may be designed to receive the one or more sensors 104. As discussed in more detail below, in some aspects, the coating 110 can then be applied over the tank liner 106 to form a fortified, leak-proof seal around the one or more sensors 104 and the one or more recessed openings 108. In some aspects, the one or more recessed openings 108 can be partially or completely integrally formed with the tank liner 106, while in other aspects, the one or more recessed openings 108 can at least be partially machined or drilled into the tank liner 106. For example, in some instances, the one or more recessed openings 108 can be molded, welded, or otherwise integrally formed on or in the body 112 of the tank liner 106, thereby decreasing variability in sensor placement and reducing the amount of processing required to create the tank liner 106. In other instances, at least a portion of the one or more recessed openings 108 (e.g., the opening 126 of FIG. 5A) can be machined or drilled into the body 112 of the tank liner 106. In some aspects, the one or more recessed opening 108 can form a register-like fitting for the sensor 104.

[0048] In some aspects, as shown in FIG. 2, the one or more recessed openings 108 as well as the one or more sensors 104 can be positioned at a height H along a length L of the tank liner 106. The length L may be imparted with a first value equal to a total distance measured between the bottom end 114 and the top end 116 of the body 112, and the height H may be imparted with a second value equal to a distance measured from the bottom end 114 of the body 112 of the tank liner 106 to the location of the one or more sensors 104. In some aspects, the second value of the height H may be about 5% to about 95%, or about 15% to about 70%, or about 25% to about 40% of the first value of the length L. For example, the second value of the height H can be about 5% to about 15%, or about 10% to about 20%, or about 15% to about 25%, or about 20% to about 30%, or about 25% to about 35%, or about 30% to about 40%, or about 35% to about 45%, or about 40% to about 50%, or about 45% to about 55%, or about 50% to about 60%, or about 55% to about 65%, or about 60% to about 70%, or about 65% to about 75%, or about 70% to about 80%, or about 75% to about 85%, or about 80% to about 90%, or about 85% to about 95% of the length L of the tank liner 106. In other instances, the second value of the height H can be no more than about 95%, or no more than about 90%, or no more than about 85%, or no more than about 80%, or no more than about 75%, or no more than about 70%, or no more than about 65%, or no more than about 60%, or no more than about 55%, or no more than about 50%, or no more than about 45%, or no more than about 40%, or no more than about 35%, or no more than about 30%, or no more than about 25%, or no more than about 20%, or no more than about 15%, or no more than about 10%, or no more than about 5% of the first value of the length L. In certain aspects, the tank-sensor system 100 can comprise a plurality of recessed openings 108 and sensors 104 positioned at various heights such that a gradient of fluid levels and/or fluid parameters can be determined. In other aspects, more than one sensor 104 can be positioned at the height H. In yet other aspects, each sensor of the one or more sensors 104 may be positioned at different heights H. In some instances, one or more sensors 104 may be positioned at any location along the length L of the tank liner 106.

[0049] In one non-limiting example shown in FIG. 3, a first sensor 104a of the one or more sensors 104 can be inserted into a first recessed opening 108a of the one or more recessed openings 108 at a first height H1, in which the first height H1 is imparted with a value of about 25% of the of the length L of the tank liner 106. A second sensor 104b can be inserted into a second recessed opening 108b at a second height H2, in which the second height H2 is imparted with a value of about 40% of the of the length L of the tank liner 106. Thus, the first sensor 104a and the second sensor 104b may, for example, monitor tank usage and transmit one or more signals indicating that the tank-sensor system 100 is in use and/or the tank-sensor system 100 requires maintenance or fluid replenishing. The first sensor 104a and the second sensor 104b may also, for example, measure a fluid parameter indicative of water quality and transmit one or more signals representing the measured parameter. In some aspects, a controller 200 (e.g., a computer processing unit), can receive one or more signals 202 transmitted from the first sensor 104a and/or the second sensor 104b, process information from the one or more signals 202, and send an alert or other notification regarding the status of one or more parameters of the tank-sensor system 100. In other aspects, the tank-sensor system 100 can include any suitable number of recessed openings 108 and sensors 104 without departing from the principles of this disclosure.

[0050] In some aspects, the coating 110 can be applied over or onto the outer surface 120 of the tank liner 106. The coating 110 may include one or more fortifying materials that are applied over or onto the outer surface 120 of the tank liner 106 to enhance the durability and chemical resistance of the tank-sensor system 100. For instance, a durable material (e.g., fiberglass or the like) can be saturated with a binding agent such as a resin (e.g., polyester, epoxy, or the like) and applied in one or more layers to laminate the tank liner 106, thereby forming the coating 110. In some cases, a release agent can be applied to portions of the tank liner 106 (e.g., internal portions) to ensure the coating 110 does not stick to unintended areas. In other cases, additional processing may be desirable to finish the coating 110, such as, but not limited to, rolling (e.g., to remove air bubbles and/or evenly distribute the binding agent), curing (e.g., to bond/harden the bonding agent to the tank liner 106), and sanding (e.g., to smoothen rough edges). Thus, in some aspects, the coating 110 can function as a leak-proof barrier or seal and fortify the tank liner 106 by encasing the one or more recessed openings 108. In some aspects, the coating 110 can be a tank winding. In certain aspects, such as the aspect shown in FIG. 5F, one or more wires 128 or other electronic components extending from the one or more sensors 104 may extend from the one or more recessed openings 108, external to the tank liner 106. In some aspects, the coating 110 can then be applied as a protective layer over the one or more wires 128, and can secure the one or more wires 128 against or proximate to the tank liner 106. In other aspects, the tank-sensor system 100 may not include any wires (i.e., the sensor 104 may be wireless and/or battery-powered) and thus the coating 110 may protect and/or insulate the tank liner 106.

[0051] Turning now to FIGS. 4A and 4B, an exemplary sensor 104 of the one or more sensors 104 is shown. The sensor 104 may be configured for insertion into an area of the tank liner 106 and for engagement with the recessed opening 108. For example, the sensor 104 may include a sensor body 130 disposed between a first end 131 and a second end 132. In some cases, one or more sensor probes 134 may extend outwardly and away from the first end 131 such that the one or more sensor probes 134 protrude into the interior cavity 122 (see FIG. 5A) of the tank 102 to measure an amount of fluid disposed in the tank and/or a parameter of the fluid (e.g., a parameter associated with water quality). In some aspects, as shown in FIGS. 4A and 4B, the sensor 104 may include two sensor probes 134. In other aspects, the sensor 104 may include one sensor probe 134, and in further aspects, the sensor 104 may include three or more sensor probes 134. In addition, the sensor 104 may be operatively and/or electronically coupled to the controller 200, which can adjust the fluid level within the tank 102 and/or parameters of the fluid (e.g., the water quality of the fluid) based on measurements from the one or more sensor probes 134. Exemplary sensor probes 134 can measure temperature, water quality parameters (e.g., a pH level, a total dissolved solids level, an oxidation-reduction potential, etc.), or any other suitable parameters. In some aspects, the one or more sensor probes 134 can be designed to measure a plurality of water quality parameters. Thus, in some aspects, the sensor 104 can be designed to measure tank usage and quality and send an alert via the controller 200 that the tank-sensor system 100 is in use and/or the tank-sensor system 100 requires maintenance and/or regeneration.

[0052] In some aspects, the second end 132 of the sensor 104 can be designed to complementarily engage the recessed opening 108, in which the second end 132 comprises a flange portion 136 and a seal portion 138. In some instances, the seal portion 138 can be designed to absorb a compressive force as the coating 110 is applied over the tank liner 106, and the flange portion 136 may be designed to limit the amount of force applied to the seal portion 138. In other instances, the flange portion 136 and the seal portion 138 may be designed to set a desirable depth or distance of the sensor 104 into the interior cavity 122 of the tank 102 and/or provide a leakproof seal between the opening 126 and the interior cavity 122 of the tank 102 (see, e.g., FIG. 5A). Thus, the flange portion 136 and seal portion 138 (together or individually) can prevent tank leakage through the recessed opening 108. Additionally, in some aspects, one or more wires 128 or other electrical components (see FIG. 5F) may route through the sensor body 130 and extend from the second end 132.

[0053] In some aspects, the seal portion 138 can be provided in various forms to enhance engagement of the sensor 104 (e.g., the flange portion 136) with portions of the recessed opening 108, including, but not limited to, an O-ring, a face seal, a bore seal, and/or other similar sealing members. In certain instances, the seal portion 138 can be provided in the form of a tapered shape (see, e.g., FIG. 4B); and, in other instances, the seal portion 138 can be provided in the form of a straight shape. Thus, the seal portion 138 can be provided in the form of a complementary shape (i.e., tapered, straight, etc.) to the recessed opening 108. In some aspects, the seal portion 138 can be integrally formed with the sensor body 130 of the sensor 104. In some aspects, the sensor 104 can be removed and replaced in the event of sensor failure. In some aspects, the sensor body 130 may be provided in the form of a tapered contour or any other suitable shape without departing from the principles of the disclosure. In one non-limiting example, the seal portion 138 can be provided in the form a tapered shape and the recessed opening 108 can be provided in the form of a straight shape or vice versa. In another non-limiting example, the seal portion 138 can be provided in the form of an O-ring and the recessed opening 108 can be provided in the form a tapered shape. In another non-limiting example, the seal portion 138 can be provided in the form of a bore seal or a face seal and the recessed opening 108 can be provided in the form of a straight shape.

[0054] In some instances, the seal portion 138 of the sensor 104 may have a thickness T (see FIG. 4B) that is the same or substantially the same as a first width W1 of the opening 126 (see FIG. 5A) of the recessed opening 108. In other instances, the seal portion 138 may have a thickness T that is less than or greater than the first width W1 of the opening 126 of the recessed opening 108. In some examples, the thickness T may be imparted with a value of 2 millimeters (mm) to 8 mm. For example, the thickness T may be imparted with a value of at least about 2 mm, or at least about 3 mm, or at least about 4 mm, or at least about 5 mm, or at least about 6 mm, or at least about 7 mm, or no more than about 8 mm. As an additional example, the thickness T may be imparted with a value of at least 2 mm, or at least 3 mm, or at least 4 mm, or at least 5 mm, or at least 6 mm, or at least 7 mm, or no more than 8 mm. The thickness T of the seal portion 138 may correspond to the desired depth or distance at which the sensor 104 projects into the interior cavity 122 of the tank 102. For example, if the thickness T of the seal portion 138 is greater than the first width W1 of the opening 126 of the recessed opening 108, then the depth at which the sensor 104 projects into the interior cavity 122 may increase. In other examples, if the thickness T of the seal portion 138 is less than the first width W1 of the opening 126 of the recessed opening 108, then the depth at which the sensor 104 projects into the interior cavity 122 may decrease.

[0055] Turning now to FIGS. 5A-5F, multiple cross-sectional views of the tank-sensor system 100 are shown, depicting the recessed opening 108 of the tank liner 106 receiving one of the one or more sensors 104. Referring to FIG. 5A, in certain aspects, the recessed portion 124 of the recessed opening 108 may have a recess diameter D1 and may be formed over or within an area of the outer surface 120 of the tank liner 106, and the opening 126 may be formed in a center area of the recessed portion 124. In some aspects, the opening 126 may have an opening diameter D2 that is smaller than the recess diameter D1. Thus, the opening 126 formed within the recessed portion 124 may be designed to prevent the sensor 104 from falling into the interior cavity 122 of the tank 102. For example, the recessed portion 124 may be designed to engage the flange portion 136 of the sensor 104 and the opening 126 may be designed to allow entry of the sensor body 130 into the inner surface 118 of the tank liner 106.

[0056] In addition, the opening 126 of the recessed opening 108 may have the first width W1 and the tank liner 106 may have a second width W2 as shown in FIG. 5A. In some instances, the first width W1 of the opening 126 may be the same or substantially the same as the second width W2 of the tank liner 106. In other instances, the first width W1 of the opening 126 of the recessed opening 108 may be less than or greater than the second width W2 of the tank liner 106. In some examples, the first width W1 of the opening 126 may be imparted with a value of 2 mm to 4 mm. For example, the first width W1 may be imparted with a value of at least about 2 mm, or at least about 2.5 mm, or at least about 3 mm, or at least about 3.5 mm, or no more than about 4 mm. As an additional example, the first width W1 may be imparted with a value of at least 2 mm, or at least 2.5 mm, or at least 3 mm, or at least 3.5 mm, or no more than 4 mm. In some examples, the second width W2 of the tank liner 106 may be imparted with a value of 2 mm to 4 mm. For example, the second width W2 may be imparted with a value of at least about 2 mm, or at least about 2.5 mm, or at least about 3 mm, or at least about 3.5 mm, or no more than about 4 mm. As an additional example, the second width W2 may be imparted with a value of at least 2 mm, or at least 2.5 mm, or at least 3 mm, or at least 3.5 mm, or no more than 4 mm. In some instances, the first width W1 of the opening 126 of the recessed opening 108 may correspond to the desired depth or distance at which the one or more sensors 104 project into the interior cavity 122 of the tank 102. For example, as the first width W1 of the opening 126 of the recessed opening 108 may increase, the depth at which the one or more sensors 104 project into the interior cavity 122 of the tank 102 may decrease and vice versa.

[0057] As best shown in the non-limiting aspects of FIGS. 5B-5D, the tank liner 106 may receive the one or more sensors 104 in the direction of arrow 140 (e.g., from an exterior of the tank liner 106 to an interior of the tank liner 106). For example, the one or more sensor probes 134 of the first end 131 of the one or more sensors 104 may be moved from an exterior of the tank liner 106, through the opening 126, and into the interior cavity 122 of the tank 102. In other aspects, the one or more sensors 104 may be formed integrally with the tank liner 106 or may be mounted in a direction different from or opposite the arrow 140 (e.g., from the inner surface 118 of the tank liner 106 to the outer surface 120 of the tank liner 106 or from an interior of the tank liner 106 to an exterior of the tank liner 106). The one or more sensors 104 may penetrate through the opening 126 to a certain depth. In some instances, the depth at which the one or more sensors 104 penetrate through the opening 126 may be determined by the opening diameter D2, the first width W1, the thickness T, and/or the tension of a reinforcement layer (not depicted) that may be substantially arranged over the tank liner 106. In some examples, the reinforcement layer may be the coating 110. The reinforcement layer may be applied to the tank liner 106 such that the reinforcement layer forms a tank winding. The tank winding may be designed to push the one or more sensors 104 through the opening 126 to a certain depth. For example, the one or more sensors 104 may penetrate partially through the opening 126, as depicted in FIG. 5D. In other instances, the tension of the tank winding may push the one or more sensors 104 substantially or all the way through the opening 126, as depicted in FIG. 5F.

[0058] Turning now to FIG. 6, a flowchart depicting an exemplary method 600 of manufacturing a tank-sensor system, such as tank-sensor system 100, is shown, according to one aspect. Generally, the method may include: (1) preparing a tank liner; (2) creating one or more openings in the tank liner; (3) inserting a sensor into the opening in the tank liner; (4) applying a coating over the tank liner; and (5) applying a finishing material to the tank liner. Each aspect of the method will be described in more detail below.

[0059] At 610, a tank liner, such as the tank liner 106, can be prepared according to any suitable technique without departing from the principles of this disclosure (e.g., molding, welding, laminating, etc.). The tank liner can include one or more recessed openings (e.g., recessed openings 108) designed to receive and retain one or more sensors (e.g., sensors 104). In some aspects, a recessed portion (e.g., recessed portion 124) of the one or more recessed openings can be integrally formed with the tank liner. In one non-limiting example, a tank liner mold can include a design for one or more recessed openings such that tank liners prepared using the mold can include integrally formed recessed openings.

[0060] At 620, an opening (e.g., opening 126) can be formed or otherwise created within the recessed portion of the one or more recessed openings. In some aspects, the opening can be machined into the recessed portion of the tank liner. Thus, in some aspects, at least some portions of the one or more recessed openings can be integrally formed with the tank liner (e.g., the recessed portion 124 shown in FIG. 5A), and the openings can be machined into the recessed portions to form overall recessed openings for the tank liner. In other aspects, the recessed portions and the openings can be integrally formed in the tank liner. In some instances, the recessed portion and/or the opening may be formed in the tank liner at a height (e.g., height H) along a length (e.g., length L) of the tank liner.

[0061] At 630, the one or more sensors can be inserted into the tank liner via the one or more recessed openings. In some aspects, certain features of the sensors (e.g., the flange portion 136 and seal portion 138 of FIGS. 4A and 4B) can engage with certain complementary features of the recessed openings (e.g., the recessed portion 124 and opening 126 of FIG. 5A) to provide a secure fit of the one or more sensors in the tank liner. In some aspects, the one or more sensors can be inserted into the tank liner from an exterior of the tank liner to reduce the risk of the sensors falling into an interior (e.g., interior cavity 122) of the tank (see, e.g., FIGS. 5B-5E). In other aspects, the sensors can be inserted from within the tank liner. Additionally, one or more wires (e.g., wires 128) or other electrical components can extend from the one or more sensors, along an outer surface (e.g., outer surface 120) of the tank liner. In some instances, the sensors can be assembled as the tank liner is prepared, while in other instances, the sensors can be pre-assembled.

[0062] At 640, an outer coating, such as the coating 110, can be applied around the outer surface of the tank liner (see, e.g., FIG. 5F). The coating may fortify the tank by providing additional structure and rigidity to the tank liner. In some aspects, the coating can be applied to the tank liner in one or more layers of durable materials and binding agents, such as a combination of fiberglass and resin/epoxy. In some aspects, the coating can form a winding around the tank liner and protect and/or insulate the one or more wires or other electrical components extending from the one or more sensors. In some aspects, the tank liner may be sanitized prior to applying the coating so that the coating adheres to the tank liner. In some aspects, additional processing may be required to smoothen and/or cure the one or more layers of coating materials.

[0063] At 650, a finishing material may be applied to the tank liner. The finishing material may protect the tank liner from degradation or corrosion by the contents disposed of in the tank. In some instances, the tank liner can be filled with a finishing material such as a resin.

[0064] Turning now to FIG. 7, a flowchart depicting an exemplary method 700 of assembling a tank-sensor system, such as tank-sensor system 100, is shown, according to one aspect. Generally, the method may include: (1) preparing a tank liner; (2) forming a recessed opening in the tank liner; (3) engaging a sensor with the recessed opening; (4) setting a depth of the sensor; and (5) applying one or more layers of binding agents to the tank liner.

[0065] At 710, a tank liner, such as the tank liner 106, can be prepared according to any suitable technique without departing from the principles of this disclosure (e.g., molding, welding, laminating, etc.).

[0066] At 720, a recessed opening (e.g., recessed opening 108) can be formed in the tank liner according to any suitable technique without departing from the principles of this disclosure. In some instances, the recessed opening may be integrally formed on the tank liner. In other instances, the recessed opening may be machined into a body (e.g., body 112) of the tank liner. In some instances, the recessed opening may be formed in the tank liner at a height (e.g., height H) along a length (e.g., length L) of the tank liner.

[0067] At 730, a sensor (e.g., sensor 104) may be engaged with the recessed opening. In some instances, the sensor may be provided with a flange portion (e.g., flange portion 136) and a seal portion (e.g., seal portion 138). The flange portion may be designed to engage the sensor with the recessed opening and may be designed to set a desired depth of insertion of the sensor through the recessed opening. The seal portion may be designed to form a water tight seal between the sensor and the recessed opening.

[0068] At 740, a depth of the sensor may be set. In some instances, the flange portion and the seal portion may maintain the depth of insertion of the sensor.

[0069] At 750, at least one or more alternating layers of a binding agent and/or a durable material may be applied to the tank liner. In some aspects, the layers can be applied to the tank liner in one or more layers of durable materials and binding agents, such as a combination of fiberglass and resin/epoxy. In some aspects, the layers can form a winding around the tank liner and protect and/or insulate the one or more wires or other electrical components extending from the one or more sensors. In some aspects, the tank liner may be sanitized prior to applying the layers so that the layers adheres to the tank liner. In some aspects, additional processing may be required to smoothen and/or cure the one or more layers of coating materials.

[0070] It will be appreciated by those skilled in the art that while the above disclosure has been described above in connection with particular aspects and examples, the above disclosure is not necessarily so limited, and that numerous other aspects, examples, uses, modifications and departures from the aspects, examples and uses are intended to be encompassed by the claims attached hereto. The entire disclosure of each patent and publication cited herein is incorporated by reference, as if each such patent or publication were individually incorporated by reference herein. Various features and advantages of the above disclosure are set forth in the following claims.