Activation device for sump pumps
An activation device for use with a sump or other type pump is provided. The device includes a switched outlet into which the electrical plug of a pump is plugged. The switched outlet is connected to a switching means that is activated by conditions related to the rising and falling of water in the area about a pump, such as the sump of a home or other building. The activation means has an electrical micro-switch associated with a lever attached to a float rod and float; biasing means, locking the switch into an on position until the occurrence of a predetermined event, are provided. As the float rises the switch is activated allowing electricity to flow to the pump. The biasing means permits the pump to continue to operate as the water level in the sump falls. When the water level falls to a desired low level, the activation means is triggered to cut electricity off to the pump, and return to a standby state.
The present invention concerns a switch for activating a sump pump in the presence of rising water. More particularly the present invention concerns a vertical float switch that causes the activation of a sump pump when an appropriate amount of water has entered a sump and causes a pump to continue to operate until sufficient water has been pumped out to cause the pump to cease operation. The pump is maintained in operation by a spring-loaded switch that is designed to stop the operation of the pump at a desired water level. The switch can be used to operate any pump and is not dependent on use with a particular or designated pump.
BACKGROUND OF THE INVENTIONWith the need to protect homes from water damage due to the natural rise of the water table the use of sump pumps has become commonplace in many homes, especially those in known flood areas. Sump pumps are typically located in a sump or pit that is excavated at or about the lowest point of the house. Sump pumps are often of the submersible-type, meaning that they operate within a pool of water; which has the added effect of keeping the pump motor cool while running.
While a pump would be able to draw the water out of the sump and into either the waste water system or to an ejection point away from the foundation of the structure, the pump must either be set to run continuously or activated by some means that can detect the presence and rising of water. A pump running continuously wastes energy and runs the risk of burning out from constant action and its activity of removing water in the sump can cause burnout by the removal of all of its surrounding cooling pool of water. It is preferable, therefore, to have a means to detect the presence of water and activate the pump thereafter. Ideally the system permits the pump to draw the water down to a safe point and then deactivate the pump.
The sump is typically below floor level and water rises therein. Sump pumps typically are placed into operation and left alone to operate only on those rare occasions when water enters into a foundation area. Oftentimes a pump can be inactive during an entire dry season; further the pump and switch are typically located in areas of the structure that are dirty, damp or otherwise not conducive to the maintenance of electrical switches, particularly sophisticated switches designed to operate only upon the arising of a designated event (such as the rise of the water table).
Typically, sump pumps are sold as a unit with both the pump and the switch; as such a particular pump manufacturer that makes superb pumps may adopt a type of switch that is poor. Purchasers of pumps typically have no choice in the switch and vice-versa. Often times the manufacturer of an excellent pump will provide a substandard switch, and vice-versa, such that the user has one or both inadequate elements of a pumping and protective system.
Many switches and activation mechanisms are available that permit the activation of a pump at appropriate times during a rising water event. Included in presently available switches are floating switches that trigger the activation of a pump upon rising to a certain level and shutting off the pump upon sinking back to a safer level; or switches floating within a tethered float. Tethered floats typically have a mercury-type switch that is activated and deactivated by the change in angle of the float, returning to a shut off position upon the return of the tethered float to its at rest position.
These switches, while effective, have flaws that can lead to a pump not activating when it is most needed. In particular, the former type of switch is most effected by the dirty conditions of its location as well as has the flaw of often-times shutting the pump off too soon in its cycle of rising and falling. The tether-type switch, because of its more free moving action, can be blocked as it pivots up to its activation level, thus failing to activate the pump. While tethered switches are often sealed away from dirt and dust, they have the same problem of shutting a pump down too quickly as the water recedes as a result of pump activity.
When a pump is shut down too quickly there is a tendency to have the pump activate and shut down often particularly in a rapid water rise cycle, such that the switch and pump are activated and deactivated too often. If the pump is shut down too early the level of water remains high enough that a small influx of water subsequent reactivates the pump quickly, the pump then removes a small amount of water again before it is deactivated again. This cycle is deleterious to the pump and switch mechanism; the nominal state being the activation and appropriate running of the pump to well drain the sump so as to provide an adequate time span before the next cycle. It is well known that pump and switch systems have a certain number of cycles in the life of the system and constant activation and deactivation causing early failure of the system by exhaustion of the life of the system.
There are other pump switches known in the art, however, there is only one other free-standing submersible float switch mechanism on the market that is known. It will be understood by persons having ordinary skill in the art that, free-standing, with respect to sump pump switches, means that the switch can be used on any sump pump and is not designed for a particular sump pump of any manufacturer. The one known free-standing switch is by SJE Rhombus of Detroit Lakes, Minn., also known as S. J. Electro. The SJ Electro switch employs magnets to keep the switch in an “on” (closed circuit) position as water is pumped from the pit. The present invention comprises an alternative design offering benefits not available before.
It would therefore be desirable to have a switch system that is better equipped to withstand the ambient conditions in a sump location and provide a means to delay the shutting off of the pump until the sump is substantially emptied. Such a switch should also address the issue of not running the pump for too long such that the pump is removed from its cooling water surroundings so that the danger of pump burn out is lessened. It is desirable to permit the owner of a pump to purchase a switch separate from the pump, so that a desired pump and switch can both be purchased rather than depending on a secondary switch provided with an excellent pump.
SUMMARY OF THE INVENTIONA switch having a watertight housing is provided for use with a sump pump to turn the pump, particularly a submersible pump, on and off automatically. The particular nature of a vertical float switch is that the float assembly moves up and down in a defined path so that very little space is required—it can be used in big sump pits or small sump pits. It will be understood that the switch of the present invention is of the type that when activated permits the flow of electricity to a pump. The activation of the pump, therefore, is determined by conditions that permit electricity to flow from an outlet into a pump ready to work. Such pumps as so called sump-pumps and other self priming pumps of types well known to persons having skill in the art can be used in association with the device of the present invention.
In a preferred embodiment of the present invention, a pump activation structure, for use with a pump, or other electrical device, is provided. The activation structure includes a housing for maintaining electronic equipment, conceptions and their various activation means in clean and dry conditions for effective activation and working. A float rod is provided having a floating activator riding thereon; the float activator designed to rise and fall depending on the level of water in, for example, a sump. Within the housing, the device includes a switch, capable of being activated and running until a given event or the elapsing of a designated period of time. It will be understood that any number of available switches can be used in the present invention, but that a switch having low power capabilities is preferred. A reed-type switch as often found in present day sump-pump switching-systems is an effective switch for the device of the present invention.
The present invention further includes an actuating member, between the float and float rod and switch. The actuating member operably connects the switch and the float rod, such that a variation in water level moves the float rod and the actuating member and toggles the switch. In a preferred embodiment, the actuating member is a lever pivotably mounted within the switch housing such that the lever toggles between on and off positions. In one embodiment, the switch includes a dead-man type activation means, wherein the switch is activated only when the lever causes a button or pedal to be depressed. Subsequently, upon release of the button or pedal the switch is turned off, causing the pump to turn off. In the device of the present invention, the lever is pushed into position by the rising of the water and thereafter is pulled out of position, at a desired condition, by the pulling caused by the fall of the water, the float and with the means discussed below.
The pump activation device includes means to permit the switch to remain in the on position as the water level falls, so as to permit the accompanying pump to work to drain the sump. In the preferred embodiment, the means includes a spring-biased retaining ball mounted within the switch housing adjacent to the lever, to temporarily retain the lever in a switch activation position. In a preferred embodiment, the retaining ball is biased by a spring against a holding structure such that upon the toggling of the switch to the on position, the ball is pushed into the holding structure preventing the switch from toggling to the off position. The switch remains in the on position until the lever is pulled with sufficient force, at a desired time, to overcome the biasing spring, and permit the lever to be pulled off of the switch activating button.
In a preferred embodiment, the housing is water-tight and the switch is protected from environmental conditions found in a sump location. Further, in one embodiment the biasing spring holds the switch in the toggled on position until a float on the float rod sinks to a desired water level pulling the float rod down to provide sufficient force to overcome the biasing spring pressure. The float rod includes stops at a set high level and a set low level, with a float suspended there between. In an at rest position, the float rests on top of the lower stop and in the presence of some water the float rises off of the lower stop.
In the operation of a device made in accordance with the teachings of the present invention, when water rises in the sump, the float rises until it reaches the upper stop and then begins to push on the stop causing the float rod to be pushed up. The rising of the float against the first stop pushes the rod within the float housing such that the lever is moved towards the activation button or pedal. The continued rising of water causes the float rod to push the lever to the activation position, activating the pump while simultaneously permitting the retaining ball into the holding structure; the ball being held in the holding structure by the biasing spring. As the water falls, in response to the activity of the pump, the float is permitted to fall with the level of the water. The biasing spring, however, retains the ball in the holding structure such that the lever is not pulled off of the activation button or pedal, permitting the pump to continue to run. Only upon the draining of sufficient water out of the pump, that is until the float is pushing down onto the lower stop with sufficient force to overcome the biasing spring and pull the ball out of the holding member, will the lever be pulled off of the activation switch causing the pump to cease operation. Power is cut off to the pump placing the pump in its at rest position to await the next rising water situation.
BRIEF DESCRIPTION OF THE DRAWINGS
While the present invention is susceptible of embodiment in various forms, there is shown in the drawings a number of presently preferred embodiments that are discussed in greater detail hereafter. It should be understood that the present disclosure is to be considered as an exemplification of the present invention, and is not intended to limit the invention to the specific embodiments illustrated. It should be further understood that the title of this section of this application (“Detailed Description of the Illustrative Embodiment”) relates to a requirement of the United States Patent Office, and should not be found to limit the subject matter disclosed herein.
Referring to
The pump, of the present invention, is therefore advantageously used in association with an activation device 20. As illustrated, the activation device 20 includes an electrical cord 21 and plug 22, having a first side 22a that is plugged into outlet 18 and a second side 22b that provides a switched outlet 22s into which the plug 14 of the pump maybe inserted. Switched outlet 22s permits the flow of electricity into pump 10 only upon the arising of a given condition, as will be described below. In this way the pump 10 is activated only when needed as determined by the conditions present in the sump 12.
Activation device 20 comprises a housing 30 having a water resistant case 32 for keeping an electrical switch 34 in a clean and dry environment; it will be understood by persons having ordinary skill in the art that a sump is often a damp and dirty environment and that an electrical device will require protection within such an environment. Water resistant case can be made of any structurally capable material molded or formed to surround and protect the inner workings of activation device 20. Such materials as plastic, rubber and various metals can be utilized without departing from the novel scope of the present invention. Water resistance within housing 30 can be improved by the use of protective sheeting materials and/or O-rings or other gaskets as are known to persons having ordinary skill in the art.
In a preferred embodiment of the device of the present invention, a low powered micro-switch 34 is provided in housing 30. Persons having skill in the art will understand that any type of switch can be utilized in the activation of the switch electrical connector of the device of the present invention, without departing from the novel scope of the present invention. In the preferred embodiment a low powered micro-switch has been chosen as ideal for this situation. Micro-switch 34 includes an activation button, or plunger, 36 having a first on position, wherein that position an electrical circuit is completed allowing electricity to flow through switched outlet 22s and an off position wherein electricity is stopped from flowing. These positions are represented, respectively by plunger 36 being in a pressed or inward position for “on” and an outwardly projecting position for “off” (as shown respectively in
Lever 42 as shown, is pivoted on a fulcrum point 43 and has an extended end 42e having a locking structure 45 for use in association with a holding structure 60 (
In the operation of the pump activation device of the present invention, referring to
Referring to
Referring to
Referring to
Referring now to
Switch 34 includes a plunger 36 which when depressed activates switch 34 and the concomitantly activation device 20. Lever 42 is pivoted about pin 43 allowing its extended end 42e to pivot down when rod 40 rises. In the illustrative embodiment, lever 42 includes a locking structure 45, which comprises a tube 52 forming a T with lever 42. A biasing means 56 and balls 52 are maintained within tube 52, in a manner well known to persons in the art. It will be understood that the biasing means 56 provide sufficient force to push balls 52 to a partially exposed position outside of each end of tube 52. In the illustrative embodiment, biasing means 56 is a coil spring, however it will be understood that any manner of biasing balls 56 to the positions shown can be used without departing from the novel scope of the present invention.
Housing 30, of activation device 20, further includes holding structure 60, which is designed to hold one or more balls 52. By holding balls 52, locking structure 60 prevents lever 42 from becoming disengaged from plunger 36 prematurely, that is before sufficient water 5 has been removed from sump 12. In one embodiment, shown in
In the illustrative embodiment, holding structure 60 comprises tubular members located adjacent the position that tube 52 will come to at the high water 5h position of the sump pump cycle. In that position, holding structures 60 will be in position to capture balls 56, within openings 50, and lock lever 42 in position engaging plunger 36 such that switch 34 is in its on position and pump 10 is powered. It will be understood that lever 42 cannot be released, so as to deactivate the pump 10, until a downward force on rod 40 is generated sufficient to overcome the outward force of the biasing means 56 so that balls 52 are released from holding structures 60. While a device having two balls 52 is shown and described it will be understood that a device having a single ball and a single locking means, can be constructed without departing from the novel scope of the present invention.
As shown in
In
As the lever 42 moves into position (closed circuit), the ball bearings 52 pass over a post hole 50 that is molded into the housing 30 of activation means 20. In one preferred embodiment, at its most narrow point, outer edge 42e of the lever is about 0.600 inches in width. That is, outer edge 42e, who's width is determined by measuring from the outer tangent surface 52t of one ball bearing 52, through tube 54 and to the outer tangent surface 52t of the second ball bearing 52, is 0.600 inches. This width is, by action of float bar 40, lever 42 and fulcrum 43, caused to pass through a zone Z that is only 0.525 inches wide. Those having ordinary skill in the art will understand that the balls 52 must be pushed inwardly, into tube 54 and the spring 56 must be compressed to accomplish this. Once the balls have passed over the lip of the post hole 60e, the balls are biased into the cavity of the post hole 50, by the force of spring 56, and stay in position until the force of the falling float 41 overcomes the force of the balls 52 and spring 56 within post hole 50. In a preferred embodiment, the outer edge 42e of lever 42 has a width of about 0.590 inches at its widest. The tension of the spring 56 creates sufficient friction so that the lever will not move out of position but will stay fixed.
Referring to
As the float 41 moves down the rod 40 and subsequently pushes on lower stop 401 the force of gravity acts on the rod; this gravitational force, and the weight of float 40, will be greater than the frictional forces holding the ball bearings 52 in place, and the balls 52 will give way. The lever 42 will move back to its original position, releasing plunger 36. The micro switch 34 will return to its normally open circuit, power off position.
Further, referring to
It will be understood by persons having skill in the art that the dimensions stated are not actual but are instead merely representative to show how the mechanism fits together. Variations in sizes, materials and tolerances are considered to be within the novel scope of the present invention.
In a further preferred embodiment of the present invention, as shown in
In the activation of the pump, as shown in
While many of the elements shown are created using molding techniques, using plastics, it will be understood that elements of the device of the present invention can be made using techniques known to persons having ordinary skill in the art without departing from the novel scope of the present invention.
It will be apparent that one difference between the embodiments shown in
Persons having ordinary skill in the art will understand that various modifications can be made to these two designs without departing from the novel scope of the present invention.
Claims
1. A pump activation structure, for use with a pump, comprising:
- a housing;
- a float rod;
- a switch, within the housing;
- an actuating member operably connected to the switch and being operably connected to the float rod, such that a variation in water level moves the float rod and the actuating member and toggles the switch, wherein the actuating member is a lever pivotably mounted within the switch housing such that the lever toggles between on and off positions; and
- at least one retaining ball mounted within the switch housing adjacent to the lever, to temporarily retain the lever in a switch activation position, wherein the at least one retaining ball is biased against a ball holding structure such that upon the toggling of the switch to the on position, the at least one ball is biased into the holding structure preventing the switch from toggling to the off position until the lever is subsequently pulled with sufficient force, at a desired time, to overcome the bias.
2. The pump activation structure of claim 1, wherein the housing is water tight and the switch is protected from environmental conditions.
3. The pump activation structure of claim 1, wherein the at least one ball is biased by a spring.
4. The pump activation structure of claim 3, wherein the spring is a coil spring.
5. The pump activation structure of claim 3, wherein the spring biases the ball outwardly against a holding structure until a float on the float rod sinks to a desired water level, designated by a stop affixed to the float rod, the float pushing on the stop to provide sufficient force to overcome the biasing spring and releasing the at least one ball from the holding structure.
6. The pump activation device of claim 1, including a holding structure responsive to a first and second retaining ball, the retaining balls each being located at the ends of a T-shaped lever, each ball being biased outwardly so as to contact and bias against a first and second ball holding structure.
7. A pump activation structure, for use with a pump, comprising:
- A water resistant housing;
- a float rod having a first stop affixed near the distal end of the rod and a second stop affixed near the proximal end of the rod;
- a float freely traversing the length of the float rod between the first and second stops; the float held on the rod by the stops, the float and rod located in a pump well;
- a switch, within the housing;
- an actuating member operably connected to the switch and being operably connected to the float rod, such that a variation in water level results in the float rod and the actuating member moving to toggle the switch, wherein the actuating member is a lever pivotably mounted within the switch housing such that the lever toggles between on and off positions; and
- a retaining ball mounted within the switch housing adjacent to the lever, to temporarily retain the lever in a switch activation position, wherein the retaining ball is biased by a spring such that upon the toggling of the switch to the on position, the retaining ball is pushed into the retaining structure preventing the switch from toggling to the off position until the lever is pulled with sufficient force, at a desired time, to overcome the biasing spring and retaining ball.
8. The pump activation structure of claim 7, wherein the housing is water tight and the switch is protected from environmental conditions.
9. The pump activation structure of claim 7, wherein the float rod and lever are hingedly connected.
10. The pump activation structure of claim 8, wherein the float rod is caused to rise when the float rises in the pump well, as the water in the well rises, and strikes the second stop fixed to the rod.
11. The pump activation structure of claim 7, wherein the biasing spring holds the switch in the toggled on position until the float on the float rod sinks to a desired water level, designated by the first stop, pulling the float rod down to provide sufficient force to overcome the biasing spring pressure.
12. The pump activation device of claim 7, including a holding structure responsive to a first and second retaining ball, the retaining balls each being located at the ends of a T-shaped lever, each ball being biased outwardly so as to contact and bias against a first and second ball holding structure.
13. The pump activation device of claim 7, wherein the retaining structure is shaped as a backwards “3” and the ball on the lever is biased into the upper element of the “3” in a first pump off position and into the lower element of the “3” in a second pump on position.
14. The pump activation device of claim 7, wherein once activated the pump remains powered on throughout the float motion between the first and second stop.
Type: Application
Filed: Feb 9, 2006
Publication Date: Dec 7, 2006
Inventor: Simple Liu (Taipei)
Application Number: 11/350,661
International Classification: F04B 49/04 (20060101);