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.

What is claimed is: 
     
         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.