Patent Application
20180169597
The present invention relates generally to a dispenser and method of operating for dispensing a solution from a solid product. More particularly, but not exclusively, the invention relates to a method and apparatus for controlling the concentration of the dispensed solution created by combining a solid product with a liquid.
Dissolution parameters of a solid product into a liquid solution, such as a liquid detergent used for cleaning and sanitizing, change based on the operating parameters of and inputs to the dissolution process. Spraying liquid onto a solid product to dissolve it into a liquid solution is one technique. With this technique, the operating parameters change in part based on characteristics within the dispenser, such as the distance between the solid product and the spray nozzle and the change in the pressure and temperature of the liquid being sprayed onto the solid product. Changes in a nozzle's flow rate, spray pattern, spray angle, and nozzle flow can also affect operating parameters, thereby affecting the chemistry, effectiveness, and efficiency of the concentration of the resulting liquid solution. In addition, dissolution of a solid product by spraying generally requires additional space within the dispenser for the nozzles spray pattern to develop and the basin to collect the dissolved product, which results in a larger dispenser.
Therefore, there exists a need in the art for a dispenser having the capability to adjust the flow scheme or turbulence of a liquid contacting a solid product based on a characteristic of either an uncontrolled parameter or condition, such as an environmental condition or a condition of the solid product to maintain a dispensed solution having a concentration within an acceptable range. There also exists a need to update the turbulence based upon the dispensing concentration.
Therefore, it is principal object, feature, and/or advantage of the present invention to provide an apparatus that overcomes the deficiencies in the art.
It is an object, feature, and/or advantage of the present invention to provide a method and dispenser for producing a solution from a solid product that maintains a desired concentration of the solution.
It is another object, feature, and/or advantage of the present invention to provide a dispenser that will adjust the flow turbulence of a liquid in contact with a solid product based upon a characteristic of the turbulence or product to result in a desired concentration.
It is yet another object, feature, and/or advantage of the present invention to provide a method of forming a solution from a solid product and a liquid that increases the likelihood that the solution will be within a desired concentration.
It is a further object, feature, and/or advantage of the present invention to provide a dispensing system that can be easily adjusted to vary the concentration of a solution based upon an end use.
These and/or other objects, features, and advantages of the present invention will be apparent to those skilled in the art. The present invention is not to be limited to or by these objects, features and advantages. No single embodiment need provide each and every object, feature, or advantage.
According to an aspect of the invention, a method for obtaining a solution from a solid product and a liquid is provided. The method includes providing a solid product in a housing of a dispenser, introducing the liquid into the housing to contact the solid product with liquid turbulence, and adjusting the liquid turbulence of the liquid based upon a characteristic of an uncontrolled condition or solid product to maintain a predetermined concentration of the solution.
The liquid turbulence may be adjusted by changing the distance between the liquid source nozzle(s) or manifold diffuse and the solid product, changing the hole diameters of the manifold diffuse, changing the hole pattern or number of holes of the manifold diffuse, changing the geometry of the holes of the diffuse, or changing the flow rate of the liquid. Characteristics affecting the turbulence or concentration may include the density of the solid product, temperature of the liquid, distance between the liquid and the solid product, or the surface area of the product being contacted by the liquid. The turbulence may be changed automatically or manually based upon the characteristic. Furthermore, the turbulence can be altered based upon known relationships. For example, a known erosion rate may be determined for a liquid having a certain temperature. The turbulence, such as the distance between the manifold diffuse and the solid product, can be altered based upon known erosion rates to accommodate or account for the temperature of the liquid.
According to another aspect of the invention, a dispenser configured to obtain a solution from a solid product and a liquid is provided. The dispenser includes a housing, a cavity within the housing for holding a solid product, and a liquid source adjacent the cavity for providing a liquid to contact the solid product to create a solution. The liquid source comprises a liquid turbulence control to control the turbulence of the liquid contacting the solid product based upon a characteristic of the turbulence or solid product. An outlet is adjacent the cavity for discharging the solution from the dispenser.
According to yet another aspect of the invention, a method of controlling the concentration of a solution of a solid product and a liquid dispensed from a dispenser is provided. The method includes providing a solid product in a dispenser, contacting the solid product with a liquid having a liquid turbulence to produce a solution, measuring the concentration of the solution, and adjusting the liquid turbulence of the liquid based upon the measured concentration of the solution to provide a desired concentration of the solution.
The present invention relates to dispensing a liquid product obtained from a solid product. Various embodiments of the present invention will be described with reference to the drawings, wherein like reference numerals represent like parts throughout the several views. Reference to various embodiments does not limit the scope of the invention. Figures represented herein are not limitations of the various embodiments according to the inventions and are presented for exemplary illustration of the invention only.
Examples of types of liquid turbulence may include changing the flow rate of the liquid, changing the direction, flow path, or spray type of the liquid, changing the distance between liquid source and solid product, changing the amount of surface area of the solid product being exposed to the liquid (either in a pool or by spray), changing the size, number or geometry of holes associated with the spray, or the like. It should be appreciated that other changes to the turbulence of the liquid are included in the invention, and the above list is not an exhaustive one.
Furthermore, the turbulence of the liquid can be adjusted either manually or in real time to aid in maintaining the concentration of the solution created by the liquid and solid product. The turbulence can be adjusted according to a characteristic of the solid product or the liquid. For example, the turbulence can be adjusted to account for the temperature of the liquid in contact with the solid product, the flow rate of the liquid, the measured concentration of the solution, the density of the solid product, the surface area/erosion aspect of the solid product, or the like. It is contemplated that the present invention maintains a desired concentration of the solution by adjusting the turbulence based upon a characteristic. For example, if the measured concentration of the solution is not within an acceptable range, or if a measured, uncontrolled characteristic of the system is determined to be different, the dispenser can be adjusted to adjust the turbulence of the liquid to account for this, and to bring the concentration of the solution within the acceptable range. This may be done by changing the, changing the flow rate, changing the distance between the solid product and a liquid source, changing the spray type, or the like. The change in turbulence will be continued until the concentration is within an acceptable range, or until the known relationship between the measured characteristic and the erosion rate of the solid product has been accounted for to obtain a solution within an acceptable concentration. Thus, the invention contemplates the adjustment of the turbulence in real time or manually.
The liquid holding means 3 generally includes one or more walls connected to provide a basin where liquid can be introduced and used to provide erosion and dissolution of a solid product 2. The liquid holding means 3 may have vertical or horizontal configurations, or other configurations, to allow a solid product 2 to be received into contact with a pool of liquid 5 within the liquid holding means 3. Accordingly, the solid product 2 may be introduced into a dispenser 1 oriented vertically, horizontally, or in another orientation to facilitate contact of the solid product 2 with the pool of liquid 5 or liquid turbulence within the liquid holding means 3. The dispenser 1 also includes an inlet 6 for supplying liquid from a source for creating a turbulence or pool of liquid 5 within the liquid holding means 3. The dispenser 1 also includes an outlet 7 whereby a liquid product is dispensed from the dispenser 1. Placement of the outlet 7 may be used to control the amount of surface area of the solid product 2 that is in contact with the turbulence or pool of liquid 5, as well as the amount of product dispensed. Thus, liquid is introduced through inlet 6 into the dispenser 1 to obtain a liquid turbulence or pool of liquid 5. Liquid product obtained from eroding and dissolving the solid product 2 is dispensed out the outlet 7. The dispenser 1 also includes support means 4 for supporting the solid product 2 within the dispenser 1. At least one surface, edge or feature of the solid product 2 rests on the support means 4. The support means 4 is configured to allow liquid to contact a surface or surfaces of the solid product 2.
The surface or surfaces of the solid product 2 that are in contact with the turbulence or pool of liquid 5 are eroded and dissolved to obtain a liquid product from the solid product 2. Erosion and dissolution of the solid product 2 into a liquid product is obtained by controlling the liquid flow scheme or turbulence within the pool of liquid 5 or by a liquid source. The present invention contemplates various techniques for controlling the liquid flow schemes within the pool of liquid 5, and thereby controlling the rate of erosion and dissolution of the solid product 2 into a liquid product or solution. Controlling the liquid flow scheme within the pool of liquid 5 controls how the water impinges on the surface or surfaces of the solid product 2 that are in contact with the liquid 5. One means for controlling the liquid flow scheme 8 of the liquid 5 is shown in
Also, as further illustrated in
Accordingly, the means for controlling the liquid flow scheme 8 within the pool of liquid 5 is adjustable manually or automatically to achieve a desired rate of erosion and dissolution of the solid product 2 into liquid product notwithstanding the install location of the dispenser 1. This may be achieved by moving or altering the means for controlling the liquid flow scheme 8 of the liquid 5. Altering the means for controlling the liquid flow scheme 8 of the liquid 5 changes the way that the liquid impinges upon the surface or surfaces of the solid product 2 in contact with the pool of liquid 5. The liquid product obtained from erosion and dissolution of the solid product 2 is dispensed from the dispenser 1 through an outlet 7, such as to some end-use application 9 as illustrated in
Therefore, the dispenser 10 of the invention includes a novel turbulence or flow scheme that is adjustable either manually or in real time based on a characteristic of either the solid product or another uncontrolled condition, such as an environmental condition. As mentioned, the characteristic may be the density of the solid product, the temperature of the liquid, the climate (humidity, temperature, pressure, etc.) of the room in which the dispenser or solid product is placed, the type of liquid used, the number of solid products used, or some combination thereof. The dispenser 10 is able to determine, based on the characteristic and the existing flow scheme or turbulence, whether the end solution comprises a concentration within an acceptable range. This may be accomplished by the use of known relationships between the characteristic and the erosion rate of the solid product, as well as the relationship between different types of turbulence and the erosion rate of the solid product. If the concentration is outside of the acceptable range, the system is manually adjusted or automatically adjusts an aspect of the turbulence of the liquid to try to get the concentration within the acceptable range.
For example, the dispenser may be adjusted to change the flow rate of the liquid coming in contact with the solid product, the distance between the liquid source nozzle and the solid product, the type of spray or pooling of the to account for more or less surface of the solid product being in contact with the liquid, or some combination thereof. The dispenser will continue to adjust this turbulence until the concentration of the solution is within an acceptable range. The turbulence is adjusted based upon known relationships between the characteristic(s) and the dispense rate of the solid chemistry. For example, by understanding the rate change of product dispense per change in degree of liquid temperature change, the turbulence can be adjusted to counteract the temperature change. The concentration is adjusted according to known relationships between the erosion or dispense rate and either the characteristic or the turbulence.
According to an exemplary embodiment, the dispenser 10 of
The front fascia 22 may include a product ID window 23 for placing a product ID thereon. The product ID 23 allows an operator to quickly determine the type of product housed within the housing 12 such that replacement thereof is quick and efficient. The ID 23 may also include other information, such as health risks, manufacturing information, date of last replacement, or the like. Also mounted to the front fascia 22 is a button 24 for activating the dispenser 10. The button 24 may be a spring-loaded button such that pressing or depressing of the button activates the dispenser 10 to discharge an amount of solution created by the solid product and the liquid. Thus, the button 24 may be preprogrammed to dispense a desired amount per pressing of the button, or may continue to discharge an amount of solution while the button is depressed.
Connected to the front fascia 22 is a rear enclosure 26 generally covering the top, sides, and rear of the dispenser 10. The rear enclosure 26 may also be removed to access the interior of the dispenser 10. A mounting plate 28 is positioned at the rear of the dispenser 10 and includes means for mounting the dispenser to a wall or other structure. For example, the dispenser 10 may be attached to a wall via screws, hooks, or other hanging means attached to the mounting plate 28.
The components of the housing 12 of the dispenser 10 may be molded plastic or other materials, and the window 18 may be a transparent plastic such as clarified polypropylene or the like. The handle 16 can be connected and disconnected from the front door 14. In addition, a backflow prevention device 56 may be positioned at or within the rear enclosure 26 to prevent backflow of the solution.
Adjacent the support member 44 is shown to be a manifold diffuse 40 including a plurality of ports 42 therethrough. As will be discussed in greater detail, the ports 42 of the manifold diffuse 40 allows a liquid to pass therethrough and can be adjusted to adjust the turbulence of the liquid being in contact with a portion of the solid product stored or positioned within the cavity 34. The ports can be varied such that any size, number, or geometry of the ports is used to adjust the turbulence of the liquid therethrough. Also shown in
Other components of the dispenser 10 include a splash guard 48 positioned generally around the top of the collection zone 36. The splash guard 48 prevents solution in the collection zone 36 from spilling outside the collection zone 36.
As stated, one advantage of the dispenser 10 according to the present invention includes the ability to make adjustments in order to obtain and maintain a desired solution having a concentration within an acceptable or predetermined range. This is generally accomplished by adjusting the turbulence of the liquid out of the liquid source nozzle 38 or that is passed through the ports 42 of the manifold diffuse 40 that is in contact with a portion of the solid product. For example, as shown and discussed, the liquid source nozzle 38 is positioned under the manifold diffuse 40. If a measured characteristic of the solid product (e.g. density, chemistry, size, etc.) or environment (liquid temperature, room climate, etc.) is determined to be different, or if the concentration of the solution in the collection zone 36 is not within the acceptable range of concentration, the turbulence of the liquid out of the liquid nozzle 38 or through the ports 42 will be adjusted. Ways to adjust the turbulence of the liquid are to adjust the distance between the liquid source nozzle 38 and the manifold diffuse 40 or the solid product, or to adjust the distance between the manifold diffuse 40 and the solid product. The dispenser may include means, such as pistons or plungers, to move either the support member 44 or the manifold diffuse 40 either closer to or away from the liquid source nozzle 38, or closer to or away from the solid product. This will alter how the water is passed through the manifold diffuse 40 and into contact with the solid product.
Furthermore, the flow rate of the liquid through the liquid nozzle 38 may be adjusted to increase or decrease the flow rate in order to increase or decrease the amount of erosion of the solid product by the liquid, which will then adjust the concentration of the solution formed between the liquid and the eroded portion of the solid product.
It is contemplated that the dispenser 10 could include an intelligent control and other means to automatically measure concentration of the solution in the collection zone 36 or to make other measurements of characteristics. These other characteristics may be the determination of the density of the solid product within the cavity 34, the temperature of the liquid passing through the liquid source 38, the amount of surface area of the solid product in contact with the liquid, the pressure of the liquid, the chemical makeup of the liquid source (hardness, alkalinity, acidity, etc.) some combination thereof, or the like. This is not intended to be an exhaustive list of characteristics that is being monitored by the dispenser 10. However, these characteristics determined by the intelligent control of the dispenser 10 will in turn cause the turbulence of the liquid passing through the liquid nozzle 38 to be adjusted to account for the characteristics in order to obtain and maintain a solution having a desired concentration. For example, if the dispenser 10 determines that the temperature of the liquid passing through the liquid nozzle 38 will cause the solid product to erode at a faster rate, the dispenser 10 may move the solid product further away from the liquid nozzle 38 in order to slow down the erosion of the solid product to maintain the concentration of the solution form therein. This is determined based upon known relationships between the temperature and erosion rate, as well as the relationship between distance and erosion rate. In addition, if the solution measured in the collection zone 36 is deemed to have a higher concentration than is acceptable, additional liquid can be passed through the diluent liquid nozzle 54, which passes the liquid directly into the collection zone 36 in order to further dilute the solution and to lower the concentration of the solution in the collection zone before discharging via the outlet 52.
As shown in
Thus, the dispenser shown and described includes an adjustment means to obtain and maintain a concentration of the solution, and to monitor characteristics of the system to adjust the turbulence of the liquid being dispensed into contact with the solid product in order to maintain a solution in the collection zone 36 having an acceptable concentration. This can be very important as some characteristics are not as controllable as others. For example, some solid products may have varying densities, even if the products comprise the same chemistry. The length of time of being stored, the climate of storage, or the like can alter the characteristics of the solid products such that it will affect the density thereof. Thus, one single type of flow scheme or turbulence being in contact with the varying solid products may not always result in the same concentration of the solution. Therefore, the dispenser 10 of the present invention allows for this to be monitored, which will allow the dispenser to make adjustments based on the varying characteristics of the environment and of the solid product in order to continuously provide a solution being within an acceptable range of concentration for the specific end use application.
Furthermore, according to some embodiments, as the dispenser 10 can be doing the determinations of the characteristics and making the adjustments of the turbulence, the dispenser can be more efficient, and operators' time will not need to be spent figuring out the varying characteristics for each system and then making adjustments thereon. Instead, the operator is able to replace a solid product in the dispenser, and then allow the dispenser to make the required determinations of the varying characteristics, e.g. temperature, density, distance, and the like, and to automatically update the components of the dispenser 10 to provide a discharging solution being within an acceptable range of concentration.
Therefore, the dispenser shown and described includes but a few possible examples of ways to obtain and maintain a concentration formed by a liquid and a solid product chemistry. As noted, plots can be made based upon testing of various characteristics and changes to the liquid turbulence. The plots can be used to set up a system having parameters (geometries, distances, flow types, flow rates, etc.) that are generalized to obtain the desired concentration. Furthermore, adjustments can be made to the dispenser to account for a change one or more of the parameters, which changes the turbulence of the liquid. For example, a change in temperature of the liquid can signal a need to change the distance between the liquid and the solid product. The plot can be used to determine the distance based upon the change in temperature. In addition, many other parameters of the turbulence could be changed to account for the change in the characteristic of the solid product or the environment.
As should be appreciated, such an invention provides numerous advantages and benefits. One advantage relates to safety. The invention will provide more consistent and predictable concentrations of a solid product chemistry and a liquid, which are set to be within safe ranges. A technician or operator will have higher confidence that the solution will be what they expect. Furthermore, the system will have economic benefits, as costs can be saved by taking into account behaviors. For example, operators may have a tendency to raise the temperature of the liquid, in order to speed up a cleaning process. The dispenser of the invention will take this into account and can actually offset the temperature change by changing another aspect of the system. This will aid in a consistent erosion of the product, which can aid in the predictability for product costs, as well as budgeting aspects for expecting to know when a product will need to be changed. The uniform erosion of the solid product will provide predictable dispensing and increased business planning and/or forecasting.
The foregoing description has been presented for purposes of illustration and description, and is not intended to be an exhaustive list or to limit to the invention to the precise forms disclosed. It is contemplated that other alternative processes obvious to those skilled in the art are to be considered in the invention.
This application is a Continuation Application of U.S. application Ser. No. 15/377,710, filed on Dec. 13, 2016, which is a Continuation Application of U.S. application Ser. No. 14/577,559, filed Dec. 19, 2014, now U.S. Pat. No. 9,550,154, issued on Jan. 24, 2017, which is a Continuation Application of U.S. application Ser. No. 13/771,351, filed Feb. 20, 2013, now U.S. Pat. No. 8,945,476, issued on Feb. 3, 2015, which claims priority under 35 U.S.C. § 119 to provisional application Ser. No. 61/601,176 filed Feb. 21, 2012, all of which are herein incorporated by reference in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61601176 | Feb 2012 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 15377710 | Dec 2016 | US |
| Child | 15898939 | US | |
| Parent | 14577559 | Dec 2014 | US |
| Child | 15377710 | US | |
| Parent | 13771351 | Feb 2013 | US |
| Child | 14577559 | US |
