Patent Grant
9468892
The present invention is directed to chemical dispensers and related methods of dispensing. More specifically, the present invention is directed to chemical dispensing systems including a mounting rack for holding chemical containers that allows for mixing or dosing of chemicals into a motive fluid such as in a car wash.
A variety of chemical dispensing systems exist in the art. For example, one conventional system utilizes a dip tube or “stinger” that is inserted so as to be positioned proximate a bottom of the container. The stinger can have a “foot valve”, which include a check valve as well as a filter/screen to prevent contaminants/particulates from being inadvertently introduced from the bottom of the container. Typically, chemicals can be supplied in containers having various capacities such as, for example, 5 gallon, 30 gallon or 55 gallon containers. The use of stingers can be disadvantageous in that they can be quite messy, can expose workers to the chemicals and often can't feed all of the chemical form the containers. Other disadvantages associated with conventional chemical dispensing systems including the difficulty in shipping, moving and otherwise handle large chemical containers. In addition, the employees who work with these chemical dispensing systems often require additional instruction and training to properly and safely change and interconnect the containers with the dispensing system, which can include chemical mixing or dosing systems.
As such, it would be advantageous to improve upon existing chemical dispensing systems to improve upon existing handling requirements, while at the same time providing additional safety and ease of use to employees working with these chemical dispensing systems.
A representative embodiment of an improved chemical dispensing system of the present invention comprises a rack based system that can hold one or more chemical dispensing containers for use in representative dispensing environments such as, for example, car washes and other chemical dispensing applications. The chemical dispensing containers can make use of concentrates or hyper concentrates of chemicals allowing smaller capacity containers, for example, about 2.5 gallons or less. The smaller capacity containers have a lower weight allowing for easier shipping and handling. In some embodiments, the smaller capacity containers can include one or more handles to enhance ergonomics during lifting and positioning. The rack based system can further comprise a modular rack that is configurable to hold a desired number of containers, for example, a minimum of two containers and a maximum of seven containers. Using the modular rack, the containers can be easily ganged together to increase capacity or build in redundancy for one or more of the chemicals through the configuration of a rack manifold using a plurality of manifold segments. Within the manifold, various flow paths can be linked or terminated between adjacent manifold segments and chemical containers.
One advantage of the chemical dispensing system of the present invention involves the use of chemical dispensing containers that utilize concentrates or hyper concentrates of chemicals. By utilizing concentrates and hyper concentrates of chemicals, chemical containers can be smaller in capacity, size and weight allowing for ease of handling and shipping, reduced floor space requirements, simpler installation and replacements and increased safety relative to both handling and chemical exposure. The chemical dispensing containers can include a dry change chemical connection to directly connect to connections on a modular rack allowing for a dry connection to a flow path and no risk of operator exposure to the chemical. In addition, the chemical dispensing containers can be fabricated of disposable or recyclable materials that allow for conventional disposal methods. Preferably, the chemical dispensing containers can be formed from low cost materials.
In one representative embodiment, a chemical dispensing container will feed chemical from an insert placed in a filler neck of the chemical dispensing container. The insert can have a foot that functions like a straw to allow access to all of the chemical within the container. An operator can remove a container shipping cap that otherwise covers the insert, wherein the insert is permanently attached to the container, for example, by welding, molding or bonding the insert to the container using suitable process such as ultrasonic welding, heat welding, spin welding, adhesive bonding and other known techniques.
In a representative embodiment, a container can comprise a 2.5 gallon HDPE container and a Rieke SC76 70 mm shipping cap or alternatively a 63 mm shipping cap. Once the shipping cap has been removed from the container, an operator can load the container onto the modular rack. A tray on the modular rack is configured to align and guide loading of the container such that the insert engages a male dry connect receiving component or “spud” on the modular rack. In some embodiments, the modular rack including the trays can be formed from Polyethylene to provide chemical resistance to the chemical dispensing system. In some embodiments, the tray can engage the modular rack or be otherwise fabricated to support each chemical dispensing container at an angle, for example, an angle of 5 to 10 degrees relative to a horizontal axis to assist feeding all of the fluid to the insert. A filler neck (or finish) of the chemical dispensing container can be positioned close to an outside wall of the chemical dispensing container or a dip tube (or foot, or straw) could be used on the insert, such that all of the concentrated chemical can feed out of the chemical dispensing container due to a feeding mechanism being at a lowest point in the chemical dispensing container when loaded onto the tray and fluidly interconnected with the modular rack. In some embodiments, the container insert can be made removable for refilling or reuse of the chemical dispensing container.
In a representative embodiment, a container insert can include a check valve that prevents fluid from leaving form the dispensing container prior to or during loading of the dispensing container onto a tray or in the event that the dispensing container is replaced or otherwise removed for maintenance or chemical change. The check valve is generally physically opened during interconnection of the dispensing container with the modular rack by a mating part or “spud” assembly on the modular rack. The spud assembly can also include a check valve to prevent unwanted chemical, motive fluid or solution from leaking from the flow paths within the modular rack when dispensing containers are disconnected from the modular rack. Through the use of check valves within each dispensing container as well as each spud assembly, attachment and removal of the dispensing container relative to the modular rack can be performed without any significant fluid loss improving both appearances and safety. The insert check valve is generally designed to be low cost while being chemically resistant. In one embodiment, the insert check valve can comprise a check ball and an elastomeric o-ring. In another alternative embodiment, the insert check valve can comprise a biasing spring and check poppet having a poppet seal that can provide a fluid tight seal bet is between a soft plastic like low density PE and the insert parent material.
In another representative embodiment, a container insert can further comprise a container vent including a membrane such as, for example, a PTFE membrane. The container even can provide the convenience of not having to open a secondary vent while the membrane prevents any splashing of the chemical concentrate following removal of the shipping cap. In an alternative embodiment the membrane can be positioned to be higher than a fluid level within the dispensing container so as to allow a lower container to refill from an upper container that is ganged to the lower container through flow patch defined within the modular rack. In some embodiments, a dispensing container can include a conventional vent or a second cap in a higher location related to the container insert.
In a representative embodiment, a chemical dispensing system can comprise a modular rack having a spine or manifold, wherein the spine is modular in design and each spine or manifold segment can be selected and otherwise connected with adjacent manifold segments to define a manifold member having one or more internal flow channels accommodating a high pressure motive fluid such as water as well as concentrated chemical that can be fed to other levels or for dispensing from the modular rack. Each manifold segment can be connected to adjacent manifold segment using a variety of suitable manifold interconnectors. In one representative embodiment, the connectors will define a continuous flow patch allowing for free flow of chemical between manifold segments. In this arrangement, two or more chemical dispensing containers can be fluidly joined together by using flow though manifold segments to increase the capacity of the chemical available on the modular rack. Typically the lowest manifold segment in a gang of similar chemical containers would be of the dispensing type. Chemical can then feed by gravity into the manifold, such that the top dispensing container in the gang would empty first and then could be replaced before the lower joined dispensing containers of similar chemical could be emptied assuring a constant flow of chemical from the stand even though one or more chemical containers were empty. Alternatively, the manifold interconnector can terminate or otherwise block the chemical flow channel between adjacent manifold segments so as to isolate chemical flow between adjacent manifold segments.
In one representative embodiment, a modular rack can include manifold segments defining two or more flow channels within the manifold, for example, a high pressure flow channel capable of operating with a high pressure motive fluid such as water at pressures of 50-250 psi while a second low pressure flow channel allows for chemical feeding from the chemical dispensing containers. Each manifold segment can be fabricated from a chemical resistant material such as cPVC or HDPE. Preferably, the manifold provides some flexibility to promote alignment of the spud assembly to the container insert for easy loading. Flexibility can be imparted to the manifold through the use of manifold interconnector between adjacent manifold segments. In some embodiments, individual spud assemblies connect to the manifold segments with a screw thread. Each spud assembly allows chemical to feed from the associated dispensing container(s) into the appropriate chemical flow channel. In some embodiments, the low pressure chemical channel can be vented to allow the low pressure channel to fill with chemical to a height of a container level. This can be advantageous if a dispensing rate from the spine temporarily outpaces the dispensing rate out of the container, i.e. the manifold could act as a small, short-term chemical reservoir. In addition, the height or pressure of the chemical fluid column within the low pressure channel might be measured to allow for a “gas gauge” or monitor of chemical remaining within the chemical dispensing container(s).
In a representative embodiment, the modular rack will include a manifold utilizing quick release chemical injectors, for example those disclosed in U.S. Pat. Nos. 8,322,367 and 8,807,158, which are herein incorporated by reference in their entirety. The injector can be configured to connect to the manifold such that the injector can be fed both high pressure water and low pressure chemical. The quick release injector can be disconnected from the manifold for maintenance or replacement without the loss of water or chemical. The high pressure channel in the manifold can include a motive fluid valve allowing high pressure water to flow into the injector when chemical delivery is desired. The motive fluid valve can be pneumatically or electrically actuated and can be selectively controlled by a control processor. In some embodiments, a check valve would not be needed on the high pressure motive fluid side of the injector when the high pressure water valve was closed as the valve would prevent the escape of high pressure water as the injector is removed from the manifold.
In another representative embodiment, each chemical dispensing container can include a keying feature that interfaces with a modular rack to prevent the accidental introduction, mixing and use of different or unintended chemicals that can cause contamination or worse, an unintended chemical reaction. In some representative embodiments, the chemical dispensing system can use the keying feature with only the most volatile or hazardous chemicals. Alternatively, the keying feature can be utilized with each chemical and chemical container that allows for the use of only one chemical with a specific location or tray on the modular rack. In one representative embodiment, the keying feature can include the placement of one or more recessed bosses in the container that corresponds with an arrangement of one or more pins on the corresponding tray of the modular rack. In order to reduce manufacturing costs for differently keyed containers, the same number and pattern of recessed bosses could be formed on every container whereby the bosses could be selectively filled with one or more plugs to create specific boss patterns. When the container is positioned in the correct and corresponding tray, the pins on the tray align with any recessed bosses/unplugged bosses allowing the container to fully seat within the tray, whereby the spud assembly is allowed to fully and fluidly engage the insert and dispense chemical.
In another representative embodiment, a modular rack system of the present invention can further comprise an engagement feature providing tactile feedback that confirms when a chemical container is fully seated on a tray, fluidly engaged with the modular rack and ready to dispense chemical. The modular rack system can further comprise a retaining or locking mechanism that provide a retention force that prevents unintended disengagement of the chemical container from the modular rack. In one representative embodiment, the spud assembly can include a segmented collar with teeth that engages a screw thread on the filler neck of the chemical container. In another embodiment, the chemical container can be formed/molded with a recess that engages a similar protruding feature on the tray. The chemical container can be formed a material that is relatively flexible and/or deformable such that an operator can manipulate the chemical container to “snap” into place. In another embodiment, the modular rack can include a sensor such as, for example, a proximity switch or photo eye that indicates the presence of a chemical container on a that level to a remotely located control system.
In another aspect, the chemical dispensing system can include an integrated monitoring system to help alert the user and/or a control system to differing chemical levels. In one embodiment, the chemical containers can be designed to be clear or opaque in one or more key, i.e. easily visible locations such that the user can quickly monitor and verify the chemical level visually. In another embodiment, the monitoring system can be automated and include a light, buzzer or similar alerting system to let the user know the chemical level is low. In a chemical dispensing system utilizing an advanced control system, the alerting function can be connected, either directly or via a wireless protocol, to a remotely located control/monitoring station or even to a mobile station such as, for example, a portable processing device such as a smart phone, a tablet computing device of a laptop computer. In one embodiment the monitoring system can include one or more ultrasonic transducers that are individually capable of measuring liquid levels within each chemical container. In some embodiments, the transducer can report a liquid level continuously or alternatively, be set to alarm when a threshold value is reached. In another representative embodiment, the monitoring system can use a simple float valve in each container to measure chemical level. When a threshold value is achieved, for example, 20% chemical remaining in the container, a light on the modular rack is illuminated. In yet another embodiment, a thermistor with a small heater can be immersed in the fluid of each chemical container. The thermistor and heater assembly can be positioned at a height in the column of fluid corresponding to a fluid level to be detected. When the fluid level drops below that level, thereby uncovering the thermistor and heater assembly, the heater assembly can no longer transfer its energy to the surrounding fluid and so heats the thermistor. The resistance of the thermistor will change signaling that the fluid level is at the predetermined level. In another representative embodiment, the monitoring system can include a pressure gauge connected to the chemical fluid column in the modular rack. As the height of the fluid column decreases within the flow channel of the modular rack as containers are emptied in the modular rack, the pressure decreases signaling an increasingly empty condition. The pressure of the fluid column can be correlated to a chemical volume or amount of fluid remaining and reported to the operator.
In a representative embodiment, a modular rack can be formed of molded or machined polymeric materials. In some embodiments, the modular rack and the individual manifold segments can be formed of polyethylene or other polymers that are selected for their chemical resistance. The modular rack can to a plurality of trays that are similarly formed of a polymeric material that may be the same or different than the material used for the modular rack. In some embodiments, each tray can be configured to act as a drip tray and can include individual drains to collect any drips or spills.
In some embodiments of the modular rack, one or more individual manifold segments can be formed or fabricated to include integrated chemical dispensing. For example, these manifold segments can comprise an air actuated valve, and a quick release chemical injector with a metering orifice. The chemical injector can be used to precisely mix dispensed chemical with a motive fluid, which is typically pressurized water. When the air actuated valve opens, the motive fluid is introduced into the injector from a high pressure motive fluid channel defined within the manifold. The injector can comprise a venturi-style injector, wherein the flow of the motive fluid causes chemical to be pulled from the other low pressure channel within the manifold segments through a metering orifice. The metering orifice can be designed to be removable and easily replaceable such that the chemical mixing ratios can be easily changed. In one embodiment, the metering orifice can be installed using screw threads to allow for easy removal or replacement. The quick release injector can incorporate a check valves in the related manifold segment such that no or little fluid escapes the manifold when individual injectors are removed for maintenance and/or replacement.
In another representative embodiment, a cartridge can be utilized to retrofit an existing container to work with the present chemical dispensing system. The cartridge can define the container insert and can comprise a breathable membrane, a quick-dry connection and a check valve. The cartridge can be configured for welding into a container or alternatively, the cartridge can be added to a conventional container when it arrives at the customer. In some embodiments, the cartridge can replace the shipping cap, for example, the shipping cap can be unscrewed followed by screwing on the cartridge. The cartridge allows for existing containers to be used with the present chemical dispensing system by the container with a breathable membrane, a chemical tight seal and a check valve to prevent chemical spillage.
In one aspect, the chemical dispensing system of the present invention reduces chemical waste by increasing the amount of chemical removed from the containers and eliminating inadvertent spillage during connection and removal of chemical containers.
In another aspect, the chemical dispensing system of the present invention improves operational safety by reducing operator exposure to chemicals. In addition, the quick connect features of the chemical containers and modular rack provide for easy and robust fluid connections.
In another aspect, the chemical dispensing system provides for the use of chemical concentrates and hyper concentrates such that smaller containers that are easily transported and handled can be utilized. In addition, chemical containers can include ergonomic features such as, for example, handles that allow them to be loaded by an individual operator and require no special skills or strength to properly load.
In yet another aspect, the chemical dispensing system can utilize a modular rack that includes a reporting feature that can continually measure chemical levels/usage or provide a signal based on threshold levels being reached. The reporting feature can include a visible or audible reporting feature or alternatively, the reporting feature can provide a signal to a control/monitoring system.
In yet another aspect, the chemical dispensing system can include a configurable modular rack that allows for chemical supply redundancy, whereby containers can be ganged together such that individual containers can run dry without the chemical dispensing system running out of chemical. A user can double up on chemical containers having a comparatively higher usage rate or for chemicals that are deemed critical.
In another aspect, the chemical dispensing system can avoid the use of vent cap openings due to a permeable membrane.
In another aspect, the chemical dispensing system can include a keying feature that verifies fluid connections between chemical containers and spuds on a modular rack to prevent hazardous and/or reactive chemicals from being mixed or inadvertently introduced.
In yet another aspect, the chemical delivery system allows for the use of smaller containers to maximize floor space.
In yet another embodiment, the chemical delivery system can reduce and/or prevent chemical contamination due to the use of a quick connect design, keying features, integrated fluid channels and a modular rack design.
The above summary of the various representative embodiments of the invention is not intended to describe each illustrated embodiment or every implementation of the invention. Rather, the embodiments are chosen and described so that others skilled in the art can appreciate and understand the principles and practices of the invention. The figures in the detailed description that follow more particularly exemplify these embodiments.
The invention can be completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:
While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
As illustrated in
Referring now to
Rack based system 102 further comprise a manifold member 130 that is generally formed and defined by selectively coupling a plurality of manifold segments 132 in interlocking, adjacent fashion using an interconnecting member 133. Typically, manifold member 130 will include the same number of manifold segments 132 as spine member 106 includes spine segments 112. While spine member 106 was further described as including five spine segments 112 as shown in
As shown in
As shown in
Injector assembly 162 as seen in
Chemical container 104 as illustrated in
In use, a user would first determine the number and amounts of chemical 242 that needed to be dispensed. For instance, a car wash installation might make use of a rack based system 102 having five different chemicals using five trays 108 as shown in
Next the user attaches the each tray to the appropriate spine segment 112 using the connecting portion 116. With the manifold member 130 assembled, the user attaches a spud assembly 160 to each manifold member 130 by attaching the manifold connector 166 to the corresponding spud mounting aperture 144. Next, the user attaches the injector assembly 162 to each manifold segment 132 by coupling the actuator 184 to the corresponding valve mounting aperture 148 and the injector body 180 to each manifold segment 132 by coupling the chemical flow member 188 to the chemical injector aperture 146 and the high pressure water flow member 190 to the water injector aperture 150. When the venturi injector body 196 is coupled to the injector body 180, the injector inlet 198 causes the chemical flow member check valve 192 to be biased to an open condition. Finally, the user positions the appropriate container 104 on each tray 108 such that the insert aperture 226 sealingly covers and engages the container connector 168. As the container 104 is connected to the spud assembly 160, both the spud check valve 176 and the container check valve 236 are biased to an open condition.
In operation, high pressure water is supplied to the manifold member 130, preferably at a lower most manifold segment 132 proximate the base plate 110 such that the high pressure water. A system controller generally provides a signal to selectively actuate the actuator 184, such that the valve member 186 is allowed to open and allow high pressure water to flow into the high pressure water flow member 190 and correspondingly through the high pressure water inlet 200 of the venturi injector body 196. As the high pressure water flows through the venturi throat 208, a venturi condition is created whereby a vacuum is applied to the chemical flow path 204 causing the venturi check valve 210 to open.
When the venturi check valve 210 is opened, chemical is drawn into the foot inlet 238 whereby it is filtered by the screen 240. The vacuum condition causes chemical to be drawn through the container flow path 234 and into the container connector 168 and through the spud flow channel 170. The chemical flows through the manifold connector 166 and into the chemical channel 140. Due to the vacuum condition, the chemical is drawn through the chemical channel 140 and into the chemical flow member 188. Finally, the chemical enters the injector inlet 198 where it is drawn into the venturi throat 208, where it is mixed with the high pressure water such that a chemical solution is dispensed from the mixes solution outlet 202 and to a desired point of application/use.
In some instance, it may be critical to have the proper chemical container 104 on the appropriate tray 108 and to make it difficult if not impossible to fluidly connect the wrong chemical container 104 to the spud assembly 160. One way to accomplish this is to fabricate the container 104 and specified tray 108 to include a keying feature 300 that prevents the container 104 from seating on the tray 108 if they are not keyed to one another. For instance, container 104 can be fabricated to have a floor surface 302 that defines bosses or channels 304 in the floor surface 302. Similarly, tray 108 can be fabricated to include one or more ridges or pins 306 that project upward from the supporting surface 118. When the bosses/channels 304 are aligned with the ridges/pins 306, the container 104 will slide onto the tray 108, whereby the floor surface 302 is flush with the supporting surface 118 and the container 104 is retained within the side walls 120a, 120b. If the bosses/channels 304 are misaligned with the ridges/pins 306, the container 104 will not properly reside on the tray 108 such that connection of the spud assembly 160 with the container insert 22 cannot be sealably accomplished.
In another alternative embodiment as illustrated in
In another embodiment, an alternative embodiment of a chemical container 370 can be utilized with the spud assembly 160 as shown in
Although specific examples have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement calculated to achieve the same purpose could be substituted for the specific examples shown. This application is intended to cover adaptations or variations of the present subject matter. Therefore, it is intended that the invention be defined by the attached claims and their legal equivalents.
The present application claims the benefit of U.S. Provisional Application No. 61/936,995 filed Feb. 7, 2014, and entitled “PACK RACK”, which is incorporated herein in its entirety by reference.
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