The present invention relates to a solid product dispenser for dispensing a solid product.
Dispensers that utilize a diluent to erode a portion of a solid product such as an all purpose cleaning agent, a detergent, a sanitizer, a rinse aid, or any other suitable chemical from which it is desired to make a use solution are well known. The product being dispensed is typically a solid product and can take the form of either a solid block of chemicals, pellets, a cast product, or an extruded product. One example of such a dispenser is found in U.S. Pat. No. 4,826,661 by Copeland et al. This patent discloses a solid block chemical dispenser for cleaning systems. The dispenser includes a spray nozzle for directing a dissolving spray onto a surface of a solid block of a cleaning composition. The nozzle sprays on the exposed surface of the solid block, dissolving a portion of the block and forming a use solution. This is just one example of a dispenser that uses a diluent and further just one example of the type of product that may be dispensed. It is recognized that there are many different dispensers which utilize diluents to erode and dispense a portion of a product, which may also have any number of forms.
When dispensing a use solution, it is often important to maintain a certain concentration of the use solution. Prior art dispensers have done this by controlling the amount of water being sprayed on the solid product and the amount of water added to the use solution and have typically accomplished this used electronics to control the water inlet valves. Still further, when the additional diluent is added to the use solution, in prior art dispensers, there is often a problem of foaming within the dispenser, which can interfere with the spray onto the solid product and affect the concentration of the use solution.
The present invention addresses the problems associated with the prior art dispensers.
One aspect of the present invention provides a product housing for use with a solid product, a solid product dispenser, and a vacuum breaker. The solid product has a bottom surface. The product housing comprises a product holder, an overflow outlet, and a flood plane. The product holder has a bottom and is configured and arranged to receive the solid product with the bottom surface proximate the bottom. The bottom of the product holder is positioned proximate above the solid product dispenser and proximate below the vacuum breaker. The overflow outlet is proximate the bottom, and the flood plane is proximate the overflow outlet.
One aspect of the present invention provides a product housing for use with a solid product, a solid product dispenser, and a vacuum breaker. The solid product has a bottom surface. The product housing comprises a product holder, an extension flange, a base portion, and a flood plane. The product holder has a bottom and is configured and arranged to receive the solid product with the bottom surface proximate the bottom. The bottom of the product holder is positioned proximate above the solid product dispenser and proximate below the vacuum breaker. The extension flange extends downward from proximate the bottom of the product holder. The base portion is operatively connected to the bottom of the product holder and includes a support flange, a railing, and an angled portion. The support flange is configured and arranged to be supported by a top portion of the solid product dispenser. The railing extends upward from proximate the support flange. The angled portion extends upward proximate the support flange and the railing toward the product holder at an angle of approximately 38 to 46° and creates an overflow outlet proximate the bottom of the product holder. The overflow outlet is a slot having a width of approximately 0.020 to 0.045 inch and a height of approximately 0.100 to 0.130 inch. The flood plane is proximate the overflow outlet and the vacuum breaker is at least approximately 3.50 inches above the flood plane. The extension flange and the angled portion are configured and arranged to assist in preventing diluent sprayed onto the bottom surface of the solid product by the solid product dispenser from exiting the overflow outlet.
One aspect of the present invention provides a solid product dispensing assembly comprising a vacuum breaker, a solid product dispenser, a solid product having a bottom surface, and a product holder. The product holder has a bottom, an overflow outlet proximate the bottom, and a flood plane proximate the overflow outlet. The product holder is configured and arranged to receive the solid product with the bottom surface proximate the bottom, and the bottom is positioned proximate above the solid product dispenser and proximate below the vacuum breaker. The vacuum breaker is at least approximately 3.50 inches above the flood plane.
A preferred embodiment dispenser constructed according to the principles of the present invention is designated by the numeral 100 in the drawings.
As shown in
The inlet portion 110 is preferably integral with the conical portion 104 thus forming with the conical portion 104 a funnel-shaped portion molded as one piece. The inlet portion 110 includes a first cavity 111 in which at least a portion of a manifold 112 having a second cavity 113 is located. The manifold 112 may be a separate component or it may be integrally formed with the housing 101. The manifold 112 includes a first passageway 114b and a second passageway 116b and may also include an optional third passageway 117b. The first passageway 114b is in fluid communication with a first inlet 114 to which a connector 114a is operatively connected. A spray nozzle 115 is operatively connected to the manifold 112 and is in fluid communication with the first passageway 114b. As shown in
A vacuum breaker 250, preferably an atmospheric vacuum breaker, is mounted to a surface such as a wall with a bracket 257. An inlet 251 is operatively connected to a bottom 252 of the vacuum breaker 250 and receives a diluent from a diluent source such as water, and the diluent exits an outlet 253 into an inlet 255 of a splitter 254 having a first outlet 256a, a second outlet 256b, and a third outlet 256c. From the first outlet 256a the diluent flows into the inlet 116, from the second outlet 256b the diluent flows into the inlet 114, and from the third outlet 256c the diluent flows into the inlet 117.
If the third inlet 117 and the third passageway 117b are included, the third passageway 117b may be closed off or sealed proximate the second cavity 113 if it is not desired to use the third inlet 117. The manifold 112 also includes a baffle 118 extending downward proximate below the spray nozzle 115 and where the passageways 116b and 117b connect to the second cavity 113. A male connecting flange 119 including apertures 120 extends outward from the bottom of the inlet portion 110.
The outlet portion 123 is funnel-shaped and includes a funnel-shaped cavity 128 and a top 134 from which a female connecting flange 124 having apertures 125 extends. The female connecting flange 124 preferably also includes four seats 126 spaced approximately 90 degrees apart from one another around the top 134 of the outlet portion 123. The cavity 128 includes a conical portion 129 and an outlet portion 130. The outer surface of the bottom of the outlet portion 123 includes a barbed outer surface 131 for connecting an outlet tubing 148 thereto. Optional mounting flanges 132 including apertures 133 may be operatively connected to opposing sides of the outlet portion 123 proximate the conical portion. Fasteners (not shown) may be inserted through the apertures 133 to secure the outlet portion 123 to a mounting surface (not shown) such as a wall.
The diluent outlet portion 136 preferably includes four arms 137 which extend outward from a top 139 of a conical portion 138 and sit within the seats 126 of the outlet portion 123. An outlet portion 141 is preferably integral with the conical portion 138 and extends downward therefrom. The conical portion 138 and the outlet portion 141 form a cavity 142 extending longitudinally therethrough. The male connecting flange 119 sits within the female connecting flange 124 of the outlet portion 123 and the apertures 120 and 125 are in alignment. Fasteners (not shown) are inserted through the apertures 120 and 125 to secure the inlet portion 110 to the outlet portion 123. An O-ring 127 seals the male connecting flange 119 and the female connecting flange 124 proximate the first cavity 111 and the cavity 128. An O-ring 140 seals the top 139 of the diluent outlet portion 136 to the manifold 112 of the inlet portion 110 proximate the second cavity 113 and the cavity 142.
The outlet portion 123 preferably has an inner diameter, the diameter of the outlet portion 130 of cavity 128, of approximately 0.54 to 0.60 inch. The barbed outer surface 131 preferably has an outer diameter of approximately 1.0 inch to support an outlet tubing 148 with an inner diameter of approximately 0.75 inch. The diluent outlet 136 preferably has an inner diameter, the diameter of cavity 142, of approximately 0.35 to 0.41 inch. The outer diameter of the diluent outlet 136 is preferably approximately 0.45 to 0.50 inch. Therefore, there is a space between the inner diameter of the outlet portion 123 and the outer portion of the diluent outlet 136 of approximately 0.03 to 0.07 inch.
The top portion 200 is shown operatively connected to the dispenser 100, but it is recognized that top portions 160 and 180 may also be used. The top portion of the dispenser is a product holder for receiving a suitable solid product such as an all purpose cleaning agent, a detergent, a sanitizer, a rinse aid, or any other suitable chemical from which it is desired to make a use solution. Although the top portion is shown for use with bottom portion 104, it is recognized that the top portion may be used with a variety of different types of dispensers and is not limited to use with bottom portion 104.
As shown in
The product holder 161 is preferably approximately 5.75 inches tall, and the flood plane 173 may be located anywhere up to approximately 2.25 inches from the bottom of the product holder 161. This will ensure that the bottom 252 of the vacuum breaker 250 is at least 3.50 inches from the flood plane 173 as is typically required by code.
As shown in
The product holder 181 is preferably approximately 5.75 inches tall, and the flood plane 193 may be located anywhere up to approximately 2.25 inches from the bottom of the product holder 181. This will ensure that the vacuum breaker is at least 3.50 inches from the flood plane 193 as is typically required by code.
As shown in
The product holder 201 is preferably approximately 5.75 inches tall, and the flood plane 213 may be located anywhere up to approximately 2.25 inches from the bottom of the product holder 201. This will ensure that the vacuum breaker is at least 3.50 inches from the flood plane 213 as is typically required by code.
The different top portions may be used as solid product lock-outs to ensure the appropriate type of product is used with the dispenser. The solid product desired to be used with a dispenser has a corresponding shape that is slightly smaller in scale than the shape of the product holder of the dispenser so that the solid product fits within the product holder while other-shaped solid products will not fit within the product holder. This is because different solid products and different product holders have different numbers of sides that have different lengths and that form different angles. No matter how the different solid products are arranged to be placed within the different product holders, the different solid products are locked-out of the different product holders. The shapes of the product holders and the corresponding products as well as the types of products are listed for illustrative purposes only and are not intended to limit the shapes and the types of products that may be used with the dispenser.
The top portion 160 includes a square-shaped product holder 161 with a cavity 162 configured and arranged to receive a square-shaped product 300, which is preferably a floor care product. As shown in
The top portion 180 includes a pentagon-shaped product holder 181 with a cavity 182 configured and arranged to receive a pentagon-shaped product 400, which is preferably an all purpose cleaner. As shown in
The top portion 200 includes a hexagon-shaped product holder 201 with a cavity 202 configured and arranged to receive a hexagon-shaped product 500, which is preferably a sanitizer. As shown in
The cavity 162 of the product holder 161 is configured and arranged to receive the product 300 therein, but products 400 and 500 will not fit within the cavity 162. More specifically, the lengths of the sides 401 and the angles D proximate the junctures of the sides 401 of the product 400 do not correspond with the lengths of the sides 161a, 161b, 161c, and 161d and the 90 degree angles proximate the junctures of the sides 161a, 161b, 161c, and 161d of the product holder 161. Further, the product 400 has dimensions of (Dimension P (4.039 inches) by Dimension R (4.146 inches)) and the product holder 161 has dimensions of Dimension I (4.005 inches) by Dimension I (4.005 inches) so the product 400 will not fit within the cavity 162 because the sides 401 protrude outward the dimension R, which is too large to fit within the cavity 162. The lengths of the sides 501 and the angles H proximate the junctures of the sides 501 of the product 500 do not correspond with the lengths of the sides 161a, 161b, 161c, and 161d and the 90 degree angles proximate the junctures of the sides 161a, 161b, 161c, and 161d of the product holder 161. Further, the product 500 has dimensions of Dimension G (3.811 inches) by Dimension T (4.250 inches) and the product holder 161 has dimensions of Dimension I (4.005 inches) by Dimension I (4.005 inches) inches so the product 500 will not fit within the cavity 162 because the sides 501 protrude outward the dimension T, which is too large to fit within the cavity 162.
Similarly, the cavity 182 of the product holder 181 is configured and arranged to receive the product 400 therein, but products 300 and 500 will not fit within the cavity 182. More specifically, the lengths of the sides 301 and the 90 degree angles proximate the junctures of the sides 301 do not correspond with the lengths of the sides 181a, 181b, 181c, 181d, and 181e and the angles L proximate the junctures of the sides 181a, 181b, 181c, 181d, and 181e. Further, although the product 300 has dimensions of Dimension A (3.550 inches) by Dimension A (3.550 inches) and the product holder 181 has dimensions of Dimension Q (4.130 inches) by Dimension S (4.242 inches), the length of the sides 181a, 181b, 181c, 181d, and 181e (Dimension J (2.985 inches)) is smaller than the length of the sides 301 (Dimension A (3.550 inches)) so one of the sides 301 of the product 300 must be moved more proximate Dimension S within the cavity 182 but then a portion of the product 300 opposite the one side 301 will not fit within the cavity 182. For example, if a side 301 were positioned within the cavity 182 parallel to side 181a more proximate Dimension S within the cavity 182, sides 182c and 182d would cut off the corners of the side 301 opposite the one side 301 that fit within the cavity 182. The lengths of the sides 501 and the angles H proximate the junctures of the sides 501 of the product 500 do not correspond with the lengths of the sides 181a, 181b, 181c, 181d, and 181e and the angles L proximate the junctures of the sides 181a, 181b, 181c, 181d, and 181e. Further, the product 500 has dimensions of Dimension G (3.811 inches) by Dimension T (4.250 inches) and the product holder 181 has dimensions of Dimension Q (4.130 inches) by Dimension S (4.242 inches) so the product 500 will not fit within the cavity 182 because Dimension T is larger than either Dimension Q or Dimension S.
Similarly, the cavity 202 of the product holder 201 is configured and arranged to receive the product 500 therein, but products 300 and 400 will not fit within the cavity 202. More specifically, the lengths of the sides 301 and the 90 degree angles proximate the junctures of the sides 301 do not correspond with the lengths of the sides 201a, 201b, 201c, 201d, 201e, and 201f and the angles N proximate the junctures of the sides 201a, 201b, 201c, 201d, 201e, and 201f. Further, although the product 300 has dimensions of Dimension A (3.550 inches) by Dimension A (3.550 inches) and the product holder 201 has dimensions of Dimension M (3.900 inches) by Dimension U (4.349 inches), the length of the sides 201a, 201b, 201c, 201d, 201e, and 201f (Dimension 0 (2.174 inches) is smaller than the length of the sides 301 (Dimension A (3.550 inches)) so one of the sides 301 of the product 300 must be moved more proximate either Dimension M or Dimension U within the cavity 202 but then a portion of the product 300 opposite the one side 301 will not fit within the cavity 202. For example, if a side 301 were positioned within the cavity 202 parallel to side 201b more proximate Dimension U within the cavity 202, sides 201d and 201f would cut off the corners of the side 301 opposite the one side 301 that fit within the cavity 202. Similarly, if a side 301 were positioned within the cavity 202 perpendicular to side 201b within Dimension M within the cavity 202, sides 201c and 201d would cut off the corners of the side 301 opposite the one side 301 that fit within the cavity 202. The lengths of the sides 401 and the angles D proximate the junctures of the sides 401 do not correspond with the lengths of the sides 201a, 201b, 201c, 201d, 201e, and 201f and the angles N proximate the junctures of the sides 201a, 201b, 201c, 201d, 201e, and 201f. Further, although the product 400 has dimensions of Dimension P (4.039 inches) by Dimension R (4.146 inches) and the product holder 201 has dimensions of Dimension M (3.900 inches) by Dimension U (4.349 inches), the length of the sides 201a, 201b, 201c, 201d, 201e, and 201f (Dimension 0 (2.174 inches) is smaller than the length of the sides 401 (Dimension B (2.701 inches)) so one of the sides 401 of the product 400 must be moved more proximate Dimension U within the cavity 202 but then a portion of the product 400 opposite the one side 401 will not fit within the cavity 202. For example, if a side 401 were positioned within the cavity 202 parallel to side 201b more proximate Dimension U within the cavity 202, sides 201d and 201f would cut off the corners of the two sides 401 opposite the one side 401 that fit within the cavity 202.
Because the products 400 and 500 will not fit within the cavity 162, the products 300 and 500 will not fit within the cavity 182, and the products 300 and 400 will not fit within the cavity 202, the product holders act as solid product lock-outs to ensure the appropriate types of products are used with the appropriate dispensers. Thus, if several dispensers are used in proximity to one another, the solid product lock-outs ensure the appropriate product is used in each dispenser.
In operation, a diluent, preferably water, is supplied via conduits well known in the art to the first inlet 114, the second inlet 116, and the optional third inlet 117. If the third inlet 117 and the third passageway 117b are included, the third passageway 117b may be closed off or sealed proximate the second cavity 113 if it is not desired to use the third inlet 117. The diluent flows through the first passageway 114b, the second passageway 116b, and the third passageway 117b.
As shown in
As shown in
If the third inlet 117 and the third passageway 117b are used, a temperature control valve (not shown) such as that disclosed in U.S. Patent Application Publication Nos. US 2006/0083668 A1 and US 2006/0083669 A1 may be used to monitor the temperature of the diluent. If the temperature of the diluent reaches approximately 105 to 120° F., more product will be dissolved by the diluent thereby increasing the concentration of the concentrated solution and the thermal valve will turn on to allow diluent to flow through the third inlet 117, which will assist in adjusting the concentration of the diluent. If the temperature of the diluent is below approximately 105 to 120° F., the thermal valve will be turned off to prevent diluent from flowing through the third inlet 117. The third inlet 117 is preferably used with products such as sanitizers or other types of products for which it is desired to control the diluent temperature. For solid products that do not require the regulation of diluent temperature, the third inlet 117 is preferably not used and the passageway 117b is closed off.
When the third inlet 117 is used, water is preferably supplied to the dispenser 100 at a rate of up to 9.0 gpm, of which up to 1.0 gpm is supplied to the first inlet and sprayed onto the solid product, up to 4.0 gpm is supplied to the second inlet, and up to 4.0 gpm is supplied to the third inlet when the thermal valve is on. When the third inlet 117 is not used and the third passageway 117b is sealed, water is preferably supplied to the dispenser 100 at a rate of up to 5.0 gpm, of which up to 1.0 gpm is supplied to the first inlet and sprayed onto the solid product and up to 4.0 gpm is supplied to the second inlet.
The concentrated solution and the diluent flow out of the dispenser 100 substantially concurrently. The flow rate of the diluent as it exits through the cavity 142 is up to 8.0 gpm. The flow rate of the concentrated solution as it exits through the cavity 130 is up to 1.0 gpm. The flow rate of the use solution as it exits through the cavity outlet tube 148 is up to 9.0 gpm. The relatively small inner diameter of the diluent outlet 136 creates a relatively fast flow rate, which creates a venturi to draw the concentrated solution out of the cavity 130. The smaller the inner diameter of the diluent outlet 136, the faster and more turbulent the diluent will exit the diluent outlet 136 thus increasing the venturi effect. The increased velocity of the diluent creates a negative pressure, which extracts the concentrated solution from the cavity 130 (and the cavities 129 and 111), and the diluent and the concentrated solution are mixed within the outlet tube 148. The inner diameter of the outlet tube 148 is preferably as small as possible and sized to allow the concentrated solution and the diluent (up to 9.0 gpm) which mix together to create a use solution as they exit the dispenser 100 freely without backing up.
The venturi is beneficial for at least two reasons. First, the concentrated solution and the diluent exit the dispenser 100 more quickly thereby reducing the time to dispense the use solution. Second, if a solid portion of a solid product breaks off and falls into the cavity of the dispenser, the increased rate at which the concentrated solution exits the cavity erodes the solid portion of the solid product more quickly.
The bottom 252 of the vacuum breaker 250 is typically required by code to be at least 3.50 inches from the flood plane 173 for backflow prevention. The flood plane 173 has been lowered to proximate the bottom of the product holder 161, and this allows the vacuum breaker to be closer to the top of the top portion 160 thus reducing the space needed for the dispenser 100. Spraying the solid product with diluent proximate the bottom of the product holder 161 and the flood plane 173 poses a challenge to keeping the diluent from spraying out of the overflow outlets 172. The overflow outlets 172 should be large enough to allow up to 9.0 gpm of diluent and concentrated solution to escape when the dispenser 100 is backed-up but help prevent diluent and concentrated solution from splashing out of the top portion 160 while the diluent is being sprayed onto the bottom surface of the solid product to create the concentrated solution. However, this challenge has been overcome by the geometry of the base portion 166 and the extension flange 164.
The extension flange 164 of the product holder 161 helps prevent diluent from splashing through the overflow outlets 172 while allowing any back-up to escape through the gap between the extension flange 164 and the flange 167. Further, the angled portion 170 helps prevent any diluent that may have gotten past the extension flange 164 from splashing through the overflow outlets 172 because the diluent will hit the angled portion 170 more proximate the flange 167 than the overflow outlets 172 and then stay within the dispenser 100. The diluent will hit the angled portion 170 more proximate the flange 167 because the extension flange 164 extends downward to block diluent from hitting the angled portion 170 more proximate the overflow outlets 172.
It is understand that one or more dispensers may be used. An example is a single dispenser may be used to dispense a cleaning agent into a mop bucket. Another example is a first dispenser may be used to dispense a detergent, a second dispenser may be used to dispense a sanitizer, and a third dispenser may be used to dispense a rinse aid into a warewashing machine.
The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.
This application is a divisional application of U.S. patent application Ser. No. 11/487,168, filed Jul. 14, 2006, which claims the benefit of U.S. Provisional Patent Application 60/795,340 filed Apr. 27, 2006.
Number | Date | Country | |
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60795340 | Apr 2006 | US |
Number | Date | Country | |
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Parent | 11487168 | Jul 2006 | US |
Child | 13104332 | US |