U.S. patent application number 17/529070 was filed with the patent office on 2022-03-10 for liquid additive delivery system and methods for ensuring substantially only a liquid is disposed within a container.
The applicant listed for this patent is 3M INNOVATIVE PROPERTIES COMPANY. Invention is credited to Brian S. Boothman, Scott D. Gullicks, Mark F. Schulz.
Application Number | 20220072748 17/529070 |
Document ID | / |
Family ID | 1000005983031 |
Filed Date | 2022-03-10 |
United States Patent
Application |
20220072748 |
Kind Code |
A1 |
Schulz; Mark F. ; et
al. |
March 10, 2022 |
LIQUID ADDITIVE DELIVERY SYSTEM AND METHODS FOR ENSURING
SUBSTANTIALLY ONLY A LIQUID IS DISPOSED WITHIN A CONTAINER
Abstract
Methods, apparatuses and systems are disclosed including a
method of filling a container with substantially only a liquid. The
method can include the removal of a gas from the container prior
to, during or after the filling of the container with the liquid.
According to one embodiment, the container includes an inner liner
and a lid. The method includes providing a volume defined by at
least the inner liner and the lid of the container. In such
embodiment, the liquid can initially be contained within a first
portion of the volume and a remaining portion of the volume can
contain a gas. The method can include removing substantially all
the gas from the volume via one or more ports that communicate with
the volume while retaining substantially only the liquid within the
volume.
Inventors: |
Schulz; Mark F.; (Lake Elmo,
MN) ; Boothman; Brian S.; (San Jose, CA) ;
Gullicks; Scott D.; (Woodbury, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
3M INNOVATIVE PROPERTIES COMPANY |
St. Paul |
MN |
US |
|
|
Family ID: |
1000005983031 |
Appl. No.: |
17/529070 |
Filed: |
November 17, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16621420 |
Dec 11, 2019 |
11207810 |
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PCT/US2018/039397 |
Jun 26, 2018 |
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17529070 |
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62524779 |
Jun 26, 2017 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29C 45/1866 20130101;
B65D 83/0055 20130101; B65D 83/0072 20130101; B65B 3/18
20130101 |
International
Class: |
B29C 45/18 20060101
B29C045/18; B65B 3/18 20060101 B65B003/18; B65D 83/00 20060101
B65D083/00 |
Claims
1. A method of dispensing a liquid during a molding process
comprising: dispensing a first amount of the liquid from a first
liquid container during the molding process; determining if the
first amount of the liquid corresponds to a specified amount of the
liquid; without replacing the first container, dispensing a second
amount of the liquid from a second container during the molding
process if the first amount of the liquid is determined not to
correspond to the specified amount of the liquid.
2. The method of claim 1, further comprising replacing the first
liquid container or the second liquid container with a third liquid
container during the molding process if the first liquid container
or the second liquid container is determined to have an
insufficient amount of the liquid remaining therein to provide the
specified amount.
3. The method of claim 2, wherein the replacing of the first
container or the second container occurs simultaneous with or
sequent to the dispensing the specified amount of the liquid.
4. The method of claim 1, wherein the first liquid container and
the second liquid container each comprises an integrated pump cap
further comprising a pump; wherein the dispensing occurs using a
dispensing device comprising a motor configured to drive the pump
in each container to dispense the specified amount of the liquid.
Description
BACKGROUND
[0001] The present disclosure relates to the containment of a
liquid within a container. More particularly, the disclosure
relates to methods for ensuring that substantially only the liquid
is disposed within the container.
[0002] Many processes require liquids to be contained within a
vessel for later dispensation. However, the addition of a gas
within such vessels in addition to the liquid can cause inaccuracy
when the liquid is dispensed. In some cases, the gas can have other
adverse effects on the liquid such as causing spoilage or
hardening. Thus, the presence of the gas within the vessel along
with the liquid can cause waste.
[0003] In light of the above, a need exists for improved methods
for the containment of liquids so as to have minimal interaction
with gas.
SUMMARY
[0004] Aspects of the present disclosure include a method of
filling a container with substantially only a liquid. The method
can include the removal of a gas from the container prior to,
during or after the filling of the container with the liquid.
According to one embodiment, the container includes an inner liner
and a lid, the construction of which will be discussed
subsequently. The method includes providing a volume defined by at
least the inner liner and the lid of the container. In such
embodiment, the liquid can initially be contained within a first
portion of the volume and a remaining portion of the volume can
contain a gas. An example of such a container having the inner
liner and the lid is disclosed in United States Patent Application
Publication No. 2013/0270303A1, entitled, "Dispensing liquids from
a container coupled to an integrated pump cap", the entire
specification of which is incorporated herein by reference in its
entirety.
[0005] According to some embodiments, the liquid is a Newtonian
fluid. In other embodiments, the liquid is a non-Newtonian fluid.
For example, the liquid can be any one or any combination of an
adhesive, cement, colorant, coating, detergent, epoxies, dye,
filler (e.g., body filler), nano-material, oil, paint (e.g.,
automotive paint), paste, pigment, caulk, urethane, polymer
additive (which may be organic or inorganic), sealant, stain,
toner, varnish, and wax.
[0006] According to some embodiments, the rheology of the liquid
may be tailored such that the viscosity of the liquid is low during
flow into the pump (priming) (e.g., at a higher shear rate), then
the viscosity can increase after the liquid has stopped flowing
into the pump (e.g., at a lower shear rate), thereby preventing the
gas from re-entering the container. This same mechanism can be used
for several of the embodiments further described below. For
example, an embodiment where the gas is removed by vacuum or higher
external pressure to push the air out through the pump, vent, or
other small orifice. The properties of the liquid can be tailored
such that the liquid seals the pump, vent, or other small orifice.
In other embodiments, the gap sizes can be adjusted in the pump to
increase the resistance to gas re-entering the container (smaller
gap size results in higher resistance to flow). Thus, the
properties of the liquid and/or gap sizes can be adjusted to
provide sufficiently easy removal of gas/priming of pump (e.g., low
resistance to flow) and sufficiently difficult re-entry of gas back
into the container (e.g., high resistance to flow).
[0007] In some embodiments, the viscosity of the fluid is higher at
a lower shear rate than it is at a higher shear rate. For example,
in some embodiments the viscosity of the fluid at 0.1 sec.sup.-1 is
1.5 times greater than the viscosity of the fluid at 1.0
sec.sup.-1. (Note that the units of shear rate are sec.sup.-1, or
reciprocal seconds). In some embodiments, 2 times greater, 3 times
greater, 4 times greater, 5 times greater, 10 times greater.
[0008] In some embodiments, the viscosity of the fluid is between
0.1 and 10,000 Pa-s at a shear rate of 1.0 sec.sup.-1. In some
embodiments, between 0.1 and 1000, between 0.1 and 500, between 1
and 100 (all at shear rate of 1 sec.sup.-1).
[0009] In some embodiments, the viscosity of the fluid is between
0.1 and 10,000 Pa-s at a shear rate of 0.1 sec.sup.-1. In some
embodiments, between 1 and 1000, between 5 and 1000, between 10 and
1000, between 50 and 1000, between 100 and 1000 (all at shear rate
of 0.1 sec.sup.-1).
[0010] The liquids may be neat (including concentrates) or in the
form of dispersion, solution, or suspension. Unless otherwise
noted, viscosity values if provided are at a temperature of
20.degree. C. and pressure of 1 bar.
[0011] Liquids including the liquids disclosed herein can be very
difficult to dispense accurately if gas is present in the
container. For example, in some cases the gas does not get pumped
efficiently in the pump, which results in liquid becoming trapped
in the container (over a reasonable pumping time). In some
embodiments, the liquid does not flow readily by gravity, resulting
in air getting to the pump before the liquid is completely removed
(especially if the container is filled upright then inverted to
pump), in turn resulting in the possibility of intermittent liquid
flow. Furthermore, the gas, if present, can cause excessive waste
of the liquid due to hardening of the liquid. Hardening of the
liquid can leave an amount of the liquid trapped within the
container that cannot be dispensed and is therefore wasted. Thus,
the disclosed methods and containers can ensure substantially no
gas is present in the container with the liquid to minimize waste.
Additionally, leaving substantially only the liquid in the
container can allow for a more precise amount of liquid to be
dispensed in a more controlled manner.
[0012] In some embodiments, the disclosed container design with the
lid, the inner liner and/or an outer housing can be used for
injection molding of colored plastics where the liquid housed by
the container comprises a liquid colorant. The disclosed container,
along with the techniques disclosed herein related to ensuring
substantially only the liquid is housed in the container, can
therefore be used to reduce molding costs. For example, a neutral
base material can be used for all colors so molders do not need to
maintain a number of different colored base materials.
Additionally, color quality and/or molded part physical properties
can be improved by eliminating the heat history from reheating
colored base plastic material that has already been melted for
coloring. Also using a liquid colorant directly eliminates
additional processing, for example drying pre-colored base plastic
materials, thereby saving the time and cost to dry the base
material.
[0013] According to one embodiment, the method of filling the
container with substantially only the liquid includes removing
substantially all the gas from the volume via one or more ports
that communicate with the volume while retaining substantially only
the liquid within the volume. As used here the term "substantially
all the gas", "substantially no gas" or the like means some
percentage of the volume of the container may still be filled by
the gas after the removal process. According to one embodiment,
this percentage is less than 5% of the volume. According to further
embodiments, the percentage can be less than 3%, in some cases less
than 1%, and in some cases less than 0.5% of the volume. These
percentages would not include any gas that is not immediately free
to escape via the one or more ports (e.g., a gas encapsulated
within glass bubbles, a gas captured as bubbles within the liquid,
or the like).
[0014] Similarly, the term "substantially only a liquid" or
"substantially only the liquid" or the like means less than an
entirety of the volume of the container may be filled by the
liquid. For example, some portion of the volume container can
contain the gas as discussed above. According to one embodiment,
"substantially only a liquid", "substantially only the liquid" or
the like means that 95% or more of the volume of the container is
filled by the liquid. According to further embodiments, 97% or more
of the volume of the container is filled by the liquid. According
to yet further embodiments, 99% or more of the volume of the
container is filled by the liquid. According to yet further
embodiments, 99.5% or more of the volume of the container is filled
by the liquid.
[0015] According to one embodiment, the gas is present in the
volume defined by at least a portion of the lid and inner liner
prior to filling of the volume with the liquid. It is therefore
desirable to remove the gas from the volume such that substantially
only the liquid remains within the volume. Contemplated steps for
the removal of substantially all the gas from the volume of the
container include at least one of applying a first pressure on a
surface of the inner liner external to the volume to partially
collapse the inner liner and applying a second pressure to the one
or more ports to draw the gas through the one or more ports, for
example. The second pressure can be a pressure that is less than a
pressure within the volume, for example, the second pressure can be
a vacuum. Applying the first pressure to the surface of the inner
liner external to the volume can include one or more of filling the
outer housing of the container with a fluid or gas and contacting
the surface of the inner liner with a mechanical feature such as a
member. Other contemplated embodiments for the removal of
substantially all the gas from the volume of the container will be
discussed subsequently.
[0016] According to some embodiments, in addition to the inner
liner and the lid, the container can be comprised of the outer
housing. The outer housing can in the form of a cup that can be
rigid. The outer housing can at least partially surround and house
the inner liner and can be coupled to the lid, for example, by a
ring. In some embodiments, the inner liner can be flexible (e.g., a
bladder) so as to be collapsible and expandable. Thus, the inner
liner can collapse as the liquid is pumped from the container.
[0017] In some embodiments, the lid can include an integrated pump
cap. The integrated pump cap can integrate a pump into the lid. The
pump can comprise a G-rotor pump, a peristaltic pump, a syringe
pump, or an elastomeric diaphragm pump, for example. The pump can
be used to dispense a specific amount of the liquid from the
container when operated. When dispensed in this manner, the liquid
can pass through one (or more) of the one or more ports (e.g., an
outlet port), for example. However, in other embodiments the liquid
can be dispensed through a dedicated outlet port that is not one of
the one or more ports used for filling of the container with the
liquid or removing the gas.
[0018] Other aspects of the present disclosure are directed to a
method of filling the container with substantially only the liquid
where the gas has been removed from the volume (or was never
present in the volume) prior to the filling. For example, the inner
liner can be flexible so as to be substantially fully collapsed
prior to filling such that substantially no gas is present in the
volume defined by the flexible liner and the lid. Thus, filling the
volume with substantially only the liquid via one or more ports
that communicate with the volume can occur sequent to collapsing
the flexible liner. In other embodiments, no flexible liner may be
present and the gas can be removed prior to filling (e.g., by
creating a vacuum in the container).
[0019] The details of one or more embodiments of the subject matter
described in this specification are set forth in the accompanying
drawings and the description below. Other features, aspects, and
advantages of the subject matter will become apparent from the
description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a perspective view of a container with a lid and a
housing according to an example of the present disclosure.
[0021] FIG. 2 is an exploded view of the container showing the lid
and housing from FIG. 1 and also illustrating an inner liner and
ring according to an example of the present disclosure.
[0022] FIG. 3 is a partial cutaway of the lid showing a pump and
integrated pump cap according to an example of the present
disclosure.
[0023] FIG. 4A is schematic view of the container similar to as
previously illustrated in FIGS. 1-3 containing a liquid and gas
within an inner volume defined by the inner liner and lid according
to an example of the present disclosure.
[0024] FIG. 4B is a schematic view of the container of FIG. 4A
having undergone a method to remove substantially all the gas from
the volume while retaining substantially only the liquid within the
volume according to an example of the present disclosure.
[0025] FIG. 5 shows the container of FIG. 4B undergoing the method
to remove substantially all the gas from the volume while retaining
substantially only the liquid within the volume by application of a
pressure differential such as a vacuum that communicates with the
volume according to an example of the present application.
[0026] FIG. 6A shows the container of FIG. 4B undergoing the method
to remove substantially all the gas from the volume while retaining
substantially only the liquid within the volume by application of a
pressure on the inner liner by increasing the pressure in the
container in a second volume between the outer housing and on an
outer surface of the inner liner, the second pressure causing
collapse of the flexible inner liner to displace substantially all
the gas from the volume according to an example of the present
application.
[0027] FIG. 6B shows the container of FIG. 4B undergoing the method
to remove substantially all the gas from the volume while retaining
substantially only the liquid within the volume by application of a
pressure on the inner liner by a mechanism such as a member, the
pressure causing collapse of the flexible inner liner to displace
substantially all the gas from the volume according to an example
of the present application.
[0028] FIG. 7 shows the container of FIG. 4B undergoing the method
to remove substantially all the gas from the volume while retaining
substantially only the liquid within the volume by application of a
lid specifically designed to displace substantially all the gas
from the volume when coupled to the remainder of the container
according to an example of the present application.
[0029] FIG. 8A shows gears or rotors of a pump can form one or more
of the one or more ports to allow substantially all the gas to pass
therethrough during the method to remove substantially all the gas
from the volume according to an example of the present
application.
[0030] FIG. 8B shows the gears of the pump of FIG. 8A are primed by
the liquid during the method to remove substantially all the gas
from the volume while retaining substantially only the liquid
within the volume according to an example of the present
application.
[0031] FIG. 9A shows a method of filling a container with
substantially only a liquid according to another example of the
present application where a flexible liner of the container is
substantially fully collapsed such that substantially no gas is
present in the volume prior to filling the volume with
substantially only the liquid.
[0032] FIG. 9B shows the method of FIG. 9A undergoing the filling
of the volume with substantially only the liquid.
[0033] FIG. 10 show another example of the container that allows
for the method of filling the container with substantially only the
liquid, the method provides at least one of the one or more ports
comprises a vent for venting the gas from the volume according to
an example of the present application.
[0034] FIG. 11 shows the container of FIG. 10 being simultaneously
filled with the liquid and having the gas vented from the volume
via at least one of the one or more ports according to an example
of the present application.
[0035] FIG. 12 shows an alternative embodiment of the container of
FIGS. 10 and 11 where the container has a first port of the one or
more ports for filling of the volume with substantially only the
liquid and has a second port of the one or more ports for venting
the gas vented from the volume according to an example of the
present application.
[0036] FIG. 13 shows yet another alternative embodiment of the
container of FIGS. 10-12 that allows for simultaneous venting of
gas from the volume and filling of the volume of the container
according to an example of the present application.
[0037] FIG. 14 shows a system that can comprise a dispenser for
precise dispensing of the liquid from one or more of containers
according to an example of the present application.
[0038] FIG. 15 shows a method of using the dispensing system of
FIG. 14 during an injection molding process according to an example
of the present application.
[0039] FIG. 16 shows another method of using the dispensing system
of FIG. 14 during the injection molding process according to an
example of the present application.
[0040] FIG. 17 shows yet another method of using the dispenser
system of FIG. 14 during the injection molding process according to
an example of the present application.
[0041] FIG. 18 show a graph of viscosity results for a
non-Newtonian fluid according to Example 1.
DETAILED DESCRIPTION
[0042] Aspects of the present disclosure relate to devices, systems
and methods for the containment of liquids. The disclosed methods
facilitate the filling a container with substantially only the
liquid(s) desired. The method can include the removal of a gas from
the container prior to, during or after the filling of the
container with the liquid. Thus, in some embodiments the method
includes removing of the gas from the container such that
substantially only the liquid remains within the container. Further
embodiments are discussed herein and in reference to various of the
FIGURES.
[0043] As a point of reference, FIG. 1 illustrates an example
container 10 that includes a lid 12, an outer housing 14 and an
inner liner 16 (shown in phantom in FIG. 1). The outer housing 14
can be a rigid component and can be a reusable and/or disposable
part of the container 10. The outer housing 14 can be configured to
couple with the lid 12 and surrounds and receives at least a
portion of the inner liner 16. Thus, the inner liner 16 can be
positioned within the outer housing 14 upon assembly. The inner
liner 16 can be comprised of a flexible material (e.g., a rubber,
flexible plastic film such as low density polyethylene (LDPE), for
example) so as to be collapsible and expandable. Thus, a volume 18
defined by the inner liner 16 and the lid 12 can be changeable in
size in some embodiments with the collapse and expansion of the
inner liner 16. According to further embodiments, the inner liner
16 can be removable from the outer housing 14 and the lid 12 so as
to be disposable.
[0044] The outer housing 14 can provide structural stability when
the container 10 is transported or otherwise used. According to the
illustrated embodiment, the outer housing 14 is removably coupled
to the lid 12, for example, using a threaded ring 20. The threaded
ring 20 can be integral to the lid 12 or can comprise a separate
piece. Threads on ring 20 can be either male or female with the
complementary mating threads formed on the outer housing 14. The
threaded ring 20 can also be used to maintain the position of the
lid 12 on the container 10. Although the threaded ring 20 is
illustrated in FIG. 1 for removably coupling lid 12 to the outer
housing 14, other coupling mechanisms may be employed such as, for
example, a bayonet connector, snap tabs or snap wings, and the
like, which may be useful for providing a "quick connect"
capability. Alternatively, the lid 12 can be coupled to outer
housing 14 by an interference or friction fit between these two
components.
[0045] According to the embodiment shown in FIGS. 1-3, the
container 10 can include an integrated pump cap 22 as part of the
lid 12. This integrated pump cap 22 includes a motor coupler 24
that, in the illustrated embodiment, rotates about a central axis
in response to a corresponding rotation of a drive component in a
dispenser (not shown). As shown, the motor coupler 24 includes a
number of teeth that can engage a corresponding set of teeth in the
motor base 24. Thus, when the motor drives a rotational drive shaft
coupled by the teeth to the motor coupler 24, the motor coupler 24
is rotated to drive the pump 26 (FIG. 3) so that contents of the
container 10 can be dispensed through an output port 28 in the lid
12. The teeth can be shaped to facilitate transfer of energy from
the motor to the pump 26 (FIG. 3). Numerous variations on this
approach are possible. For example, motor base (not shown) and the
motor coupler 24 can have the same number of engagement teeth or a
different number of engagement teeth, or they may interact without
the use of gears that mesh such as by frictional engagement or
magnetic coupling. For simplicity and ease of design, it is
preferred to have the motor transfer rotational energy to the
driveshaft but linear energy transfer can be used too via, for
example, a rack and pinion mechanism. Advantageously, pump cap 22
may be readily disassembled from the motor base and/or lid 12
without using tools so as to facilitate cleaning and installation
of a different container 10.
[0046] Referring now specifically to FIG. 3, the drive motor can be
coupled to the integrated pump cap 22 in order to drive the pump 26
to dispense a specified amount of the liquid. In some embodiments,
a G-rotor pump is integrated into the cap 22 of lid 12 in order to
pump the liquid, in response to the driving motor. However, many
other types of pumps may be readily integrated into the integrated
pump cap 22 depending on the nature of the material to be pumped
and other application-specific considerations (e.g., cost,
efficiency, accuracy, size, weight, whether moving parts can be
incorporated into the cap or should be isolated away from the cap,
etc.) such as a peristaltic pump, a syringe pump, or an elastomeric
diaphragm pump.
[0047] FIG. 3 shows a cutaway view of the integrated pump cap 22 to
illustrate additional details. The cutaway view shows the motor
coupler 24 and the output port 28. In the example of FIG. 3, the
pump 26 can be formed from metal, plastic, other materials, or
combinations thereof. For example, in some implementations, the
pump housing is molded or otherwise fabricated from glass-filled
nylon, and the gears are molded or otherwise fabricated from a
polytetrafluoroethylene (e.g., Teflon.TM.)-impregnated acetal. The
pump 26 has controlled rotation such that precise amounts of the
liquid from the container 10 are dispensed through the output port
28. In some embodiments, the integrated pump cap 22 is mounted to
the motor such that the motor coupler 24 is coupled to the motor at
an upward orientation with the remainder of the container 10 below
the pump 26. However, such orientation is not always necessary. For
example, the majority of the container 10 can be positioned above
the pump 26 such that the liquid is gravitationally directed to an
input of the pump 26. Other embodiments are also contemplated. In
some embodiments, the liquid can be dispensed from the container 10
by methods other than the pump 26. For example, such methods can
include pressurizing the container (e.g., pressurizing the space
between an outer container and an inner liner), installing a siphon
tube that extends from output port 28 to the bottom of the
container, or by using a bladder or other mechanism that expands to
expel liquid from the container.
[0048] As shown in FIG. 3, the motor coupler 24 is coupled to a
shaft 25. The shaft 25 is further coupled to an inner or first
rotor 29A. The pump 26 includes an inner rotor 29A that sits off
center within and engages an outer or second rotor 29B. As the
motor coupler 24 is turned by the motor (not shown), the shaft 25
rotates. Rotation of the shaft 25 causes the inner rotor 29A to
rotate within the outer rotor 29B. The outer rotor 29B has more
slots than the number of rotor lobes on the inner rotor 29A such
that the inner rotor 29A rotates in an eccentric manner with the
outer rotor 29B. This rotation is such that in a first position an
input port is exposed allowing fluid to flow from the container
into a space between the lobes of the inner rotor 29A. As the inner
rotor 29A and outer rotor 29B continue to rotate, an output is
exposed between the lobes and the liquid is pushed out of the pump
through output port 28. The outer rotor 29B revolves at a slower
rate than the inner rotor 29A, thereby rotating and changing the
volume of the chambers created by the slots.
[0049] The pump 26 can be reversible allowing liquid to be pumped
from outside the container 10 through the output port 28 (which in
this configuration may be regarded as an input port) and into the
container 10. However, in other embodiments, the pump can be
non-reversible such that the liquid can only be pumped out of the
container. The pump 26 can also be configured to allow the gas to
pass through the volume between the inner rotor 29A and the outer
rotor 29B to reach the outlet port 28. The flow of such gas can be
either be into the container 10 or out of the container 10 as will
be further discussed subsequently.
[0050] Now referring to FIG. 2, the integrated pump cap 22 includes
a pump cap housing 30, and a container coupler 32 (as part of or
separate from the housing 30) in addition to the output port 28,
and the motor coupler 24. The pump cap housing 30 may be formed as
a single piece or as a combination of pieces that are removably
attached together or that are fixed together (e.g., by sonic
welding). For example, a portion of the pump cap housing 30 can be
configured to fit the remainder of the container 10 (either the
outer housing 14 and/or the inner liner 16).
[0051] According to some embodiments, a portion of the lid 12 can
be removed in order to form an aperture in which to couple a pump
housing including the pump for dispensing the liquid from the
container. In some implementations, the pump cap housing 30
includes a first portion positioned on one side of the lid aperture
and a second portion positioned on the other side of the lid
aperture, where the two portions are configured to engage in order
to lock the portions together and to the lid. An o-ring or other
seal or gasket can be positioned between the lid 12 and a portion
of the pump cap housing 30 to prevent liquid leaks. In some
alternative implementations, the pump cap housing is joined to the
lid (e.g., by sonic welding or using an adhesive) to bond the pump
cap housing to the lid. In yet other embodiments, the pump cap
housing 30 can be integrally formed with the lid 12 for closing the
container.
[0052] The container coupler 32 allows the integrated pump cap 22
to attach to the container 10. In the embodiment of FIG. 2, the
container coupler 32 is in the form of male or female threads that
join with complementary threads formed on the container 10. In
other implementations, the container coupler 32 is configured to
provide an interference or friction fit with the container. In
still other embodiments, the container coupler 32 may be a bayonet
connector, snap tabs, snap wings or the like (with complementary
engaging structure formed on the container), which may be useful
for providing a "quick connect" capability. Alternatively, the
container coupler 32 may be provided as a weld (e.g., a sonic weld)
or as an adhesive that joins the pump cap 22 to the container 10.
As previously described, the output port 28 is configured to output
liquids from the container 10 as driven by the pump 26.
[0053] Still referring to FIG. 2, the lid 12 can be coupled to the
rigid outer housing 14 and/or the flexible inner liner 16.
Additional stability can be obtained by, for example, forming the
inner liner 16 with a rim 17 at an open end 19 that rests on the
upper edge 15 of the outer housing 14. Securing the lid 12 to the
outer housing 14 by the techniques mentioned above may compress the
rim of the inner liner 16 between the upper edge of the outer
housing 14 and the lid 12. If the lid 12 is coupled to the inner
liner 16 this may be accomplished by a friction fit between the lid
12 and the inner liner 16 or by sealing the lid 12 to the inner
liner 16 using, for example, sonic welding or an adhesive
[0054] According to some embodiments, the outer housing 14 may
contain a gas hole comprising a vent that remains open, or
alternatively, that can be opened and closed as desired. If closure
is desired, a strip of tape or a valve can be utilized to close the
vent. In this manner, when the gas hole is open, the inner liner 16
may collapse as liquid is pumped from the container 10 thereby
facilitating dispensing the liquid. Thus, the inner liner 16 in
combination with the lid 12 provides the volume 18 that is a sealed
liquid container. The volume 18 can collapse as the liquid is
dispensed and can expand as the liquid is pumped or otherwise
provided to the volume 18. This construction allows for an air
tight dispensing that reduces the risk of contamination to the
liquid. For example, some liquids contemplated to be housed within
the volume 18 can react with oxygen, (e.g., the liquids can cure
when exposed to air). Additionally, the sealed construction can
reduce the chances that the liquid escapes from the container and
contaminates the surroundings. Other liquids can easily be
contaminated by particulates in the air which can impair their
function and also interfere with the dispensing. As previously
discussed, the inner liner 16 can be composed of various flexible
materials, for example, LDPE.
[0055] Although the container 10 is described as including an outer
housing 14 and an inner liner 16, it may be a single component in
the form of a container without a liner or an outer housing. Thus,
the inner liner can be a layer or part of the outer housing. The
container that may be rigid or flexible and may contain a vent to
equilibrate the pressure inside the container with atmospheric or
another pressure when the vent is open as previously discussed. A
flexible container may be composed of various flexible polymeric
materials, for example, LDPE or, if more strength or durability is
desired, an ethylene vinyl acetate (EVA) resin such as
Elvax.RTM..
[0056] Bearing in mind the configuration of the container 10,
further details and alternatives are described in detail with
reference to the subsequent FIGURES. For example, various methods
of ensuring substantially only the liquid fills the volume within
the container 10 are now described with reference to the subsequent
FIGURES.
[0057] FIGS. 4A and 4B show a container 110 such as the container
10 previously illustrated in FIGS. 1-3. As such, the container 110
includes a volume 118 defined by portions of an inner liner 116 and
a lid 112. The container 110 also includes an outer housing 114.
The lid 112 or other parts of the container 110 can include one or
more ports 128 as will be described subsequently and for which an
example includes the outlet port 28 previously described in
reference to FIGS. 1-3. The one or more ports 128 communicate with
the volume 118 as well as the ambient or a device (e.g., a vacuum
or a part of the dispenser as described in United States Patent
Application Publication No. 2013/0270303A1).
[0058] FIG. 4A shows liquid 102 (indicated as shaded) and a gas
(indicated as "GAS" in FIG. 4A but simply shown in white
hereinafter for brevity) are contained in the volume 118. In
particular, a first portion 104 of the volume 118 contains the
liquid 102 and a remaining portion 106 contains the gas. As used
herein, the gas can include any gas such as air, aerosol, or an
inert gas, for example. The liquid 102 can be provided to the
volume 118 by a pump, for example. The liquid 102 can be any one or
any combination of an adhesive, cement, colorant, coating,
detergent, epoxies, dye, filler (e.g., body filler), nano-material,
oil, paint (e.g., automotive paint), paste, pigment, caulk,
urethane, polymer additive (which may be organic or inorganic),
sealant, stain, toner, varnish, and wax as previously described.
Similarly, the viscosity and/or the shear rate of the liquid 102
can vary as previously discussed. In some embodiments, components
of the container 110 such as a pump of like or similar construction
to the pump 26 previously described can be specifically configured
to accommodate and facilitate pumping of the liquid(s) disclosed
herein to dispense the liquid 102 from the volume 118.
[0059] FIG. 4B shows the container 110 having undergone a method
108 to remove substantially all the gas from the volume 118 via the
one or more ports 128 while retaining substantially only the liquid
102 within the volume 118. As shown in FIG. 4B, the inner liner 116
is flexible and has at least partially collapsed in response to, to
aid, or to facilitate the removal of the gas.
[0060] FIG. 5 shows the container 110 undergoing one embodiment of
a method 200 to remove substantially all the gas (the flow of which
is indicated by arrow) from the volume 118 while retaining
substantially only the liquid 202 within the volume 118. According
to the embodiment of FIG. 5, a pressure differential is applied
such that a pressure P1 within the volume 118 differs from a
pressure P2 within a first device 204. Although indicated as a
device, the first device 204 can simply be a region such as the
immediate ambient around the container 110 that has a pressure
differential relative to the pressure P1 of the volume 118. The
volume 118 communicates with the first device 204 via the one or
more ports 128. According to one embodiment, the first device 204
comprises a vacuum 206 that communicates with the volume 118 via
the one or more ports 128. In other embodiments, the first device
204 need not comprise the vacuum 206 but can be a container, volume
or region with a pressure differential relative to the pressure P1
of the volume 118 sufficient to cause the gas to flow from the
volume 118. In further embodiments, the first device 204 can be
used with a dispenser as described in United States Patent
Application Publication No. 2013/0270303A1 or another device could
be used to drive the pump to pump the air out in some
embodiments.
[0061] As shown in FIG. 5, the container 110, the first device 204
and the other components illustrated can be part of a system 208
that includes a second device 210 to regulate communication between
the volume 118 and the first device 204 (or ambient) via the one or
more ports 128. For example, the second device 210 can comprise a
one way valve, a check valve or the like. In other example
embodiments, the second device 210 can comprise a plug or a seal
such as a membrane that can be punctured (e.g. by item 212) to
facilitate communication between the volume 118 and the second
container 204 (or ambient). Although a regulating device such as
the second device 210 is not shown or specifically described in the
prior or some of the remaining embodiments, it should be recognized
that such a device (e.g., a valve, a plug, a seal, or the like) can
be included as desired.
[0062] FIG. 6A again shows the container 110, an example of which
includes the container 10 of FIGS. 1-3 as previously discussed. The
container 110 is undergoing another embodiment of a method 300 to
remove substantially all the gas (the flow of which is indicated by
arrow A) from the volume 118 while retaining substantially only the
liquid 302 within the volume 118. According to the embodiment of
FIG. 6A, a pressure differential is applied such that the pressure
P1 within the volume 118 differs from a third pressure P3 within a
second volume 304 defined between an outer surface(s) 306 of the
inner liner 116 and an inner surface(s) 308 of the outer housing
114. This pressure differential can cause a collapse of the
flexible inner liner 116 that reduces the volume 118 and displaces
substantially all the gas from the volume 118 as shown.
[0063] As shown in FIG. 6A, the third pressure P3 can be supplied
from a third device 310. The third device 310 can be a pump, blower
or the like, for example. According to further embodiments, the
third device 310 can simply be a region such as the immediate
ambient around the container 110 that has a pressure differential
relative to the pressure P1 of the volume 118. The second volume
304 communicates with the third device 310 via one or more of the
one or more ports 128 (e.g., via port 128A). As shown in FIG. 6A,
the port 128A can differ from an outlet port 128B from which the
gas exits the volume 118. As shown, a regulating device 314 such as
a valve, plug or seal (e.g. a membrane) can be utilized with the
embodiment of FIG. 6A.
[0064] FIG. 6B shows an embodiment of a method 400 whereby a member
402 is utilized to cause a collapse of the inner liner 116 of the
container 110 that reduces the volume 118 and displaces
substantially all the gas from the volume 118 as indicated by arrow
A while retaining substantially only the liquid 302 within the
volume 118. The member 402 is moveable to contact and apply a
fourth pressure P4 to the outer surface(s) 306 of the inner liner
116 to create a pressure differential between the pressure P1
within the volume 118 and the fourth pressure P4. This pressure
differential can cause at least a partial collapse of the flexible
inner liner 116 that reduces the volume 118 and displaces
substantially all the gas from the volume 118 as shown. Although
shown as a piston type mechanism, the member 402 can comprise a
spring, diaphragm, a second bladder, or another mechanism that can
be deployed as needed to facilitate the collapse of the inner liner
116.
[0065] FIG. 7 shows an embodiment of a method 500 whereby the lid
112 of the container 110 has been modified in a manner so as to be
configured to displace the gas and the liquid 502 as desired. In
particular, the gas can be displaced so as to be substantially
removed from the volume 118 while substantially only the liquid 502
is retained within the volume 118 when the lid 112 is coupled to
the housing 114 to form the container 110. According to FIG. 7, the
lid 112 has been provided with a projection 504 so as to extend
downward into the volume 118 when the lid 112 is disposed on
remainder of the container 110. Ports 506A, 506B (others not shown)
comprising some of the one more ports facilitate movement of
substantially all the gas from the volume 118 upon coupling of the
lid 112 to the remainder of the container 110.
[0066] It should be recognized the geometry of the lid 112 can be
configured in other manners in keeping with the enclosed teachings
so as to facilitate removing substantially all the gas from the
volume 118 while retaining substantially only the liquid 502 within
the volume 118. For example, the lid 112 may not project down into
the volume 118 in the same manner as shown in FIG. 7 but the method
can rather rely on precise filling of the volume 118 with the
liquid 502 taking into account any displacement that would result
due to the lid 112.
[0067] FIGS. 8A and 8B show an enlargement of a lid 612 constructed
in a manner identical to that of the lid 12 of FIGS. 1-3. Thus, the
lid 612 can include the integrated pump cap 22 and the pump 26 as
previously described. The pump 26 has the rotors 29A and 29B. The
volume between the rotors 29A and 29B and between the rotors 29A
and 29B and the lid housing 612A can define separate of one or more
ports 628 that communicate with the volume 618 (only a portion of
which is shown in FIGS. 8A and 8B).
[0068] As shown in FIG. 8A, the one or more ports 628 can allow for
the passage of substantially all the gas to an outlet port 628A.
FIG. 8B shows that the one or more ports 628 can also be configured
to allow for passage of the fluid 602 to the outlet port 628A. In
some cases, the pump 26 can be driven to turn the rotors 29A and
29B to facilitate the passage of the liquid 602 through the one or
more ports 628. In this manner the pump 26 can be primed with the
liquid 602. Furthermore, the liquid 602 can be tailored so as to
effectively form a seal in the one or more ports 628 or at the
outlet port 628A against the ambient if desired. For example, the
rheology of the fluid may be tailored such that the viscosity of
the fluid is low during flow into the pump (priming) (e.g., at a
higher shear rate), then the viscosity increases after the fluid
has stopped flowing into the pump (e.g., at a lower shear rate),
thereby preventing the gas from re-entering the container. This
same mechanism can be used for several of the above embodiments
where the gas is removed by vacuum or higher external pressure to
push the air out through the pump, vent, or other small orifice.
The fluid properties can be tailored such that the fluid seals the
pump, vent, or other small orifice. In other embodiments, the gap
sizes can be adjusted in the pump to increase the resistance to gas
re-entering the container (smaller gap size results in higher
resistance to flow). Thus the fluid properties and/or gap sizes can
be adjusted by one skilled in the art to provide sufficiently easy
removal of gas/priming of pump (e.g., low resistance to flow) and
sufficiently difficult re-entry of gas back into the container
(e.g., high resistance to flow).
[0069] FIGS. 9A and 9B shows another method 700 whereby a container
710 has been provided with an inner liner 716 and a lid 712 that
define a volume 718. FIG. 9B shows the method 700 where the
container 710 and the inner liner 716 are partially filled during a
filling process. The inner liner 716 is flexible as previously
discussed such that the method 700 substantially fully collapses
the inner liner 716 in a manner that leaves substantially no gas is
present in the volume 718 as shown in FIG. 9A. Sequent to
collapsing the inner liner 716, the method 700 fills the volume 718
with substantially only a liquid 702 via one or more ports 728 that
communicate with the volume 718 as shown in FIG. 9B. Put another
way, the method 700 utilizes a pre-collapsed inner liner 716 that
forms the volume 718 with substantially no gas therein as shown in
FIG. 9A. The method 700 then fills the inner liner 716, which
expands in response, with substantially only the liquid 702 as
shown in FIG. 9B.
[0070] FIGS. 10-13 show various designs for the one or more ports
that can allow for simultaneous filling of the volume defined by
the inner liner and the lid with the liquid while also venting the
gas from the volume.
[0071] For example, FIG. 10 shows a lid 812 having a first port
828A in the manner previously discussed similar to ports 28 and
128. The first port 828A can be used to receive a liquid 802 and to
dispense the liquid 802 according to embodiment of FIG. 10. A
second port 828B has been provided for venting of the gas from a
volume 818. However, in other embodiments, such as the embodiment
of FIG. 11, the first port 828A can be used for venting
substantially all the gas from the volume 818 and the second port
828B can be used for filling with the liquid 802.
[0072] According to the embodiments of FIGS. 10 and 11, at least
one of the first port 828A or the second port 828B that is used for
venting can be positioned to communicate with substantially a last
to fill location for the liquid 802 contained by the volume 818.
Thus, in FIG. 10, the second port 828B is positioned at or adjacent
substantially a highest point of the container 810 on the lid
812.
[0073] FIG. 12 shows yet another embodiment of a container 910 used
with a method 900. The container 910 has two or more ports that are
used according to the method 900 for simultaneous filling of the
volume with a liquid 902 and for venting of a gas from a volume
918. In the embodiment of FIG. 12, a first port 928A communicates
with an inner liner 916 at a relatively lowest point of the inner
liner 916 (corresponding to a relatively lowest point of the volume
918 defined by the inner liner 916 and a lid 912). Rather than the
flexible inner liners previously described, the inner liner 916 can
be constructed of a rigid or semi-rigid material so as to
substantially maintain a desired shape and have a desired volume
throughout the filling and venting process in some cases. In other
cases, a flexible inner liner such as those previously described
can be utilized. As shown in FIG. 12, the first port 928A receives
the liquid 902, which can be pumped or can otherwise be made to
flow into the volume 918 through an outer housing 914 as well as
the inner liner 916. Simultaneous with filling of the liquid 902,
the gas can be vented from the volume 918 via a second port 928B.
According to the embodiment of FIG. 12, the second port 928B can be
positioned to communicate with substantially a last to fill
location for the liquid 902 contained by the volume 918. Thus, in
FIG. 12, the second port 928B can be positioned at or adjacent
substantially a highest point of the container 910 on the lid
912.
[0074] FIG. 13 shows another embodiment of a container 1010 used
with a method 1000. The container 1010 can have two or more ports
that are used according to the method 1000 for simultaneous filling
of the volume with a liquid 1002 and venting of a gas from a volume
1018. In the embodiment of FIG. 12, the container 1010 has been
inverted on the x-y coordinate scheme relative to the embodiment of
FIG. 11. Thus, a first port 1028A communicates with an inner liner
1016 at a relatively highest point of the inner liner 1016
(corresponding to a relatively highest point of the volume 1018
defined by the inner liner 1016 and a lid 1012). Rather than the
flexible inner liners previously described, the inner liner 1016
can be constructed of a rigid or semi-rigid material so as to
substantially maintain a desired shape and have a desired volume
throughout the filling and venting process. In other cases, a
flexible inner liner such as those previously described can be
utilized. The first port 1028A receives the liquid 1002, which can
be pumped or can otherwise be made to flow into the volume 1018
through an outer housing 1014 as well as the inner liner 1016. As
shown in FIG. 12, simultaneous with filling of the liquid 1002, the
gas can be vented from the volume 1018 to a second volume 1004
(defined between and inner surface of the outer housing 1014 and an
outer surface of the inner liner 1016) via the second port 1028B.
The gas can be further vented or otherwise exhausted from the
second volume 1004 to the ambient as desired. According to the
embodiment of FIG. 13, the second port 1028B can be positioned to
communicate with substantially a last to fill location for the
liquid 1002 contained by the volume 1018. Thus, the second port
1028B can be positioned at or adjacent substantially a highest
point of the container 1010 on the inner liner 1016. The first port
1028A and the second port 1028B can be sealed after filling via a
valve, membrane, insert, plug or the like (not specifically shown).
The container 1010 can optionally be re-oriented such that an
outlet port 1028C and the lid 1012 can be positioned above the
outer housing 1114 and inner liner 1112. In other embodiments the
container 1010 can remain in the orientation shown and can be used
to dispense substantially only the liquid 1002 from that
orientation.
[0075] Dispensing System and Methods Example
[0076] FIG. 14 shows a system 1200 that can include any of the
containers (along with the methods) as previously described and
shown. The system 1200 comprises a dispensing system 1202 for
precise dispensing of the liquid as previously described from the
container. According to the embodiment of FIG. 14, the dispensing
system 1202 includes a motor base 1204 and two or more containers
1206A and 1206B.
[0077] According to the embodiment of FIG. 14, the motor base 1204
includes one or more motors (not explicitly shown separately) for
driving the pump contained in the integrated pump cap (previously
shown and described in reference to FIGS. 2 and 3) of the
container. The motor can be an AC or DC electric motor (e.g., a
stepper motor, servo motor, etc.) configured to drive a driveshaft
that engages the integrated pump cap 106. Alternatively, the motor
can be pneumatic, hydraulic, piezo-electric, mechanical (e.g.,
using a rack and pinion, crankshaft, cam or other similar
mechanism), or hand-driven, provided that it is configured to
transfer energy to a driveshaft that engages the integrated pump
cap (FIGS. 2 and 3). For simplicity and ease of design, it is
preferred to have the motor transfer rotational energy to the
driveshaft but linear energy transfer can be used too.
[0078] The motor base 1204 can also include a programmable
controller, either as a separate unit or as part of the motor
itself, such that particular commands can be input in order to, for
example, release a specified amount of liquid according to the
command. The amount can be according to the weight of the liquid
dispensed. For example, one command can cause the motor to operate
such that one gram of liquid is dispensed. A second command can
cause the motor to dispense two grams of liquid and so on. Thus, a
particular liquid can be dispensed in different amounts depending
on the application. For example, different liquid colorant amounts
can be dispensed depending on the desired color and the amount of
plastic material that is to be colored. In some other
implementations, motor commands may be calibrated to dispense a
liquid by volume rather than by weight (e.g. a programmed number of
milliliters).
[0079] The controller can calculate motor driving time based on a
specific flow rate of the pump for a given motor speed. This can
depend on the particular liquid being dispensed (e.g., as a
function of the viscosity or density of the liquid). Thus, the
motor speed and flow rate can be used to calculate a motor run time
to dispense a specified amount (weight or volume) of the
liquid.
[0080] The motor base 1204 can include an interface for entering
commands, e.g., for particular liquid dispensing. For example, one
or more interface controls can allow the user to specify a
particular command using menus, command codes, or a combination of
both (e.g., using buttons, touch screen interface, or other
input).
[0081] Alternatively, in some implementations, the motor base 1204
is coupled to another device that provides a control interface, for
example, a computing device. The computing device can include
software for both controlling the motor base 1204 and providing a
user interface. The user interface can allow the user to provide
commands for dispensing liquids. For example, one or more interface
controls can allow the user to specify a particular command using
menus, command codes, or a combination of both (e.g., using
buttons, touch screen interface, or other input).
[0082] According to the embodiment of FIG. 14, two or more
containers 1206A and 1206B can be coupled to the motor base 1204
and can be driven to dispense the liquid as described above. By
having the two or more containers 1206A and 1206B various
additional functionality can be achieved by the system 1200. For
example, the two or more containers 1206A and 1206B can carry a
liquid having substantially a same formulation. In such instances,
if the liquid of one container (e.g., container 1206A) is exhausted
the motor base 1204 can be switched to drive dispensing from the
second container (e.g., container 1206B). This allows for seamless
transition such that the liquid can be substantially supplied
continuously without substantial interruption to replace a
container. The container (e.g., container 1206A) with the exhausted
liquid can be replaced by personnel while the liquid from the
second container (e.g., container 1206B) is being dispensed.
Although the examples below are to a series process and system, it
should be recognized that the motor base 1204 could be driven in
parallel on some occasions to facilitate simultaneous dispensing
from both (or more) containers 1206A and 1206B as desired.
[0083] In some implementations, liquid colorants are the liquid
dispensed by the dispensing system 1202 (and further described
methods below) into an injection molding device in order to produce
colored plastic articles. However, other types of molding devices
may be used too including blow molding, injection blow molding,
extrusion molding, compression molding, and rotational molding
devices for example. In particular, a neutral plastic base material
(e.g., pellets or beads of plastic resin) can be heated by the
molding device. Advantageously, the plastic base material may
possess its "natural" color (i.e., the inherent color of the
plastic resin without the addition of dyes, pigments or other
colorants). The plastic base material may be white, beige, grey, or
other neutral color and it may be transparent, translucent or
opaque. A precise amount of a liquid colorant can be dosed into the
neutral plastic base material so that the melted plastic base
material is colored accordingly. The amount of colorant will vary
depending on the nature of the plastic base material, the colorant,
the desired color, etc. but an amount of about 0.001%-3% by weight
or volume is generally useful. The colored melted plastic is then
delivered by injection or extrusion into a mold cavity or an
extruder head having the shape or profile of the plastic article
that is to be formed which could be, for example, a bottle, a film,
or many other products conventionally produced by plastic molding
devices.
[0084] While the dispensing system 1202 and methods 1300 and 1400
are particularly described in the context of a dispenser for
delivering liquid colorant to a molding device, this is merely to
illustrate one preferred application. The invention disclosed
herein may be used to dispense a variety of liquids as previously
described and the dispensed liquid may be delivered to devices
other than molding devices (e.g., a mixing or blending device or a
device that fills a container) or may be delivered for immediate
end use (e.g., a sprayed liquid or an extruded paste). Examples of
other additives that could be dispensed included antioxidants,
processing stabilizers, heat stabilizers, lubricants, light
stabilizers, flame retardants, optical brighteners, biocides,
antimicrobials, oxygen scavengers, fragrances, conductive
additives, repellants, foaming agents, anti-static agents,
nucleating agents, clarifying agents, plasticizers, surface
modifiers, slip agents, chain extenders, crosslinking agents,
coupling agents, and compatibilizers. The amount of additive will
vary depending on the nature of the plastic base material, the
additive, the desired properties, etc. but an amount of about
0.0001%40% by weight or volume is generally useful.
[0085] FIG. 15 shows one method 1300 of using the dispensing system
1202 during the injection molding process. The method 1300 includes
initiation of an injection molding cycle 1302. Initiating an
injection molding cycle can include releasing base plastic material
from a hopper into a heating portion of the injection molding
device to melt the base plastic material. During such molding cycle
the method 1300 attempts to dispense an amount of the liquid
colorant from the first container (e.g., container 1206A). The
method 1300 than determines 1306 if the amount dispensed from the
first container corresponds to a desired amount of liquid colorant
was sufficient. If the amount liquid dispensed is determined to be
sufficient, the liquid colorant along with plastic(s) or other
materials is injected into the mold 1308. However, if the amount
dispensed from the first container does not correspond to the
desired amount (i.e. is determined to be insufficient) a remaining
amount of liquid colorant to achieve the desired amount is
dispensed 1310 from a second container (e.g., container 1206B) and
is injected along with plastic(s) or other materials into the mold
1312. At any time in the method 1300 sequent to the step 1306 where
it is determined if the amount of liquid dispensed is determined to
be insufficient, the first container (e.g., container 1206A) can be
replaced or refilled to provide for a full container. Replacement
with a full container can occur without interruption of the molding
process as the method proceeds with steps 1310 and 1312 in parallel
with the replacement of the first container.
[0086] FIG. 16 shows another method 1400 of using the dispensing
system 1202 during the injection molding process. The method 1400
includes a determination 1402 of an amount of liquid colorant
desired to dose for each injection molding cycle. For example,
personnel can input parameters to the injection molding device or
to a control interface for a motor that drives the pump of the
integrated pump cap. In some implementations, commands are
associated with a timing cycle for the injection molding machine
such that the precise amount of colorant can be dosed for each
molding cycle. The method 1400 can determine 1404 if the first
container (e.g., container 1206A) has sufficient liquid colorant
remaining to provide for the desired dose. For example, the weight
of the first container can be sensed or other parameters of the
first container indicative of fill level can be monitored or
sensed. If the amount of liquid colorant remaining in the first
container is determined to be sufficient, the method 1400 proceeds
to initiate the injection molding cycle 1406. Initiating an
injection molding cycle can include releasing base plastic material
from a hopper into a heating portion of the injection molding
device to melt the base plastic material. The determined 1408 dose
of liquid colorant is added to the melting or melted base plastic
material from the first container. The melted colored plastic is
then injected 1410 into a mold cavity to form a final color molded
plastic.
[0087] However, if the method 1400 determines the first container
(e.g., container 1206A) has insufficient liquid colorant remaining
to provide for the desired dose, the method proceeds to determine
1412 if the second container (e.g., container 1206B) has sufficient
liquid colorant remaining to provide for the desired dose. For
example, the weight of the second container can be sensed or other
parameters of the second container indicative of fill level can be
monitored or sensed. If the amount of liquid colorant remaining in
the second container is determined to be sufficient, the method
1400 proceeds to initiate the injection molding cycle 1416.
Initiating an injection molding cycle can include releasing base
plastic material from a hopper into a heating portion of the
injection molding device to melt the base plastic material. The
determined 1418 dose of liquid colorant is added to the melting or
melted base plastic material from the second container. The melted
colored plastic is then injected 1420 into a mold cavity to form a
final color molded plastic. At any time in the method 1400 sequent
to the step 1404 where it is determined if the amount of liquid in
the first container is insufficient to provide for the desired
dose, the method 1400 can provide an alert 1414 to personnel that
the first container needs to be replaced or refilled. Similarly,
the method 1400 can provide for an alert 1422 to personnel should
it be determined that both the first container and the second
container contain insufficient liquid colorant to provide for the
desired dose.
[0088] FIG. 17 shows yet another method 1500 of using the
dispensing system 1202 during the injection molding process. The
method 1500 can proceed as the molding cycle begins 1502. The
method 1500 includes an initial determination 1504 if the first
container and the second container are empty. If both are empty the
dispensing system 1202 is not activated 1506. However, if one or
both of the first container and the second container are not empty,
the method 1500 activates 1508 the dispenser system 1202 and makes
a determination if the first container is empty 1510 and if the
second container 1520 is empty. If it is determined both are empty
an alarm 1507 or alert can be activated.
[0089] If it is initially determined at step 1508 the first
container is not empty, the method 1500 can proceed to dispense
1512 a desired amount of liquid from the first container and inject
1514 this amount into the mold. However, if the first container is
later determined 1510 to be empty, the method 1500 can send an
alarm 1516 or another signal to the user and also can activate 1518
the dispenser system 1202 to dispense from liquid container
two.
[0090] If it is initially determined at step 1508 the second
container is not empty, the method can proceed to dispense 1522 a
desired amount of liquid from the second container and inject 1524
this amount into the mold. However, if the second container is
later determined 1520 to be empty, the method 1500 can send an
alarm 1524 or another signal to the user and also can activate 1526
the dispenser system 1202 to dispense from liquid container
one.
[0091] As discussed previously, liquids other than colorants may be
dispensed and molding systems other than injection molding systems
may be used. The operational principles of these alternatives can
be understood from the block diagrams and other FIGURES and
description provided.
[0092] The operations described in this specification, in
particular, processing commands for a motor to drive a pump to
dispense a specified amount of liquid, can be implemented as
operations performed by a data processing apparatus on data stored
on one or more computer-readable storage devices or received from
other sources.
[0093] The term "data processing apparatus" encompasses all kinds
of apparatus, devices, and machines for processing data, including
by way of example a programmable processor, a computer, a system on
a chip, or multiple ones, or combinations of the foregoing. The
apparatus can include special purpose logic circuitry, e.g., an
FPGA (field programmable gate array) or an ASIC
(application-specific integrated circuit). The apparatus can also
include, in addition to hardware, code that creates an execution
environment for the computer program in question; e.g., code that
constitutes processor firmware, a protocol stack, a database
management system, an operating system, a cross-platform runtime
environment, a virtual machine, or a combination of one or more of
these. The apparatus and execution environment can realize various
different computing model infrastructures, such as web services,
distributed computing and grid computing infrastructures.
[0094] A computer program (also known as a program, software,
software application, script, or code) can be written in any form
of programming language, including compiled or interpreted
languages, declarative or procedural languages, and it can be
deployed in any form, including as a stand-alone program or as a
module, component, subroutine, object, or other unit suitable for
use in a computing environment. A computer program can be deployed
to be executed on one computer or on multiple computers that are
located at one site or distributed across multiple sites and
interconnected by a communication network.
[0095] Alternatively or in addition, the program instructions can
be encoded on or can be included in a computer storage medium, a
computer-readable storage device, a computer-readable storage
substrate, a random or serial access memory array or device, or a
combination of one or more of these. Moreover, while a computer
storage medium is not a propagated signal, a computer storage
medium can be a source or destination of computer program
instructions encoded in an artificially generated propagated
signal. The computer storage medium can also be, or be included in,
one or more separate physical components or media (e.g., multiple
CDs, disks, or other storage devices).
[0096] The processes and logic flows described in this
specification can be performed by one or more programmable
processors executing one or more computer programs to perform
actions by operating on input data and generating output. The
processes and logic flows can also be performed by, and apparatus
can also be implemented as, special purpose logic circuitry, e.g.,
an FPGA (field programmable gate array) or an ASIC
(application-specific integrated circuit).
[0097] Processors suitable for the execution of a computer program
include, by way of example, both general and special purpose
microprocessors, and any one or more processors of any kind of
digital computer. Generally, a processor will receive instructions
and data from a read-only memory or a random access memory or both.
The essential elements of a computer are a processor for performing
actions in accordance with instructions and one or more memory
devices for storing instructions and data. Devices suitable for
storing computer program instructions and data include all forms of
non-volatile memory, media and memory devices, including by way of
example semiconductor memory devices, e.g., EPROM, EEPROM, and
flash memory devices; magnetic disks, e.g., internal hard disks or
removable disks; magneto-optical disks; and CD-ROM and DVD-ROM
disks.
[0098] To provide for interaction with a user, embodiments of the
subject matter described in this specification can be implemented
on a computer having a display device, e.g., a CRT (cathode ray
tube) or LCD (liquid crystal display) monitor, for displaying
information to the user and a keyboard and a pointing device, e.g.,
a mouse or a trackball, by which the user can provide input to the
computer. Other kinds of devices can be used to provide for
interaction with a user as well; for example, feedback provided to
the user can be any form of sensory feedback, e.g., visual
feedback, auditory feedback, or tactile feedback; and input from
the user can be received in any form, including acoustic, speech,
or tactile input. In addition, a computer can interact with a user
by sending documents to and receiving documents from a device that
is used by the user; for example, by sending web pages to a web
browser on a user's client device in response to requests received
from the web browser.
[0099] Although the present disclosure has been described with
reference to preferred embodiments, workers skilled in the art will
recognize that changes can be made in form and detail without
departing from the spirit and scope of the present disclosure.
WORKING EXAMPLES
[0100] Summary of Materials
[0101] The material used the example, referred to as Fluid 1, was a
liquid colorant dispersion DXO RED 1077-20, available from PolyOne
(Avon Lake, Ohio).
[0102] Test Methods
[0103] Viscosity Measurement
[0104] Viscosity measurements were made using a Discovery HR-2
Instrument equipped with a 25 mm diameter parallel plate, ETC steel
from TA Instruments (New Castle, Del.). Viscosities were measured
at 20.degree. C. using a flow ramp procedure at 5 points per decade
at shear rates from 0.01 to 10 sec.sup.-1 with a 1.00 mm gap
offset, trimmed at 1.05 mm gap. After loading the material in the
instrument, the sample was conditioned by soaking for 120 sec
followed by applying a preshear at 1 sec.sup.-1 for 30 sec. After
conditioning the sample, a soak time of 120 sec was applied to the
material before viscosity measurements.
Example 1
[0105] The viscosity of Fluid 1 was measured as described above.
The results are shown in FIG. 18. In Example 1, a container in
accordance with this invention comprising a collapsible liner
(available from 3M.TM. PPS.TM. Large Lid and Liner Kit, Part Number
16024) inside a rigid outer cup (available from 3M.TM. PPS.TM.
Large Cup and Collar, Part Number 16023) was filled with Fluid 1,
leaving approximately 25 mm of space at the top of the collapsible
liner. A lid comprising a pump as described in United States Patent
Application Publication No. 2013/0270303A1 (in this case, G-Rotor
pump) was put onto the liner to cover its top, then the collar from
the above-described 3M.TM. PPS.TM. Large Cup and Collar kit was
fastened to the outer cup, thereby holding the pump lid securely to
the liner and outer cup. Care was taken to ensure that the liquid
did not touch the pump lid during assembly. A vacuum tube was
assembled which comprised a plastic spout attached to one end of
the hose and the other end of the hose was attached to a vacuum
pump. The vacuum pump was turned on such that air would flow
through the plastic spout into the vacuum pump. The plastic spout
was placed into the outlet port of the pump lid of the container
until the liquid in the container first touched the plastic spout
on the vacuum tube. The liner partially collapsed when the air was
removed. After one week, the liner remained partially collapsed,
indicating that air had not re-entered the container through the
pump.
Example 2
[0106] The procedure of Example 1 was repeated to create a sealed
container of Fluid 1 without air in it. A plastic spout was
attached to the pump lid outlet. The container was shaken slightly
by hand, inverted and placed onto a dispenser as described in
United States Patent Application Publication No. 2013/0270303A1.
Fluid 1 was dispensed from the sealed container into a separate
container at an initial rate of approximately 5 grams/sec. The
dispensing continued until the rate of liquid dispensing from the
pump decreased to 0.0 grams/sec for 2 seconds. The weight of fluid
remaining in the collapsed container was recorded. Results are
shown in Table 1.
Comparative Example 1
[0107] This is a comparative example of dispensing Fluid 1 from a
container without first removing the air from the container. The
procedure of Example 2 was repeated, with the exception that air
was not removed from the container before placing the container on
the dispenser. Results are shown in Table 1.
TABLE-US-00001 Weight of Fluid Weight of Fluid in Remaining in
Container Before Container after Sample Dispensing (g) Dispensing
(g) Example 2 813 37 Comparative 804 425 Example 1
Exemplary Claims
[0108] In the First Embodiment, a method of filling a container
with substantially only a liquid, the method can include: providing
a volume defined by at least an inner liner and a lid of the
container, wherein the liquid is contained within a first portion
of the volume and a remaining portion of the volume contains a gas;
and removing substantially all the gas from the volume via one or
more ports that communicate with the volume while retaining
substantially only the liquid within the volume.
[0109] In the Second Embodiment, the method of the first
embodiment, wherein the step of providing the liquid and the gas
includes pumping the liquid into volume through the one or more
ports prior to, simultaneous with, or after the step of removing
substantially all the gas from the volume.
[0110] In the Third Embodiment, the method of any one or any
combination of previous embodiments, wherein the step of removing
substantially all the gas from the volume includes at least one of
applying a first pressure on a surface of the inner liner external
to the volume to partially collapse the inner liner and applying a
second pressure to the one or more ports to draw the gas through
the one or more ports.
[0111] In the Fourth Embodiment, the method of the third
embodiment, wherein the second pressure comprises a pressure less
than a pressure in the volume.
[0112] In the Fifth Embodiment, the method of the third embodiment,
wherein the step of applying the first pressure comprises one or
more of filling second volume external to the inner liner to a
pressure higher than a pressure in the volume and contacting the
surface of the inner liner with a member to cause at least a
partial collapse of the inner liner.
[0113] In the Sixth Embodiment, the method of any one or any
combination of previous embodiments, wherein the step of removing
substantially all the gas from the volume via the one or more ports
includes coupling the lid to a remainder of the container to
displace the gas through the one or more ports.
[0114] In the Seventh Embodiment, the method of any one or any
combination of previous embodiments, wherein the method
simultaneously includes the step of providing the liquid and the
gas to the volume and removing substantially all the gas from the
volume via the one or more ports.
[0115] In the Eighth Embodiment, the method of any one or any
combination of previous embodiments, wherein at least one of the
one or more ports are in the lid and the lid includes a pump cap
that further comprises: a pump coupled to the pump cap and disposed
within the volume; a dispenser communicating with the pump via at
least one of the one or more ports and configured to dispense one
or both the liquid and the gas from the container; and a motor
coupled to rotationally drive the pump to dispense the liquid
through at least one of the one or more ports and to the
dispenser.
[0116] In the Ninth Embodiment, the method of the eighth
embodiment, further comprising priming the pump with the liquid
during removing substantially all the gas from the volume via the
one or more ports.
[0117] In the Tenth Embodiment, the method of the eighth
embodiment, further comprising providing a device comprising one or
more of a plug, a membrane, or a valve coupled to the dispenser and
configured to prevent gas from entering the volume via at least one
of the one or more ports.
[0118] In the Eleventh Embodiment, the method of any one or any
combination of previous embodiments, wherein at least one of the
one or more ports are positioned at substantially a last to fill
location of the volume and the step of removing substantially all
the gas from the volume includes simultaneously venting the gas
from the at least one of the one or more ports and filling the
volume with the liquid until the liquid reaches the at least one of
the one or more ports.
[0119] In the Twelfth Embodiment, the method of any one or any
combination of previous embodiments, wherein the liquid comprises
any one or any combination of adhesives, cements, colorants,
coatings, detergents, epoxies, dyes, fillers (e.g., body filler),
nano-materials, oils, paints (e.g., automotive paints), pastes,
pigments, caulks, urethanes, polymer additives (which may be
organic or inorganic), sealants, stains, toners, varnishes, waxes
having a viscosity at a shear rate of 0.1 l/s that is 1.5 times
greater than the viscosity of the fluid at a shear rate of 1.0
l/s.
[0120] In the Thirteenth Embodiment, the method of any one or any
combination of previous embodiments, wherein the liquid comprises
any one or any combination of adhesives, cements, colorants,
coatings, detergents, epoxies, dyes, fillers (e.g., body filler),
nano-materials, oils, paints (e.g., automotive paints), pastes,
pigments, caulks, urethanes, polymer additives (which may be
organic or inorganic), sealants, stains, toners, varnishes, waxes
having a viscosity of between 0.1 and 10,000 Pa-s at a shear rate
of 1.0 l/s.
[0121] In the Fourteenth Embodiment, the method of any one or any
combination of previous embodiments, wherein the liquid comprises
any one or any combination of adhesives, cements, colorants,
coatings, detergents, epoxies, dyes, fillers (e.g., body filler),
nano-materials, oils, paints (e.g., automotive paints), pastes,
pigments, caulks, urethanes, polymer additives (which may be
organic or inorganic), sealants, stains, toners, varnishes, waxes
having a first viscosity that is relatively lower at a higher shear
rate such as during flow into the pump, and then a second viscosity
that is relatively higher at a lower shear rate such as after the
liquid has stopped flowing into the pump.
[0122] In the Fifteenth Embodiment, the method of any one or any
combination of previous embodiments, wherein the inner liner
comprises a flexible material that is collapsible as at least one
of the liquid and the gas are withdrawn from the volume and is
expandable as at least one of the liquid and gas is provided to the
volume.
[0123] In the Sixteenth Embodiment, a method of filling a container
with substantially only a liquid, the method can include: providing
a flexible liner and a lid that define a volume; collapsing the
flexible liner substantially fully such that substantially no gas
is present in the volume; and sequent to collapsing the flexible
liner, filling the volume with substantially only the liquid via
one or more ports that communicate with the volume.
[0124] In the Seventeenth Embodiment, the method of the sixteenth
embodiment, wherein the step of removing substantially all the gas
from the volume includes at least one of applying a first pressure
on a surface of the inner liner external to the volume to partially
collapse the inner liner and applying a second pressure to the one
or more ports to draw the gas through the one or more ports.
[0125] In the Eighteenth Embodiment, the method of the seventeenth
embodiment, wherein the second pressure comprises a pressure less
than a pressure in the volume.
[0126] In the Nineteenth Embodiment, the method of the seventeenth
embodiment, wherein the step of applying the first pressure
comprises one or more of filling second volume external to the
inner liner to a pressure higher than a pressure in the volume and
contacting the surface of the inner liner with a member to cause at
least a partial collapse of the inner liner.
[0127] In the Twentieth Embodiment, the method of any one or any
combination of embodiments 16-19, wherein at least one of the one
or more ports are in the lid and the lid includes a pump cap that
further comprises: a pump coupled to the pump cap and disposed
within the volume; a dispenser communicating with the pump via the
at least one of the one or more ports and configured to dispense
one or both the liquid and the gas from the container; and a motor
coupled to rotationally drive the pump to dispense the liquid
through the least one of the one or more ports and to the
dispenser.
[0128] In the Twenty-first Embodiment, the method of the twentieth
embodiment, further comprising priming the pump with the liquid
during removing substantially all the gas from the volume via the
one or more ports.
[0129] In the Twenty Second Embodiment, the method of the twentieth
embodiment, further comprising providing a device comprising one or
more of a plug, a membrane, or a valve coupled to the dispenser and
configured to prevent gas from entering the volume via at least one
of the one or more ports.
[0130] In the Twenty Third Embodiment, the method of any one or any
combination of embodiments 16-22, wherein at least one of the one
or more ports are positioned at substantially a last to fill
location of the volume and the step of removing substantially all
the gas from the volume includes simultaneously venting the gas
from the at least one of the one or more ports and filling the
volume with the liquid until the liquid reaches the at least one of
the one or more ports.
[0131] In the Twenty Fourth Embodiment, the method of any one or
any combination of embodiments 16-23, wherein the liquid comprises
any one or any combination of adhesives, cements, colorants,
coatings, detergents, epoxies, dyes, fillers (e.g., body filler),
nano-materials, oils, paints (e.g., automotive paints), pastes,
pigments, caulks, urethanes, polymer additives (which may be
organic or inorganic), sealants, stains, toners, varnishes, waxes
having a viscosity having a viscosity at a shear rate of 0.1 l/s
that is 1.5 times greater than the viscosity of the fluid at a
shear rate of 1.0 l/s.
[0132] In the Twenty Fifth Embodiment, the method of any one or any
combination of embodiments 16-23, wherein the liquid comprises any
one or any combination of adhesives, cements, colorants, coatings,
detergents, epoxies, dyes, fillers (e.g., body filler),
nano-materials, oils, paints (e.g., automotive paints), pastes,
pigments, caulks, urethanes, polymer additives (which may be
organic or inorganic), sealants, stains, toners, varnishes, waxes
having a viscosity of between 0.1 and 10,000 Pa-s at a shear rate
of 1.0 l/s.
[0133] In the Twenty Sixth Embodiment, the method of any one or any
combination of embodiments 16-23, wherein the liquid comprises any
one or any combination of adhesives, cements, colorants, coatings,
detergents, epoxies, dyes, fillers (e.g., body filler),
nano-materials, oils, paints (e.g., automotive paints), pastes,
pigments, caulks, urethanes, polymer additives (which may be
organic or inorganic), sealants, stains, toners, varnishes, waxes
having a viscosity that is relatively lower at a higher shear rate
such as during flow into the pump, and then a second viscosity that
is relatively higher at a lower shear rate such as after the liquid
has stopped flowing into the pump.
[0134] In the Twenty Seventh Embodiment, a system for dispensing a
liquid can include: a first liquid container; a second liquid
container; and a dispensing device configured to couple to both the
first liquid container and the second liquid container, the
dispensing device configured to actuate dispensing of a specific
amount of liquid from either container as desired.
[0135] In the Twenty Eighth Embodiment, the system of the
twenty-seventh embodiment, wherein the dispensing device includes a
motor configured to drive a pump in each container to dispense the
specified amount of the liquid.
[0136] In the Twenty Ninth Embodiment, the system of any one or any
combination of embodiments 27-28, wherein the dispensing device is
configured to switch dispensing from the first liquid container to
dispensing from the second liquid container upon a sensed condition
related to the amount of liquid remaining in the first liquid
container.
[0137] In the Thirtieth Embodiment, the system of any one or any
combination of embodiments 27-29, wherein the dispensing device is
configured to allow the replacement of either the first liquid
container or the second liquid container with a third container
including during dispensing.
[0138] In the Thirty First Embodiment, the system of the thirtieth
embodiment, wherein the dispensing device is configured such that
the replacement of either the first liquid container or the second
liquid container occurs simultaneous with the dispensing device
dispensing the specific amount of liquid from the other of the
first liquid container or the second liquid container.
[0139] In the Thirty Second Embodiment, the system of the thirtieth
embodiment, wherein the dispensing device is configured to dispense
from both the first liquid container and the second liquid
container simultaneously or sequentially.
[0140] In the Thirty Third Embodiment, a method of dispensing a
liquid during a molding process comprising: receiving a command to
dispense a specified amount of the liquid; determining if one of a
first liquid container or a second liquid container has a
sufficient amount of the liquid remaining therein to supply the
specified amount; dispensing the specified amount of the liquid
from at least one of the first liquid container or the second
liquid container if the at least one of the first liquid container
and the second liquid container is determined to have the
sufficient amount of liquid; and replacing the first liquid
container or the second liquid container with a third liquid
container during the molding process if the first liquid container
or the second liquid container is determined to have an
insufficient amount of the liquid remaining therein to provide the
specified amount.
[0141] In the Thirty Fourth Embodiment, the method of example 33,
wherein the replacing of the first container or the second
container occurs simultaneous with or sequent to the dispensing the
specified amount of the liquid.
[0142] In the Thirty Fifth Embodiment, the method of any one or any
combination of examples 33-34, wherein dispensing the specified
amount of the liquid from at least one of the first container or
the second container includes dispensing from both the first
container or the second container during the molding process.
[0143] In the Thirty Sixth Embodiment, a method of dispensing a
liquid during a molding process comprising: dispensing a first
amount of the liquid from a first liquid container during the
molding process; determining if the first amount of the liquid
corresponds to a specified amount of the liquid; without replacing
the first container, dispensing a second amount of the liquid from
a second container during the molding process if the first amount
of the liquid is determined not to correspond to the specified
amount of the liquid.
[0144] In the Thirty Seventh Embodiment, the method of the
thirty-sixth embodiment, further comprising replacing the first
liquid container or the second liquid container with a third liquid
container during the molding process if the first liquid container
or the second liquid container is determined to have an
insufficient amount of the liquid remaining therein to provide the
specified amount.
[0145] In the Thirty Eight Embodiment, the method of the
thirty-seventh embodiment, wherein the replacing of the first
container or the second container occurs simultaneous with or
sequent to the dispensing the specified amount of the liquid.
[0146] In the Thirty Ninth Embodiment, a device for dispensing a
liquid can include: a motor configured to couple to both a first
liquid container and a second liquid container, the motor
configured to actuate dispensing of a specific amount of liquid
from either container as desired.
[0147] In the Fortieth Embodiment, the device of the thirty-ninth
embodiment, wherein the device includes a motor configured to drive
a pump in each container to dispense the specified amount of the
liquid.
[0148] In the Forty First Embodiment, the device of any one or any
combination of embodiments 39-40, wherein the device is configured
to switch dispensing from the first liquid container to dispensing
from the second liquid container upon a sensed condition related to
the amount of liquid remaining in the first liquid container.
[0149] In the Forty Second Embodiment, the device of any one or any
combination of embodiments 39-41, wherein the dispensing device is
configured to allow the replacement of either the first liquid
container or the second liquid container with a third container
including during dispensing.
[0150] In the Forty Third Embodiment, the device of the
forty-second embodiment, wherein the device is configured such that
the replacement of either the first liquid container or the second
liquid container occurs simultaneous with the dispensing device
dispensing the specific amount of liquid from the other of the
first liquid container or the second liquid container.
[0151] In the Forty fourth Embodiment, the device of the
forty-second embodiment, wherein the device is configured to
dispense from both the first liquid container and the second liquid
container simultaneously or sequentially.
* * * * *