U.S. patent number RE44,310 [Application Number 13/161,633] was granted by the patent office on 2013-06-25 for connect/disconnect coupling for a container.
This patent grant is currently assigned to Colder Products Company. The grantee listed for this patent is Brian J. Blenkush, Thomas Anthony Braun, Richard Chadbourne, Charles Peter deCler. Invention is credited to Brian J. Blenkush, Thomas Anthony Braun, Richard Chadbourne, Charles Peter deCler.
United States Patent |
RE44,310 |
Chadbourne , et al. |
June 25, 2013 |
Connect/disconnect coupling for a container
Abstract
A container insert having at least two primary pieces, wherein
one of the pieces includes keying features that may be replaceable
with other pieces having different keying features. A related
single piece container insert includes multiple keying features
formed on the interior and exterior surfaces of the container
insert. A related coupling assembly includes a venting system that
vents a fluid into the container after a valve in the coupling
assembly, which is positioned in the container contents flow path,
has been opened.
Inventors: |
Chadbourne; Richard (Eagan,
MN), Braun; Thomas Anthony (Minneapolis, MN), deCler;
Charles Peter (Edina, MN), Blenkush; Brian J. (Grand
Rapids, MN) |
Applicant: |
Name |
City |
State |
Country |
Type |
Chadbourne; Richard
Braun; Thomas Anthony
deCler; Charles Peter
Blenkush; Brian J. |
Eagan
Minneapolis
Edina
Grand Rapids |
MN
MN
MN
MN |
US
US
US
US |
|
|
Assignee: |
Colder Products Company (St.
Paul, MN)
|
Family
ID: |
34968307 |
Appl.
No.: |
13/161,633 |
Filed: |
June 16, 2011 |
Related U.S. Patent Documents
|
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
60569308 |
May 6, 2004 |
|
|
|
Reissue of: |
11095125 |
Mar 30, 2005 |
7546857 |
Jun 16, 2009 |
|
|
Current U.S.
Class: |
141/354; 141/351;
137/614.04; 251/149.6; 141/353; 141/352 |
Current CPC
Class: |
B67D
1/0835 (20130101); B67D 7/0294 (20130101); Y10T
137/87957 (20150401) |
Current International
Class: |
B65B
1/04 (20060101); F16L 37/32 (20060101); F16L
37/28 (20060101) |
Field of
Search: |
;141/2,18,59,346,347,351-356 ;137/588,614.04 ;251/149.6 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
WO 95/00435 |
|
Jan 1995 |
|
WO |
|
WO 01/66458 |
|
Sep 2001 |
|
WO |
|
WO 2005/108280 |
|
Nov 2005 |
|
WO |
|
WO 2006/110541 |
|
Oct 2006 |
|
WO |
|
Other References
International Search Report and Written Opinion mailed Feb. 11,
2008. cited by applicant.
|
Primary Examiner: Maust; Timothy L
Attorney, Agent or Firm: Merchant & Gould P.C.
Parent Case Text
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Patent
Application Ser. No. 60/569,308 filed on May 6, 2004, and entitled
CONNECT/DISCONNECT COUPLING FOR A CONTAINER, which application is
incorporated herein by reference.
Claims
We claim:
1. A coupling assembly for removing the contents of a container
from an opening in the container, the coupling assembly comprising:
a container insert coupled to the container opening and including:
a first open cavity extending through the container insert; a first
keyed surface formed in a surface of the cavity; a first engagement
surface formed in a surface of the cavity; and a dispense unit
including: a first dispense member having a second open cavity
extending there through and a second engagement surface formed on
an outer surface thereof, the second engagement surface being
configured to engage the first engagement surface to releasably
couple the dispense unit to the container insert; a second dispense
member having a third open cavity extending there through, the
second dispense member being at least partially disposed within the
second open cavity and being adjustably coupled to the first
dispense member; a valve assembly positioned in the third open
cavity; and a second keyed surface configured to mate with the
first keyed surface prior to engagement of the first and second
engagement surfaces when the dispense unit is brought into contact
with the container insert.
2. The assembly of claim 1, wherein the second keyed surface is
removably coupled to the second dispense member.
3. The assembly of claim 2, wherein the second keyed surface in
part retains the second dispense member within the first dispense
member.
4. The assembly of claim 1, wherein the first dispense member
further includes a first recess area extending coaxial with the
second open cavity from a first end toward a second end of the
first dispense member, the first recess area defining a valve seat
configured to engage a portion of the valve assembly after
engagement of the first and second engagement surfaces when the
dispense unit is brought into contact with the container insert the
dispense unit is brought into engagement thereby opening the valve
assembly.
5. The assembly of claim 1, wherein the container insert includes a
top insert member and a bottom insert member, the top insert member
being configured to adjustably engage the container at the
container opening, and the bottom insert member including the first
keyed surface.
6. The assembly of claim 1, wherein the container insert is mounted
flush with an exterior surface of the container.
7. The assembly of claim 1, wherein the container insert comprises
a moldable plastic.
8. The assembly of claim 1, wherein the container insert is
configured for a useful life of five or less uses.
9. The assembly of claim 2, wherein the second keyed surface is
coupled to the second dispense member with a snap-fit or welded
connection.
10. The assembly of claim 2, wherein the second keyed surface is
coupled to the second dispense member with an interference fit that
permits resistive rotation of the second keyed surface relative to
the second dispense member.
11. The assembly of claim 1, wherein the container insert includes
a valve assembly, wherein the container insert valve assembly and
the dispense unit valve assembly are adjustable from a closed
position into an open position after engagement of the first and
second engagement surfaces when the dispense unit is brought into
contact with the container insert.
12. The assembly of claim 1, wherein the dispense unit includes at
least one lip seal configured to engage a surface of the first open
cavity to form a seal there between.
13. The assembly of claim 1, further comprising a venting assembly
configured to provide a source of fluid into the container upon
removal of the container contents through the coupling
assembly.
14. The assembly of claim 1, further comprising a reader device
coupled to the dispense unit and configured to identify and record
information related to the container.
15. The assembly of claim 14, further comprising an information
storage device coupled to the container insert and configured to
store information related to the container.
16. A coupling assembly for removing the contents of a container
from an opening in the container, the coupling assembly comprising:
a container insert coupled to the container opening and including:
a first open cavity extending through the container insert and
including at least first and second contact surfaces; and a
dispense unit including: a first dispense member having a second
open cavity extending there through and a third contact surface
formed on an outer portion thereof, the third contact surface being
configured to engage the first contact surface to releasably couple
the dispense unit to the container insert; a second dispense member
having a third open cavity extending there through and a fourth
contact surface formed on an outer portion thereof, the second
dispense member being at least partially disposed within the second
open cavity and being adjustably coupled to the first dispense
member; and a third dispense member having a fifth contact surface
on an outer portion thereof and a sixth contact surface on an inner
surface thereof, the fifth contact surface being configured to
engage the second contact surface, and the sixth contact surface
being configured to engage the fourth contact surface in an
interference fit connection; whereby the interference fit
connection provides cooperative movement of the second and third
dispense members to ensure engagement between the second and fifth
contact surfaces, while providing relative rotational movement
between the second and third dispense member during engagement of
the first and third contact surfaces.
17. The assembly of claim 16, wherein the first contact surface
includes a first keyed surface and the third contact surface
includes a second keyed surface configured to mate with the first
keyed surface.
18. The assembly of claim 16, wherein the second contact surface is
a female threaded structure and the fourth contact surface is a
threaded male structure configured to mate with the female threaded
structure to create positive attachment of the container insert to
the dispenser unit.
.Iadd.19. A coupling assembly for removing contents of a container
from an opening in the container, the coupling assembly comprising:
a container insert configured to be coupled to the opening of the
container and having first and second insert ends, the container
insert including a first seal positioned adjacent to the first
insert end to seal the container insert with respect to the
container, and defining a first insert cavity with insert threads,
a second insert cavity, a third insert cavity with an insert valve
engagement member, and a dip tube engagement surface adjacent to
the second insert end for engaging a dip tube that extends into the
container, the container insert defining an insert passage
extending from the first insert end to the second insert end and
through the first, second, and third insert cavities, and the
container insert defining an insert vent path extending through the
container insert to the first insert cavity; and a dispense unit
including a main dispense body including first and second dispense
ends, and a coupling ring with threads positioned to engage the
insert threads when coupled thereto and a first dispense seal
positioned to seal the container insert with respect to the first
insert cavity, a coupling sleeve extending to the first dispense
end, a valve assembly positioned axially within the coupling
sleeve, the valve assembly including a poppet member with first and
second ends, the first end including a valve that seals against a
shoulder formed in a first dispense cavity defined by the dispense
unit, and a spring member positioned in the first dispense cavity
to force the valve into a closed position against the shoulder, and
the dispense unit defining a dispense passage through the coupling
sleeve and the first dispense cavity to a dispense port, and
defining a dispense vent path extending through the coupling sleeve
to a vent port; wherein, when the dispense unit is coupled to the
container insert, the insert vent path mates with the dispense vent
path to define a complete and separate vent path extending from
within the container to the vent port, and the insert valve
engagement member forces the poppet member against the spring
member so that the valve unseats with respect to the shoulder to
place the insert passage in fluid communication with the first
dispense cavity and the dispense port..Iaddend.
.Iadd.20. The coupling assembly of claim 19, wherein the coupling
ring is configured to rotate about the main dispense
body..Iaddend.
.Iadd.21. The coupling assembly of claim 19, further comprising an
adapter including first and second adapter ends, the first adapter
end of the adapter being configured to mate with the dispense port,
and the second adapter end being configured to mate with a
connector..Iaddend.
.Iadd.22. The coupling assembly of claim 19, further comprising a
shipping cap that is configured to seal the dip tube and the
container insert during shipping..Iaddend.
.Iadd.23. The coupling assembly of claim 22, wherein the shipping
cap includes cap threads formed on an outer surface thereof that
are sized to engage the insert threads formed in the first insert
cavity of the container insert, and a sealing member that seals
with respect to the first insert cavity of the container
insert..Iaddend.
.Iadd.24. The coupling assembly of claim 19, further comprising a
key coupled to an exposed surface of the container
insert..Iaddend.
.Iadd.25. The coupling assembly of claim 19, wherein, when the
dispense unit is coupled to the container insert, the coupling
sleeve defines a dispense keyed surface that mates with an insert
keyed surface of the container insert..Iaddend.
.Iadd.26. The coupling assembly of claim 25, wherein the insert
keyed surface includes a plurality of keys that are sized and
positioned to engage key slots formed in the dispense keyed surface
when the dispense keyed surface mates with the insert keyed
surface..Iaddend.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to connect/disconnect
couplings and coupling valve assemblies, and more particularly
relates to quick connect/disconnect couplings for use with
containers.
2. Related Art
A variety of industries use pails, drums, and larger Intermediate
Bulk Containers ("IBC's" or "Totes") for the delivery of liquid
chemical media. These containers typically have a variety of
closure sizes and styles depending on the size and type of
container. Some common closure types are threaded bung openings,
snap-in, and crimp-in closures. Some example threaded bung openings
include 2'' buttress female and 2'' NPS female (commonly used in 30
gal, 55 gal, and larger drums and IBC's), 63 mm male (commonly used
in 5 gal jerry cans), and European Mauser. One example snap-in or
crimp-in closure is the FLEXSPOUT.RTM. made by Rick Connection
Systems of Auburn, Ind.
There are a billion or more rigid containers and countless other
types of semi-rigid and flexible containers produced each year
around the world. In order to extract the contents of a container,
most containers are simply tipped over so that the contents inside
are emptied through one of the openings of the container or a
simple valve inserted into the opening. Other containers have an
opening in the bottom (typically the larger IBC's) that allow for a
bottom dispense through a simple hand valve.
A smaller percentage of the containers are emptied of their
contents while the container remains upright using a top feed
device such as a hand operated pump or a motor driven mechanical
positive displacement pump that draws the contents out of the
container via a dip-tube. Most of these containers are intended to
be low cost "one way" containers (i.e., the containers are filled
once and never seen again by the original filler). The containers
may be refilled again by secondary fillers typically up to a
maximum of 5 refills before the containers are destroyed or
recycled.
An example life cycle of a container is shown with reference to
FIG. 28. At step A, the pre-cleaned or in-housed cleaned containers
are received. In step B, the containers are clean room chemical
filled and certified, and fitted with dust caps. In step C, the
containers are shipped as a dedicated container to the same user.
In step D, the dust cap is torn away and the user certifies the
contents by checking extractables and/or particles levels, and the
dispense head is installed. In step E, the container contents are
extracted, the dispense head is removed, and new dust caps are
installed for the return trip. In step F, the empty container is
shipped to a supplier. In step G, the clean container is returned
to step B for filling. In step H, a dirty container is returned to
step A for cleaning.
The basic system requirements for a dispense system for a container
can be characterized by the following four factors: closed or open
systems, reusable or disposable systems, industrial (low-purity)
grade or high grade (ultra-pure) chemical systems, and DOT/UN
approved or unapproved systems.
Closed systems are designed to prevent exposure of a user to the
contents of the container at any phase of the connection cycle
(disconnected phase, connecting/disconnecting phase, and connected
dispensing phase). Open systems have at least the following two
design possibilities: 1) a system that allows the user to be
exposed to the container contents (either liquid or vapors) when
the connect/disconnect system is being connected or disconnected
and/or when the system is in the connected/dispense phase, and 2) a
system that allows air to enter the container when product is
withdrawn or allows vapors to escape when the system is in the
connected/dispensing phase.
Reusable systems typically include a dip tube that is intended to
be used for many (100+) connection cycles. A reusable system may
have to be removed several times from the container during its life
to allow for cleaning. Disposable systems typically include a dip
tube that is intended to be used less than five connection cycles
and then thrown away. Disposable systems may be inserted into the
container once with the intent of being disposed of along with the
container.
Industrial (low-purity) grade (IPG) chemical systems make up about
80% of all chemicals supplied. Chemicals that fall under this
category include those chemicals wherein the purity of the chemical
is suitable for common chemical applications such as industrial
cleaners, soaps, surfactants, clean-in-place (CIP) chemicals for
dairy and food, dry cleaning and laundry, and agricultural
pesticides and herbicides as well as other general use
applications. IPG's must be delivered in a reasonably clean system
but do not require the "super" clean requirements needed for
handling Ultra Pure chemicals such as metallic extractability,
total organic carbon (TOC), and particle contaminants. High grade
(ultra-pure) chemical systems (HPG) applications make up about 20%
of all chemicals supplied. Chemicals that fall under this category
include chemicals wherein the purity of the chemical must meet
criteria for which ultra filtration down to the parts per million
(PPM), parts per billion (PPB), or even parts per trillion (PPT) of
particles and/or metals is necessary. This classification typically
involves such specialized applications as microelectronics,
laboratory, and BioPharm industries.
The specific product requirements that differentiate an IPG from an
HPG system are primarily related to the materials of construction,
handling procedures, and whether the system is "closed" or "open",
as described above. As to materials of construction, metals are
typically not allowed or desired to come in contact with the
container contents. Plastic resins must be very clean and free from
metallic contaminants, colorants, etc. These same standards apply
for seals that may come into contact with the container
contents.
As to handling procedures, the materials must be handled in a way
that minimizes the transfer of contaminants to the piece parts or
finished goods during production or shipping (e.g., mold release
agents are not allowed), regrind plastic resin should not be used
in components that have direct contact with the container contents,
and lubricants are typically not permitted.
Whether the system is "closed" or "open" is relevant to the extent
that Ultra-Pure chemicals often require minimum contact with
oxygen. Typically, an inert gas "blanket" is maintained within the
container above the container contents vs. allowing air having a
high O.sub.2 content to enter the container and make up for the
container contents that are removed. Typically this blanket gas
will be nitrogen, CO.sub.2, or other inert gas.
Whether or not a dispense system is Department of Transportation
(DOT) and/or United Nations (UN) approved relates to standards for
shipping a combined container and closure system. This combination
of container and closure system must be approved and certified by
the DOT and/or the UN before being transported. Container with
closure systems that are used "in house" therefore are required to
meet different safety and other standards as opposed to container
with closure systems that must be shipped over-the-road.
SUMMARY OF THE INVENTION
In accordance with the present invention, improvements upon
existing fluid coupling designs for containers have been made by
providing a coupling assembly that provides a quick
connect/disconnect function for removing the contents of a
container that is relatively cost effective and safe.
One aspect of the invention relates to a container insert having at
least two primary pieces, wherein one of the pieces includes keying
features that may be replaceable with other pieces having different
keying features. Another aspect of the invention relates to a
single piece container insert wherein multiple keying features are
formed on the interior and exterior surfaces of the container
insert. Another aspect of the invention relates to a coupling
assembly having a venting system configured to vent a fluid into
the container after a valve of the coupling assembly, which is
positioned in the container contents flow path, has been
opened.
Another aspect of the invention relates to a check valve assembly
configured for use at an end of the a dip tube that helps seal the
end of the dip tube or alter a pressure condition in the dip tube
as the level of container contents lower towards empty. Another
aspect of the invention relates to a method of providing a fluid
flow path out of a container by coupling a dispense unit to a
container insert that has been mounted in an aperture of the
container.
The above summary of the present invention is not intended to
describe each disclosed embodiment or every implementation of the
present invention. Figures in the detailed description that follow
more particularly exemplify embodiments of the invention. While
certain embodiments will be illustrated and describing embodiments
of the invention, the invention is not limited to use in such
embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings in which like reference numbers
represent corresponding parts throughout:
FIG. 1 is a perspective view of an example coupling assembly
incorporating principles of the present invention;
FIG. 1A is a perspective view of an example shipping cap that may
be used with the coupling assembly shown in FIG. 1;
FIG. 2 is an exploded perspective view of the container insert
shown in FIG. 1;
FIG. 3 is an exploded perspective view of the dispense unit shown
in FIG. 1;
FIG. 4 is an exploded cross-sectional plan view of the container
insert shown in FIG. 2;
FIG. 5 is an exploded cross-sectional plan view of the dispense
unit shown in FIG. 3;
FIG. 6 is a cross-sectional view of an assembled container insert
assembly shown in FIG. 1;
FIG. 7 is a cross-sectional view of the dispense unit shown in FIG.
1;
FIG. 8 is a cross-sectional view of the coupling assembly shown in
FIG. 1 with the dispense unit in a first, detached position
relative to the container insert;
FIG. 9 is a cross-sectional view of the coupling assembly shown in
FIG. 1 with the dispense unit in a second position relative to the
container insert in which the keyed surface of the dispense unit is
engaged with a keyed surface of the container insert;
FIG. 10 is a cross-sectional view of the coupling assembly shown in
FIG. 1 with the dispense unit in a third position relative to the
container insert in which the threads of the dispense unit are at
least partially engaged with threads of the container insert;
FIG. 11 is a cross-sectional view of the coupling assembly shown in
FIG. 1 with the dispense unit in a fourth position relative to the
container insert and the valve is in an open position;
FIG. 12 is a cross-sectional view of another container insert
embodiment according to principles of the present invention having
an umbrella style venting member;
FIG. 13 is a close-up view of a wiper rib feature of the dispense
unit shown in FIG. 7;
FIG. 14 is a cross-sectional view of the dip tube shown in FIG.
4;
FIG. 15 is a cross-sectional view of another example coupling
assembly that includes a reader assembly according to principles of
the present invention;
FIG. 16 is a perspective view of another example coupling assembly
incorporating principles of the present invention;
FIG. 17 is an exploded perspective view of the container insert
shown in FIG. 16;
FIG. 18 is an exploded perspective view of the dispense unit and
adapter manifold shown in FIG. 16;
FIG. 19 is an exploded cross-sectional plan view of the container
insert shown in FIG. 16;
FIG. 20 is an exploded cross-sectional plan view of the dispense
unit and adapter manifold shown in FIG. 16;
FIG. 21 is a cross-sectional plan view of the coupling assembly
shown in FIG. 16 with the container insert, dispense unit and
adapter manifold in the initial mating position and the valves in
closed positions;
FIG. 22 is a cross-sectional plan view of the coupling assembly
shown in FIG. 16 with the container insert, dispense unit and
adapter manifold coupled together with the valves in opened
positions;
FIG. 23 is an exploded cross-sectional plan view of the coupling
assembly shown in FIG. 16 with the vent path illustrated with flow
lines;
FIG. 24 is a perspective view of an example single-piece container
insert according to principles of the present invention;
FIG. 25 is a cross-sectional view of the container insert shown in
FIG. 24;
FIG. 26 is a perspective view of an example dip tube check
valve;
FIG. 27 is a side view of the check valve shown in FIG. 26; and
FIG. 28 is a schematic flow chart showing an example container life
cycle.
While the invention is amenable to various modifications and
alternate forms, specifics thereof have been shown by way of
example and the drawings, and will be described in detail. It
should be understood, however, that the intention is not to limit
the invention to the particular embodiments described. On the
contrary, the intention is to cover all modifications, equivalents,
and alternatives falling within the spirit and scope of the
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the following description of the illustrated embodiments,
reference is made to the accompanying drawings that form a part
hereof, and in which is shown by way of illustration of the
embodiments in which the invention may be practiced. It is to be
understood that other embodiments may be utilized as structural
changes may be made without departing from the spirit and scope of
the present invention.
An example coupling assembly 10 is shown and described with
reference to FIGS. 1-15. Coupling assembly 10 includes a container
insert 12, a dispense unit 14, and a dip tube 16. The container
insert 12 and dispense unit 14 are configured for a quick
connect/disconnect function relative to each other.
Coupling assembly 10 provides a semi-closed system for dispensing
and storing contents in a container. Coupling assembly 10 is not a
true closed system in that the dip tube 16 and the container insert
12 may not have a shut-off valve. The coupling system 10 may
include a shipping cap 13 (see FIG. 1A) that will seal the dip tube
16 and container insert 12 during shipping. Because there is no
separate valve in the dip tube 16 and container insert 12, contents
of the container will be exposed to a user outside of the container
during the typically brief time when the shipping cap 13 is removed
and the dispense unit 14 is not yet connected to the container
insert 12.
When in the connected state, the following three general
possibilities exist for dealing with the vapors and potential user
contact with the container contents while protecting the user from
the container contents: A fully open vent provides air intake into
the drum while vapors are allowed to escape through the same
opening that the incoming air travels through. A checked un-ported
vent is typically a relatively inexpensive air checking device
control that could be incorporated into the container insert or the
dispense unit if an objective is to reduce the cost of the
container insert. This arrangement would allow venting air into the
container but not allow vapors or the container contents out
through the vent opening. A ported vent involves incorporation of
an isolated and sealed air vent flow path through the container
insert into the dispense unit, which would have an external port.
For example, a barb flared (MPT) could be used and would allow the
user to have potentially three options for managing the pressure
conditions inside the drum as follows: (1) simply vent the vapors
to atmosphere, (2) install a one-way check valve into the port that
allows air into the drum, but not allow vapors out of the same port
(this would provide for a sealed container in the event of a tip
over condition), or (3) plumb the vapor flow path to a controlled
location such as an air scrubber or filter (this option may provide
a method for the end user to apply an inert layer of "blanket gas"
to the container contents to prevent oxidation (e.g.,
nitrogen)).
Of these several options, a fully open vent is potentially the
least desirable solution because it is relatively unsafe and does
not provide a sealed container, although this option may be the
least expensive. A ported vent option may provide the most
flexibility and may be the most desirable solution in many
circumstances, although it may involve a compromise between flow
capacity and expense. A checked unported vent is a somewhat
compromised solution between the fully opened vent and the ported
vent options. Coupling assembly 10 could include any of these
venting options, although the ported vent option is probably the
most desirable and is described in further detail below with
reference to the Figures.
Coupling assembly 10 is preferably designed and configured so that
at least some of the components can be produced at relatively low
costs so as to be potentially disposable. Specifically, the
container insert 12, dip tube 16, and associated sealing member
(not shown) positioned between the container insert 12 and the
container may be designed so that the combined cost of these
features is such that it is cost effective to dispose of these
components, for example, when the container is disposed of or after
a limited number of uses.
Coupling assembly 10 may be best suited for industrial pure grade
(IPG) applications, although the use of certain materials at an
increased cost may make coupling assembly 10 available for use with
high purity grade (HPG) chemical systems as well.
Coupling assembly 10 is also preferably designed to be capable of
being DOT/UN Certified with a variety of different container sizes.
Although the coupling assembly 10 must be approved and certified
while in use with a particular container, the coupling assembly 10
by itself includes features that should make it possible to obtain
such certification.
While the container insert 12 is preferably a disposable part that
only needs to have a life of about, for example, five to ten
cycles, it is important that the dispense unit 14 also be a
relatively low cost product, although constructed in a way so that
it has a far greater life cycle, such as, for example, 1000 or more
cycles at a ratio of about 500:1 to the life cycle of the container
insert 12.
It is also desirable that the container be compatible with as many
chemicals and other container contents as possible while keeping
the number of container insert configurations to the lowest number
possible so as to minimize potential inventory while maximizing
build lots. Two major factors that may influence this objective is
the material selection for the container insert 12 and related
seals (not shown), and the number of container interfaces. Both
polyethylene and polypropylene may be preferred choices for the
container insert material because of the very broad chemical
compatibility and relatively low cost of these materials. Other
materials for construction may include high-density polyethylene
(HDPE) or Teflon materials such as PTFE or PFA, although the cost
of Teflon materials may be too high for use except for applications
related to high purity grade (HPG) chemical systems. One major
consideration when choosing materials for the container insert 12
is the DOT/UN Certification requirement that requires testing at
0.degree. F., a temperature at which polypropylene materials often
do not perform well. The materials may also be "Fluorinated"; a
process that exposes the finished polyethylene part to a Fluorine
gas resulting in a part that has typically better chemical
resistance than standard polyethylene materials.
The dip tube 16 is made from materials different from those used by
the container insert 12 or dispense unit 14. For example, in
industrial pure grade (IPG) applications, the dip tube may include
some type of "rigid" polytube such as polypropylene, polyethylene,
or a soft flexible TYGON.RTM. type material. The size of the dip
tube is preferably about 3/8 to about 3/4 inch outer diameter. For
high pure grade (HPG) applications, tubing is preferably made of a
rigid type material such as FEP or PFA having dimensions of about
1/2 to about 1 inch outer diameter with a wall thickness of about
0.06 to 0.07 inches.
If possible, it is preferred that all of the coupling assembly
parts are made from a polymer material due to the relatively low
cost and high resistance to wear and corrosion of these materials
as compared to metals and other materials. This objective is also
applied to any springs or other mechanisms that may be required in
the coupling assembly 10. In some embodiments, it may be possible
to use coated metal materials or metal materials at locations that
are not exposed to the container contents. Some example materials
for use in the springs include Hastelloy C, 316SS, PPS, PEEK, and
PTFE/FEP encapsulated 316SS.
The coupling assembly 10 may be well suited for container
applications that involve a "pump sucking" of the container
contents from the containers so that the coupling assembly will be
exposed to a slight vacuum (about -5 psi maximum). Typically, drum
pressure ratings are about 15 psig for plastic materials and 36
psig for metal materials, while some special pressure vessels will
be functional within any of these pressure conditions. The couple
assembly 10 is also preferably created for use within a temperature
range of about -32.degree. to 140.degree. F.
Coupling assembly 10 may be configured with features that reduce
fluid spillage upon disconnect of the container insert 12 and the
dispense unit 14. Preferably, the fluid spillage at disconnect is
minimized to levels less than 0.1 cc/disconnect range if
possible.
Coupling assembly 10 is also configured with features that will
minimize the turbulence in the flow path through the coupling
assembly. Agitation of the pump contents is preferably minimized in
order to avoid aeration of the pumped material and the generation
of particles and degradation of flow performance. The coupling
assembly 10 is also functional without the use of lubricant.
Referring now to FIGS. 2-4, the container insert 12 includes top
and bottom members 20, 22, first and second ends 24, 26, 27, an
open cavity 28 that defines a flow path, a dip tube engagement
surface 30, a valve engagement member 32, a keyed surface 34, a
check valve assembly 36, and a top member connection surface 38.
The dip tube engagement surface 30 may include ribs. channels or
features on an internal or external surface of the container insert
at the first end at 24 for connection of the dip tube 16. The valve
engagement member 32 may include a wall structure 40 having
internal and external surfaces 42, 44, and a slot 46 formed in the
wall 40. The slot 46 may be useful for facilitating draining of any
fluids collected around external surface 44 into the open cavity
28, thereby preventing fluids from puddling within the container
insert 12 and reducing the chance for exposure by the user to the
container contents.
The check valve assembly 36 includes a vent aperture 48, a venting
valve member 50, and a vent valve seat 52. The interface between
the vent valve member 50 and the vent valve seat 52 provides an
airtight seal under normal pressure conditions between the inside
of the container and atmospheric pressure outside of the container.
However, when a vacuum pressure condition exists within the
container, the vent valving member 50 is drawn radially outward
away from the vent valve seat 52 thereby exposing the vent aperture
48 and allowing airflow from outside the container, through the
container insert 12, past the vent valving member 50, and into the
internal volume of the container. A venting path between the vent
aperture 48 and atmospheric pressure outside of the coupling
assembly 10 is described further below with reference to the
dispense unit 14.
The vent valve member 50 is shown in FIG. 4 as an O-ring sealing
structure but may have other shapes and sizes in other embodiments.
For example, an umbrella style vent valve member 51, as shown in
FIG. 12, can be used in combination with a slightly modified vent
valve seat 53. The vent valve member 51 is only one example lip
seal configuration, while many alternative lip seals and other
sealing member configurations are possible for providing a similar
valving function.
The bottom member 20 includes several distinct sections between the
first and second ends 24, 26 that each have different internal and
external diameters. These various sections and their respective
dimensions may be modified in other embodiments for interfacing
with alternative dispense unit configurations as well as
alternative dip tube designs.
The top member 22 includes first and second ends 60, 62 to and an
open cavity 64 that defines a flow path through the top member 22.
The open cavity includes a plurality of threads 66 formed therein,
a bottom member connection surface 68, a container engagement
member 70 having a plurality of threads 71, a sealing member groove
72, and an actuator seat 74. The bottom member connection surface
68 includes a small protrusion or raised lip sized to engage a
recessed portion formed in the top member connection surface 38. In
other embodiments, the bottom member connection surface 68 may
include a groove that mates with a protrusion formed in the top
member connection surface 38, or any other combination of features
that provide a connection between the top and bottom members 20,
22.
In yet further embodiments, the top and bottom members 20, 22 may
be integrally formed as a single piece at the intersecting point
defined by features 38 and 68 shown in FIG. 4. Such a single piece
unit may be difficult to form in the context of molded materials
because of the combination of slots, cores, threads, apertures, and
so forth involved in molding or otherwise forming features of the
container insert 12. An example single piece container insert 600
is described in further detail below with reference to FIGS. 24 and
25.
The container engagement member 70 may have any number of different
sizes and features for connecting to a particular container
opening. For example, the member 70 may be in the form of a bung,
cap, or pail cover, such as, for example, a two inch buttress bung,
S56X4 buttress bung, S70X6 buttress bung, a two inch NPS or BSP
bung, a DIN 61, an S63 cap, or a flex spout or other removable pail
cover. FIG. 4 illustrates the container engagement member 70
including a bung style male threaded portion having a plurality of
threads 71 sized to fit within a common threaded opening of a
container.
The sealing member groove 72 is sized to receive an annular seal
(not shown) that provides a sealing function between the top member
22 and the container. The actuator seat 74 is preferably sized for
receiving a specialized drive tool for removing and installing the
container insert 12 in a container with a desired amount of torque
force.
A shipping cap such as, for example, shipping cap 13 shown in FIG.
1A, may be used to seal a container when the dispense unit 14 is
not coupled to the container insert 12. The shipping cap 13
includes threads 1 formed on an outer surface thereof that are
sized to engage the internal threads 66 of the top member 22.
Shipping cap 13 also includes a sealing member seat 2 sized to
retain a sealing member such as an O-ring or similar structure that
is capable of forming a seal between an outer circumference surface
of the sealing member (not shown) and an inner surface of the
container insert.
The shipping cap 13 may also include an actuator seat 3 that is
configured for engagement by an off-the-shelf tool such as, for
example, a #4 Phillips or a 3/8'' flat standard screwdriver, or a
standard square, hexagon, or torque type driving tool structure.
Although it is possible to form actuator seat 3 with features that
would require a specialized installation tool for installing and
removing the container insert, or applying a specific amount of
torque in doing so, the actuator seat 3 is preferable configured to
provide a relatively reliable seal that can be established with a
relatively low amount of torque using a relatively conventional
tool available to most users. Thus, the shipping cap 13 provides
additional convenience for a user while minimizing the chances of
damaging the cap 13 or container insert from the user over
tightening the shipping cap 13, which may more frequently occur
when using specialized tools.
Referring now to FIGS. 1-3 and 5-10, the dispense unit 14 includes
a coupling ring 80, a coupling sleeve 82, a spring 84, an adapter
member 86, and a valve assembly 88. The coupling ring 80 includes
first and second ends 90, 92, an open cavity 94 defining a flow
path through the coupling ring 80, a drum insert engagement surface
96 having a plurality of threads 97, an actuator surface 98, and a
vent slot 99 formed in the engagement surface 96. The drum
engagement surface 96 and associated threads 97 are configured to
engage the plurality of threads 71 of the container engagement
member 70. The actuator surface 98 may be used by a user to rotate
the engagement surface 96 once the threads 97 are in position for
engagement with the threads 71 of the container insert 12. The vent
slot 99 provides a vent path between air outside of the coupling
assembly 10 a space beyond the sets of threads 97, 71 in the
coupling assembly 10.
The coupling sleeve 82 includes first and second ends 100, 102, a
sealing member seat 104, a key member 106 having a plurality of key
slots 108 formed in an exterior surface of a key member 106, a
plurality of interference members 110 formed on an exterior surface
of the coupling sleeve 82, an adapter connection member 112, and a
poppet sealing surface 114. The sealing member seat 104 is
positioned at the first end 102 and is configured to receive a
sealing member (not shown) such as an O-ring that provides a fluid
seal between the first end 100 of the coupling sleeve 82 and the
open cavity 28 of the bottom member 20 of the container insert
12.
The key member 106 may be integrally formed into the coupling
sleeve 82 or may be a separate member (as shown in the Figures)
that is snap fit or otherwise coupled to the coupling sleeve 82 at
a predetermined position. When key member 106 is a separate member,
it may be used to retain the coupling ring 80 in a predetermined
position along the length of the coupling sleeve 82 between the
first and second ends 100, 102. Key member 106 may include a
plurality of key slots 108 (see FIG. 1) that are sized to engage a
plurality of key members 35 formed on the key surface 34 of the
container insert 12. Preferably, the key slots 108 are slightly
larger in size than the key members 35 so as to provide a venting
path along the length of the slots 108 between an end of the vent
slot 99 and the vent apertures 48 formed in the check valve
assembly 36 of the containment insert 12. Thus, the combination of
the vent slot 99, the key slots 108 (particularly the key slots 108
that are not coupled to a key member 35) and the check valve
assembly 36 provides an air flow path from outside the container to
inside the container when the coupling assembly 10 is properly
mounted to a container and is in use removing contents of the
container. A reduced diameter on key member 106 relative to the
diameter of the keyed surface 34 of the container insert 12 is a
primary source of venting between the vent slot 99 and the vent
aperture 48.
The interference members 110 may be formed at spaced locations
around a circumference of the couplings sleeve 82 in alignment with
the coupled axial position of the key member 106 to the coupling
sleeve 82. Interference members 110 contact an inner diameter
surface of the key member 106 thereby providing a releasable
connection with key member 106. The interference forces between the
key member 106 and the interference members 110 can be overcome
using a predetermined amount of torsional force as applied to
either the key member 106 or the coupling sleeve 82 when one or the
other of those parts is maintained in a fixed rotated position. The
use of multiple interference members rather than a single continual
circumferential surface to provide an interference fit is
advantageous for several reasons. One reason is that the contact
surface area between the interference members 110 and the inner
diameter surface of the key member 106 is relatively small, which
makes it possible to overcome the interference fit tension force
with relative ease. Second, the use of multiple, relatively small
interference members reduces the need for high manufacturing
tolerances as compared to the tolerances needed to form a
continuous interference surface around an entire circumference of a
cylindrical member.
The use of an interference fit between the key member 106 and the
coupling sleeve 82 is advantageous for moving the key slots 108
into an aligned rotated position relative to the key members 35 of
the container insert 12. However, the relative ease in overcoming
the interference forces between the key member 106 and the
interference surface 110 makes it possible to rotate the remaining
coupling sleeve members 82 relative to the container insert 12
after the slots 108 and key members 35 are engaged. This option may
be helpful, for example, when there is a need to rotate the hose or
dispense line (not shown) that is coupled to the dispense unit 14
for removing the container contents (e.g., to remove kinks from the
tube).
The adapter housing connection member 112 is configured with a slot
or other structure sized to receive the adapter member 86 thereby
providing a positive connection between the adapter member 86 and
the coupling sleeve 82. The adaptor housing connection member 112
may have alternative designs to those shown in the Figures to
provide, for example, a releasable connection or a permanent
connection between the coupling sleeve 82 and the adapter member
86.
The poppet seat surface 114 extends within an interior diameter of
the coupling sleeve 82 and provides a fluid seal between the valve
assembly 88 and the coupling sleeve 82. In some embodiments, the
poppet seat surface 114 may be at other locations along the length
of the coupling sleeve 82 depending on, for example, the size,
shape. and position of various valve assembly members and the
desired sealing surface defined by the valve assembly members.
The spring 84 is positioned within the adapter member 86 and
provides an axial tension force against the valve assembly 88,
thereby maintaining a seal between the valve assembly 88 and the
coupling sleeve 82 when the dispense unit 14 is in a rest state.
The spring 84 may be made from any material suitable for the
coupling assembly 10 application, and may include, for example,
polymer materials, metal materials, or embedded metal
materials.
Adapter member 86 includes first and second ends, 120, 122, first
and second bore sections 124,126, an adapter portion 128, and a
coupler sleeve connection member 130. The first bore section 124 is
sized to connect to a dispense line (not shown), and second bore
section 126 is sized to house the spring 84. Other embodiments may
include additional bore sections and different sized first and
second bore sections 124, 126 to accommodate different dispense
unit features. The adapter portion 128 may include structures on an
external surface thereof that assist in providing a sealed
connection with a dispense line. The connection member 130 may have
any desired configuration for securing the adapter member 86 to the
coupling sleeve 82 with a releasable or a permanent connection.
The valve assembly 88 includes a poppet 132, a sealing member seat
134, and a poppet activator 136 having first and second ends 138,
140. The poppet 132 is shaped to form a seal with the poppet seat
surface 114 of the coupling sleeve 82. The poppet 132 may seal with
the coupling sleeve 82 at various positions on the poppet 132 such
as, for example, on a slanted surface or on a surface extending
parallel to an axis of the dispense unit 14. The sealing member
seat 134 is sized to receive a sealing member such as, for example,
an O-ring that provides additional sealing function between the
valve assembly 88 and the coupling sleeve 82.
The poppet activator 136 extends axially from a rest position of
the poppet 132 to the first end 100 of the coupling sleeve 82. The
second end 140 may include a plurality of openings adjacent to the
poppet 132 to promote flow of the container contents through the
valve assembly 88. The first end 138 of the poppet activator 136 is
configured to contact the valve engagement member 32 of the
container insert 12. Engagement of the poppet activator 136 with
the valve engagement member 32 is shown and described further with
reference to FIGS. 7-10 below. In use, the poppet activator 136
moves the poppet 132 against the axial forces applied by spring 84
to open and close the valve assembly 88.
Coupling assembly 10 provides for a unique progressive coupling and
valving sequence as shown and described with reference to FIGS.
7-10. When coupling the container insert 12 and dispense unit 14
together (see FIG. 7), the first end 90 of the coupling ring, first
end 100 of the coupling sleeve, and the first end 138 of the poppet
activator are inserted into the open cavity 28 of the bottom member
20 and the open cavity 64 of the top member 22 of the container
insert 12 until the key member 106 of the coupling sleeve 82
engages the keyed surface 34 of the container insert 12. The key
member 106 may be rotated due to the interference connection with
the interference members 110 of the coupling sleeve 82 and the
coupled connection between the coupling sleeve 82 and the adapter
member 86 to align the key slots 108 with the key members 35 of the
container insert 12. When the key slots 108 and key members 35 are
properly aligned, features 108, 35 can move axially but not
rotationally relative to each other, thus allowing the dispense
unit 14 to move further axially relative to the container insert 12
until the threads 97 of the drum insert engagement surface 96 of
coupling ring 80 engage the threads 66 of the top container insert
member 22 (see FIG. 8).
With the threads 97 and 66 contacting each other, the threads 97
can be rotated relative to the threads 66 by rotating the actuator
surface 98. Preferably, the coupling ring 80 can rotate freely
relative to the coupling sleeve 82, thus making it possible for the
key features 108, 35 to remain in engagement with each other and
continue to move axially relative to each other while the threads
97 rotate relative to the threads 66. Continued rotation of the
threads 97, 66 relative to each other moves the entire dispense
unit 14 axially relative to the container insert 12 until the
poppet actuator first end 138 contacts the wall 40 of the valve
engagement member 32 (see FIG. 9). Continued rotation of the
threads 97 via the rotation of the actuator surface 98 then moves
the coupling sleeve 82 axially relatively to the poppet activator
136 because the poppet activator 136 is held in a stationary
axially position due to contact with the wall 40. As a result, the
poppet activator 136 moves the poppet 132 axially relative to the
poppet seat surface 114 of the coupling sleeve 182 until the
plurality of openings in the second end 140 of the poppet activator
136 are exposed to fluid communication with the adaptor member
first and second sections 124, 126 (see FIG. 10).
The sequence of connecting and valving functions for the coupling
assembly 10 ensures: 1.) proper keying of the container insert 12
and dispense unit 14 features, 2.) a positive connection between
the container insert 12 and dispense units 14, and 3.) opening of
the valve for dispensing of the contents of the container.
To further reduce spillage when disconnecting the container insert
12 and dispense unit 14, the coupling sleeve 82 may include a wiper
rib 150 positioned in contact with an outer circumference surface
of the poppet activator 136, as shown in the detailed view of FIG.
13. The wiper rib 150 prevents fluids captured between the poppet
activator 136 and the coupling sleeve 82 from exiting that space as
the poppet 132 and a poppet activator 136 move relative to the
coupling sleeve 82. The wiper rib 150 may be particularly useful
when handling high viscous materials that would not otherwise drain
quickly from the space between the coupling sleeve 82 and valve
assembly 88 into the space surrounding the outer surface of the
wall 40 for draining through the slot 46 and out of the container
insert 12 at the time of removing the dispense unit 14 from the
container insert 12.
The dip tube 16 may include a plurality of radially extending
support structures 154 as shown in FIG. 14. The support structure
154 may extend radially inwardly into the internal volume defined
by the dip tube, or may extend radially outwardly (not shown). The
radial ribs 154 may provide resistance to deformation of the dip
tube along its length. Radial ribs 154 may also provide additional
stiffness enabling the use of a relatively small diameter dip tube,
thus enhancing the primeability of the dip tube compared as
compared to a larger diameter dip tube. The ability of a dip tube
to be primed is based primarily on the volume of the fluid in the
tube and wetting friction between the tube and the fluid. The
radial ribs 154 may enhance priming of the dip tube 16 when the
ribs 150 extend radially inwardly in the dip tube 16 due to
increases in wetting friction related to increased surface
area.
In another coupling assembly configuration 200 shown in FIG. 15,
the coupling assembly 200 includes a "smart reader" system for
identifying information related to the container and the container
contents. The coupling assembly 200 includes a container insert
212, a dispense unit 214, and an adapter member 286 having a reader
board 222 and a reader antenna ring 220 attached thereto. The
reader board 220 and reader antenna ring 220 may be coupled to a
remote system via a power cable 224 or a wireless system (not
shown), and are used to read information from a tag ring 218 that
is covered with a tag cover 216 in the container insert 212. The
tag ring 218 is mounted to a container engagement member 270 of the
container insert 212 on a surface facing the dispense unit 214 such
that the tag ring 218 is in a line of communication with the reader
antenna ring 220. The tag ring 218 may include information related
to the identity of the container such as the size and
certification, and information related to the container insert such
as, for example, a certification ratings, number of uses, the
contents of the container, the dates when the container was filled
or emptied, and the length of time of connection between the
container insert 212 and dispense unit 214.
The coupling assembly 10 is configured to maximize the cross
sectional flow opening out of the container through assembly 10,
thereby enabling a larger flow capacity than would otherwise be
obtainable with known coupling assemblies. By positioning the
primary valve features (e.g., poppet 132, spring 84 and portions of
the poppet activator 136) outside of the container insert 12, the
width of those features does not directly affect the flow area that
is otherwise restricted by the container opening diameter. For
example, if the poppet 132 were positioned within the container
engagement member 70 inside the opening of the container, the
poppet diameter would have to be reduced significantly, which would
relate to a much smaller cross sectional area of the poppet
activator 136 in order for all the features (for example, the
bottom member connection surface 68, the coupling sleeve 82, the
key member 106, etc.) to fit within the container opening.
There are several advantages to using the multiple piece container
insert 12 as described above. Using separate bottom and top members
20, 22 makes it possible to reduce the cost of generating different
top member designs for different container openings and different
bottom member designs for different key configurations. For
example, when producing container inserts for an industry that uses
the same container opening but many different keyed systems that
relate to, for example, different container contents (e.g.,
chemicals, food, etc.), several different bottom member
configurations may be produced and secured to the same top member
configuration. In another example, one particular bottom member may
be produced, for example, for a single container content that must
be stored or shipped in many different container sizes having
different container opening configurations. As a result, many
different top member configurations may be produced and separately
coupled to the single bottom member configuration.
The multiple piece dispense unit 14 may provide another advantage
by using a separate key member that is coupled to the coupling
sleeve 82. A separate key member 106 can be produced for many
different key configurations related to, for example, different
container contents, industries, etc. Thus, the majority of the
dispense unit 14 components can be produced with a single design
while only the key member 106 is changed and separately coupled to
the couplings sleeve 82 for different keying configurations and
applications. In other embodiments, the features of key member 106
may be integrally formed into the coupling sleeve 82, which option
may be well suited for high production of a single key
configuration.
Referring now to FIGS. 16-23, another coupling assembly embodiment
300 includes a container insert 312, a dispense unit 314, and an
adaptor manifold 318. Coupling assembly 300 includes a dual valve
system with one valve associated with the container insert 312 and
a second valve associated with the dispense unit 314. The two-valve
system of coupling assembly 300 is particularly advantageous for
reducing spillage of fluids at the time of disconnect and for
eliminating substantially all contact between a user and the
container contents at all times.
Coupling assembly 300 is essentially a fully closed system that
includes a shut-off valve in the container insert and may include a
shipping cap (not shown) to ensure sealing of the container
contents and the container insert 312 during shipping. When in the
connected state, a sealed event path is provided for (discussed
further below) for allowing make-up air or the addition of an inert
gas such as Nitrogen into the container through a port in the
coupler assembly 300.
Because the container insert 312 and the dispense unit 314 include
separate valving features and valving features typically have a
relatively high cost, it may be difficult to design the coupling
assembly 300 to be "disposable" like some of the components of
coupling assembly 100 described above. Preferably, at least the dip
tube 316 and any seals, caps, or covers for the coupling assembly
300 are "disposable" in nature. In the event that components of
coupling assembly 300 can be made in high quantities (for example,
1 to 2 million parts) it may be possible to implement tooling and
other production functions that would permit disposability of some
coupling assembly components.
The coupling assembly 300 is preferably designed for use in most
industrial pure grade (IPG) applications and may be designed for
high pure grade (HPG) applications by using, for example, virgin
resin for wetted components. In order to meet high pure grade
applications, the wetted materials could be made of a polymer
material such as PEEK, PPS, or PTFE/FEP, clean room assembly using
Class 100 clean room bags may be used, and the coupler assembly is
preferably configured for DOT/UN certification for shipping
purposes.
The coupling assembly 300 does not include springs in the flow path
and may also include a check valve in the dip tube (such as the
check valve 500 shown in FIGS. 26 and 27) to further isolate the
container contents from the user. Further, the container insert 312
preferably includes materials and requires manufacturing methods
that result in a product that has lower costs than the dispense
unit and therefore can have a shorter life cycle if desired.
Referring now to FIGS. 17, 19, 21 and 22, the container insert 312
includes an insert sleeve 322 and a base 324. The insert sleeve 322
includes first and second ends 326, 328, first and second bore
sections 330, 332, a poppet valve contact portion 334, first,
second and third lip seals 336, 338, 340, a plurality of track
followers 342, and first and second key cutouts 344, 346. The base
324 includes first and second ends 350, 352, first, second, and
third bore sections 354, 356, 358, a valve protrusion 360 having a
plurality of openings 362 formed therein, and a dip tube engagement
surface 364 configured to receive a dip tube (not shown). Base 324
also includes a container engagement surface 366 having a plurality
of threads 367, a sealing member seat 368, a coupling ring seat
370, a collar seat 372, a plurality of helical vent tracks 374
(generally rectangular cross-section), a plurality of key tracks
375 (generally curved cross-section), a first vent aperture 376,
and a key member 378.
Fluid flowing through the container insert 312 primarily contacts
the first and second bores 330, 332 of the insert sleeve 322 and
the third bore section 358 of the base 324 (see the fluid flow path
in FIG. 22). The contact portion 334 is configured to engage an end
of the coupling sleeve of the dispense unit 314 as described
further below. The lip seals 336, 338, 340 provide a sealing
connection between the insert sleeve 322 and the base 324 and may
be replaced with other sealing structures in other embodiments such
as, for example, O-rings. The track followers 342 are formed on an
outer surface of the insert sleeve 322 and are configured to engage
the helical key tracks 375. The vent tracks 374 provide a vent path
between the bore section 354 and the vent aperture 376. A
difference in cross-sectional shape between the venting tracks 374
and the key tracks 375 may be useful to ensure that the track
followers 342 engage the correct tracks (key tracks 375). Venting a
fluid such as air between the sleeve insert 322 and the base 324 is
discussed in further detail below.
The first key cutouts 344 are formed on an inner surface of the
second bore 332 of the insert sleeve 322 and are sized to receive
key members of a coupling sleeve (described further below) of the
dispense unit 314, thereby requiring the insert sleeve 322 to
rotate with the coupling sleeve when the coupling assembly 300 is
assembled. The second key cutout 346 is formed at the end 328 of
the insert sleeve 322 and is sized to engage the key member 378
formed in the first bore section 354 of the base 324. The second
key cutout 346 assists in properly aligning the insert sleeve 322
within the base 324 and may be sized to limit the amount of
rotation of the sleeve insert 322 relative to the base 324.
The valve protrusion 360 of the base 324 includes a valve contact
surface 361 configured to engage an end of a stem poppet 382
(described below) of the dispense unit 314, and also includes a
plurality of openings 362 that provide fluid communication between
the second and third bore sections 356, 358. The threads 367 of the
container engagement surface 366 are sized to engage threads in the
opening of a container to which the coupling assembly 300 is
secured. Other embodiments may include different connection
features other than threads for providing a positive attachment of
the container insert 312 to a container. The sealing member seat
368 is sized to retain a sealing number (not shown) that provides
an airtight seal between the outer surface of the base 324 and the
container. The coupling ring seat 370 is sized to receive an
attachment feature of the coupling ring of the dispense unit, and
the collar seat 372 is configured to engage features of the collar
of the dispense unit 314.
The first vent aperture 376 is formed in an outer wall of the base
324 and provides fluid communication between an outer surface of
the container insert 312 and the second bore section 356, which
bore is vented with the helical vent tracks 374 as described above.
Example fluid flow through first vent aperture 376 is illustrated
in FIG. 23 as flow line B.
Referring now to FIGS. 18 and 20-23, the dispense unit 314 includes
a coupling sleeve 380, a stem poppet 382, a collar 384, a coupling
ring 386, and a spring 388. Coupling sleeve 380 includes first and
second ends 390, 392, a bore 393, first and second sealing member
grooves 394, 396, a vent aperture 398 extending to an outer wall
thereof, and helical tracks 400 formed on the inner diameter
surface of the bore 393. The first end 390 is configured to engage
the insert sleeve 322 of the container insert 312 as shown in FIGS.
21 and 22. A sealing member (not shown) positioned in the first
sealing member groove 394 provides an airtight seal between the
coupling sleeve 380 and the base 324 of the dispense unit 314 when
the valves of the coupling assembly 300 are open, as shown in FIG.
22. A sealing member (not shown) positioned in the second sealing
member groove 396 provides a seal between the first end 390 and the
insert sleeve 322 of the container insert 312. The vent aperture
398 provides a vent path for venting the inner volume of the
container, which will be described in further detail below.
The helical track 400 is sized to receive a key member of the stem
poppet 382. The coupling sleeve 380 may also include key members
401 that are formed in an outer surface thereof and sized to engage
the key cutouts 344 in the insert sleeve 322. Engagement of the key
member 401 in the key cutouts 344 provides a connection between the
coupling sleeve 380 and the insert sleeve 322 such that the sleeves
380, 322 rotate together when the coupling assembly 300 is
assembled.
The stem poppet 382 includes first and second ends 402, 404, flow
openings 406, an adapter manifold engagement member 408, a coupling
ring engagement surface 410, a vent path 411, a collar engagement
surface 412, and first, second and third sealing member grooves
414, 416, 418. The flow openings 406 provide fluid communication
between an inner bore 403 of the stem poppet 382 and the inner
bores 330, 332 of the insert sleeve 322. The flow openings 406 are
sealed relative to the coupling sleeve 380 with sealing members
(not shown) retained in the first and second sealing member grooves
414, 416.
The vent path 411 provides a venting path between the venting
features of the adapter manifold 318 and the vent aperture 398
formed in the coupling sleeve 380 when the valves are in the open
position (see FIG. 22). The function of vent path 411 will be
described in further detail below.
The coupling ring engagement surface 410 is configured to engage
the coupling ring 386 and the collar engagement surface 412 is
configured to engage the collar 384 as shown in FIG. 21. The third
sealing member groove 418 is configured to retain a sealing member
(not shown) to form a seal between the stem poppet 382 and the
coupling sleeve 380. Stem poppet 382 may also include a key member
419 formed on an outer surface thereof that is sized to engage the
helical tracks 400 of the coupling sleeve 380.
The adapter manifold engagement structure 408 is configured to
engage connection features of the adapter manifold 318 for coupling
the adapter manifold 318 to the dispense unit 314. Other
embodiments may include different connecting structures such as
snap fit, weld, and latch connectors.
The collar 384 includes a spring seat 422 configured to retain the
spring 388 (see FIG. 21) between the coupling ring 386 and the
collar 384. The coupling ring 386 includes a container insert
engagement structure 420 that is configured to engage the coupling
ring seat 370 formed in a second end 352 of the base 324. The
structure of the coupling ring seat 370 may be used to control the
amount of rotation of the coupling ring 386 relative to the base
324. A poppet stem connection structure 421 provides a positive
attachment between the coupling ring 386 and the stem poppet 382
such that rotation of the coupling ring 386 causes rotation of the
stem poppet 382 whether or not the collar 384 is fixed to the stem
poppet 382.
The adapter manifold 318 includes a vent connector 430, first and
second vent paths 432, 434, a primary fluid path 438, and a poppet
connection structure 436. The vent connector 430 is configured as a
generic weld joint that may be coupled to any desired venting
source, such as, for example, atmospheric air or a source of gas
such as, N, or other inert gas. The vent paths 432, 434 provide
fluid communication with the vent paths 411 formed in the stem
poppet 382. The second vent path 434 may be a cylindrical channel
surrounding the primary fluid path 438 such that connection of the
adapter manifold 318 to the dispense unit 314 provides venting
communication with the vent path 411 at any rotated position of the
adapter manifold 318 relative to the dispense unit 314. The poppet
connection structure 436 may provide a positive attachment with a
snap fit, weld, latch or other locking feature, or may be, for
example, a mere interference fit connection with the stem poppet
382. The adapter manifold 318 may have a variety of different
configurations providing for a source of replacement or venting
gases or may be configured with a simple vent port to atmospheric
air. The adapter manifold 318 may include any suitable connection
with the primary fluid path 438 when removing the container
contents through the coupling assembly 300.
Preferably, the adapter manifold 318 is coupled to the dispense
unit 314 to ensure a proper connection prior to the dispense unit
314 being coupled to the container insert 312 so that the coupling
assembly 300 is ready for dispensing the container contents as soon
as the dispense unit 314 is coupled to the container insert 312.
The container insert 312 is inserted into a container (not shown)
with the threads 367 of the engagement surface 366 engaging threads
or other connecting structures of the container. Coupling the
container insert 312 to the container also draw a sealing member
(not shown) positioned in the sealing member seat 368 against a top
surface of the container thereby providing an airtight seal between
the container insert 312 and the container.
With the container insert 312 secured to the container, the
dispense unit 314 is brought into engagement with the container
insert. Coupling of the container insert 312 and dispense unit 314
begins with alignment of the key members 401 of the coupling sleeve
380 with the first key cutouts 344 of the insert sleeve 322. With
the key features 401, 344 engaged, the dispense unit 314 is further
inserted into the container insert 312 until the first end 402 of
the stem poppet 382 and the first end 390 of the coupling sleeve
380 are brought into contact with the contact portion 334 and the
valve protrusion 360, respectively, of the container insert 312.
The container insert engagement structure 420 of the coupling ring
386 is concurrently coupled with a first track portion 369 of the
seat 370 (see FIG. 17). With the engagement structure 420
positioned in the first track 369, the coupling ring 386 can be
rotated relative to the base 324 to create a positive attachment
between the container insert 312 and the dispense unit 314 while
concurrently opening the valves of the coupling assembly 300 to
provide a fluid flow through the coupling assembly 300.
When the coupling assembly 300 is assembled, rotation of the
coupling ring 386 causes rotation of the stem poppet 382 because of
the positive attachment of those features via the poppet stem
connection structure 421 and the coupling ring engagement surface
410. Rotation of the stem poppet 382 causes the key member 419 to
move in the helical tracks 400 of the coupling sleeve 380 thereby
forcing the coupling sleeve 380 to move axially in a direction
toward the valve protrusion 360. Because the coupling sleeve 380 is
also coupled to the insert sleeve 322 via the key members 401 and
the first key cutouts 344, the insert sleeve 322 rotates with the
coupling sleeve 380. Contact between the first end 402 of the
coupling sleeve 380 and the contact portion 334 of the insert
sleeve 322 forces the insert sleeve 322 to move axially relative to
the valve protrusion 360 until the openings 362 are exposed to
fluid communication with the flow openings 406 in the stem poppet
382 (see FIG. 22).
Reverse rotation of the coupling ring 386 will draw the insert
sleeve 322 axially in a reverse axial direction because of the
connection between the coupling ring 386 and the stem poppet 382,
the connection between the stem poppet 382 and the coupling sleeve
380, and the connection between the coupling sleeve 380 and the
insert sleeve 322. The combination of keys, key slots, helical
tracks, and track followers of coupling assembly 300 provides for
the opening and closing of the coupling assembly valves without the
use of springs or other mechanical devices that may otherwise be
required.
The coupling assembly 300 also provides for a quick
connect/disconnect of the container insert 312 and dispense unit
314 with relative ease, and opening of the valve with a relatively
simple rotation of the coupling ring 386 when the container insert
312 and dispense unit 314 are engaged with each other. The coupling
assembly 300 further provides for a sealed container at all times
until after the container insert 312 and dispense unit 314 are
sealed together and the valves are opened, thus eliminating or at
least significantly reducing the chances of the user being exposed
to the container contents.
The coupling assembly 300 also substantially eliminates any
dripping of the container contents from the dispense unit 314 or
container insert 312 when removing the dispense unit from the
container insert 312 because of the many different seals used in
the coupling assembly 300 and the interface of various components
of the dispense unit and container insert. Closing of the coupler
assembly valves substantially captures any container contents
behind a sealing member within an enclosed space of either the
dispense unit 314 or the container insert 312 thereby preventing
dripping container contents.
Coupling assembly 300 also provides for venting of the container
during removal of the container contents. FIG. 23 illustrates a
venting flow path A through the first and second vent paths 432,
434 of the adapter manifold 318, the vent path 411 of the stem
poppet 382, the vent aperture 398 of the coupling sleeve 380, the
key cutout 346 of the insert sleeve 322, the helical vent tracks
374, and the first vent aperture 376 of the base 324. As
illustrated by a comparison between FIGS. 21 and 22, the vent path
A shown in FIG. 23 is open only when the valves of the coupling
assembly 300 are fully open for fluid communication of container
contents through the coupling assembly 300.
Referring first to FIG. 21, the vent aperture 398 is positioned on
a side of the third sealing member groove 418 (with its associated
sealing member that is not shown) when the coupling assembly valves
are in a closed position such that the vent aperture 398 is not in
fluid communication with the vent path 411. However, as shown in
FIG. 22, the vent aperture 398 is in fluid communication with the
vent path 411 when the valves are in the open position. Again
referring to FIG. 21, the vent path A is further obstructed when
the valves of the coupling assembly are closed because the vent
aperture 376 is sealed from the remaining vent path by the second
lip seal 338. However, referring to FIG. 22, the vent aperture 376
becomes exposed to complete the vent path A when the insert sleeve
322 and associated second lip seal 338 have moved axially into an
open valve position.
As a result of the coupling assembly 300 venting configuration,
venting is not open until after the valves of the coupling assembly
are open. As the container contents are drawn out of the container
via the fluid flow path B (see FIG. 22), air or other gases can be
drawn or forced into the container via the vent path A. Some
venting configurations may allow for a positive pressure to be
applied along the venting path A, thereby creating a positive
pressure within the container rather than a typical negative
pressure condition that exists when removing container contents
through the coupling assembly. Other embodiments may also include a
one-way valve positioned along the vent flow path A that permits
fluids to flow only into the container and not back out of the
container along the flow path A.
The coupling assemblies 10, 300 may benefit from use with the dip
tube check valve assembly 500 shown in FIGS. 26 and 27. The check
valve assembly 500 may be coupled to an end of a dip tube, such as
dip tube 16 shown in FIG. 4, that is inserted into and positioned
at a bottom of a container (not shown). The check valve assembly
500 may provide an additional valve function in association with
the valves of coupling assemblies 10, 300 to maintain a barrier
between the container contents (and associated fumes in the
container) and a user operating the coupling assemblies 10, 300.
The check valve assembly 500 may be useful for at least partially
sealing closed a relatively empty container to which the container
insert 12 is coupled when the dispense unit 14 is removed and a
shipping cap has not yet be coupled to the container insert 12. The
check valve assembly 500 may also be particularly useful for
sensing when the container is nearly empty of its contents and
signaling the pumping unit to turn off so that the dispense line
and pump are not filled with air. A dispense line filled with air
often requires priming before the dispense unit can be used
again.
Check valve assembly 500 includes a tube portion 502, a valve
member 504, a valve support member 506, and a base 508. The tube
portion includes a dip tube connector end 510 that is configured
for coupling to either an inner or outer diameter surface of a dip
tube, and an open end 512. The valve member 504 includes a top
surface 514, a sealing surface 516, and a bottom edge 518. The
valve support member 506 includes a top stop member 520, and first
and second valve supports 522, 524. The base 508 includes first and
second flow openings 526, 528, first and second base supports 530,
532, and a floor member 534. The flow openings 526, 528 are in
fluid communication with the open end 512 of the tube 502 and
provide a fluid flow path C from the container into the tube 502
and into a dip tube (not shown).
The check valve assembly 500 functions to seal off flow into a dip
tube to which the assembly 500 is coupled by contacting the sealing
surface 516 of the valve member 504 against the base 508 around the
openings 526, 528. The valve member 504 can be lowered into a
position where the sealing surface 516 contacts the base 508 only
when a level of container contents in the container drops to a
level that allows the otherwise floating valve member 504 to drop
into close proximity to the openings 526, 528. When the valve
member 504 gets close to the openings 526, 528, suction forces that
are drawing the container contents out of the container through the
openings 526, 528 pull the sealing surface 516 of the valve member
504 against the base 508 around the openings 526, 528, thereby
sealing the check valve assembly 500 in a closed condition. When a
level of the container contents is relatively high, the valve
member 504 floats upward while supported by the valve supports 522,
524 until the top edge 514 engages the top stop 520. As the level
of the container contents drops, the valve member 504 also drops
toward the base 508 until drawn into sealing engagement with the
base 508 under suction forces as described above.
In another embodiment, the valve member 504 does not seal against
the base 508 as the container contents drop below the top stop 520.
However, as the valve member 504 lowers, the flow path into
openings 526, 528 becomes obstructed by the valve member 504,
thereby altering the pressure within the dispense line out of the
container. This change of pressure can be identified by a sensor or
other device that then signals the dispense pump to shut off before
air enters the dispense line and pump.
Other check valve embodiments may include features having different
shapes and sizes than those shown in FIGS. 26 and 27. For example,
the base and valve member may have a rectangular shape and the base
may include one, three, or more openings into the tube portion of
the check valve assembly. Other embodiments may include a valve
member that can drop below the base of the check valve assembly to
contact and seal against a floor of the container in place of or in
addition to sealing against the base around the openings of the
base.
The check valve assembly features may be made from any suitable
material that is resistant to corrosion, relatively cost effective
to manufacture, and performs the check valve functions as desired.
One example valve member includes silicon rubber for enhanced
pliability and sealing functionality, and the remaining check valve
features include a polymer material such as polyethylene.
The check valve assembly 500 may further include a sensor 540 that
monitors features of the check valve assembly 500 and provides a
signal when a predetermined condition is met. In one embodiment,
the sensor 540 monitors the fluid flow through check valve openings
526, 528 and generates a flow signal when fluid flow reaches a
certain low level (e.g., when fluid flow stops). In another
embodiment, the sensor 540 monitors a position of the valve member
504 relative to the base 508, in particular one of the openings
526, 528, and generates a position signal when a predetermined
distance is reached. The flow and position signals may be
representative of, for example, the level of container contents,
the rate of fluid flow, the amount of time remaining until the
container is "empty", etc. The sensor 540 may include multiple
sensors or may include other additional components as needed to
conduct the desired monitoring and measuring.
The signals produced by the sensor 540 may be collected, processed
and distributed by a controller positioned at a remote location
outside of the container in which the check valve 500 resides. The
signal may also be sent directly to a dispense unit, pump, or other
device that is coupled to an opposing end of the dip tube to which
the check valve 500 is coupled and is used to remove the container
contents. The signals produced by the sensor 540 may be used to
shut down or modify the dispense unit, pump, or other device when
the sensor signals indicate a predetermined condition exists in the
container.
Referring now to FIGS. 24 and 25, an example single piece container
insert 612 is shown including an open cavity 628 that defines a
flow path, a dip tube engagement surface 630, a valve engagement
member 632, a keyed surface 634 having a key member 635, and a
check valve seat 652. The valve engagement member 632 may include a
wall structure 640 and a slot 646 in the wall 40. The check valve
seat 652 includes a vent aperture 648 and is sized to receive a
sealing member (not shown) such as an O-ring, lip seal, or umbrella
seal.
The container insert 600 also includes an open cavity 664 having a
plurality of threads 666 formed therein, and a container engagement
portion 670 having a plurality of threads 671, a sealing member
groove 672, and an actuator seat 674.
A single piece container insert 612 may have some advantages over
the two piece container insert 12 described above. For example, a
single piece device may be more robust than a two piece device
because there is no chance of multiple pieces detaching from each
other during use. Also, a two piece device requires assembly of the
pieces while a single piece device requires no assembly. One
potential disadvantage of a single piece device relates to
manufacturing the device with the number of features both inside
and out of the container insert. Forming these many features in two
separate pieces may reduce the manufacturing complexity as compared
to a single piece manufacturing process.
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.
* * * * *