Dissolving and Dispensing Apparatus

1. Field of the Invention

The present invention relates to dispensing systems, and more particularly to dispensers for caustic materials including dissolving means therein and safety provisions therefor.

2. Description of the Prior Art

In commercial applications of washing machines, for example, it is desirable to reduce the cost of detergent and of maintenance time by repeated utilization of a detergent solution until its replacement. During such repeated use, it is occasionally necessary to replenish the solution with an appropriate solution of mixed detergent in order to compensate for drained solution, absorption of grease, oils, solvents, foods and other chemicals.

Early dispensers of the prior art were primarily divided into two classifications. A first class utilized a reservoir of pre-dissolved powdered materials, which, when activated, overflowed concentrated solution into the wash tank. Such systems, however, required an entire package of chemicals to be wetted, thereby releasing some of the active ingredients into the air, or providing for release at uneven rates into the tank. Typical chemicals dispensed by such systems include chlorine, surfactants, light phosphates, and oil surfaced powders.

In such prior art devices, a reservoir was fed by hand, using a scoop to transfer powdered materials from a larger container or from a package which was torn open at the reservoir. For caustic, irritant, or acidic chemicals, however, such replenishment methods provide a hazard of dangerous contact by the operator with the chemical.

A second class of dispensers relates to feeding of dry chemical from a drum by forcing water into the drum, thereby pressurizing a solution outwardly therefrom. Since this system involved the use of pressure and a dependence on the solid connection at the drum, safety of the connection was critical and could not be assured. Moreover, the chemical utilized in the apparatus was wetted prior to its use, thus providing dissipation problems similar to those associated with the above described reservoirs.

Various dispensing devices of the prior art are shown in the following U.S. patents:

Clauson U.S. Pat. No. 1,704,913; Ash U.S. Pat. No. 2,038,260; Forsyth Jr. U.S. Pat. No. 2,062,704; and Lane U.S. Pat. No. Reissue 20,262.

Gatchet U.S. Pat. No. 2,601,672 illustrates dissolution and dispensing of a dry fertilizer, while Klumb U.S. Pat. No. 2,573,576 and Fletcher et al U.S. Pat. No. 2,624,119 disclose further mixing devices.

Dispensers for powdered soap are disclosed in Hall U.S. Pat. No. 874,072; Bohlig U.S. Pat. No. 1,041,417; and Gilmore U.S. Pat. No. 2,520,003.

Harper U.S. Pat. No. 1,653,627 discloses a drinking glass washer, while McDougall U.S. Pat. No. 3,072,137 and Holmes U.S. Pat. No. 3,166,086 provide fluid mixing devices.

None of the above cited art references, however, provide for safety features to avoid the contact between an operator and caustic materials which might be used therein. Such devices, a fortiori, do not provide for duplicated safety systems to assure, in a fail-safe manner, that an operator will not be exposed to such materials. Further, the prior art devices above described do not provide apparatus for maintaining dry chemicals from being prematurely wetted, nor for assuring that an operator need not come in contact with such chemicals during a changeover or replenishment cycle.

In a more recent device of the prior art, however, as disclosed in U.S. Pat. No. 4,063,663 to Larson et al., a dispenser apparatus is provided which includes a curved screen member for retainably supporting a powdered detergent thereabove and which includes a nozzle below the screen. The detergent container forms a part of the dispensing apparatus and includes a door at its top for manual replenishment of the detergent. A safety feature, in the form of a mercury switch, is triggered by opening of the door to disable the nozzle and thus to minimize the possibility of the operator being sprayed by the caustic materials involved. However, in the event that the switch should fail when the operator opens the access door, a hot, caustic solution could easily splash into the operator's face. Moreover, an operator is required to load the caustic materials manually through the access door, and thus must come in contact with the potentially hazardous chemicals. Still further, the access door must be opened in order to determine whether the detergent needs to be replaced or replenished.

The screen in the prior art device presents the potential, under varying water pressure conditions, that free flow of solution may not be permitted, and that, therefore, the chemical might be overwetted or, in situations of low pressure, may not be dissolved. Such uneven results may require increased operator attention and intervention in the operation of the device, thus increasing its cost of operation and furthering the potential of hazardous contact with the chemical utilized therein.

It is accordingly an object of the present invention to overcome the deficiencies of the prior art and to provide an apparatus for dissolving and dispensing chemicals, including fail-safe protection systems for an operator.

It is a further object of the invention to provide for a dispenser, the bracket including a water passageway therein.

Still a further object of the invention is the utilization of a screen for receiving and supporting detergent provided from a container.

Another object of the invention is the provision of a dissolving and dispensing system wherein an operator need not come in contact with the chemicals utilized therein, by providing a coupling means for accepting a standardized shipping container for such chemicals.

It is a further object of the invention to provide a safety switch responsive to the proper positioning of the dispensing apparatus in its dispensing position to activate a nozzle and an alignment for said switch to insure positive activation.

Yet another object of the invention is the provision of a nozzle within a rotatable dispensing apparatus, the nozzle fixedly pointed towards an input opening in the dispenser when in its normal dispensing position, and pointed towards a discharge port of the dispenser when in its inverted, container replacement position.

In accordance with the foregoing objects, the present invention provides a dissolving and dispensing apparatus for powdered detergent including a funnel means having a coupling means attached to its wide opening for coupling to a container of powdered detergent, and preferably to a standardized shipping container thereof. A screen is provided within the funnel means to receive thereon powdered granules from said container. A nozzle is disposed below the screen for directing a spray at the screen, thus wetting and dissolving the powdered granules immediately in contact therewith. The nozzle further directs a spray at the funnel wall below the screen, in order further to agitate the chemicals and to force the dissolved chemicals towards the side of the funnel. A narrow discharge port is provided at the other end of the funnel for discharging the dissolved detergent therefrom to a receiving tank in a washing machine, for example.

The apparatus includes a pivotable, rotating dispensing apparatus having a wall support for mounting on a wall adjacent the washing machine or on a surface of the washing machine, and a second portion forming part of the funnel portion. A stop is provided in the wall support to assure that rotation from the normal dispensing position to the container replacement position may be had in only one direction, and that the reverse rotation may be had only in the opposite direction, thus avoiding the possibility of twisting and kinking of the discharge tube. The stop further helps hold the apparatus in its dispensing position. A detent means is provided for insuring the proper orientation of the wall support and funnel portion, and a microswitch is provided to disable the flow of water to the nozzle when the apparatus is rotated for changing of containers. The detent means and the switch means may cooperate with one another.

A locking means is provided to assure that the spray arm and nozzle combination remain pointed upwardly even when the apparatus is rotated to its container changing position. Thus, even if the switch were to fail during the changing of containers, any discharge of solution through the intake opening, now located below the nozzle, would merely be gravity fed leakage of solution not entering the discharge tube, as opposed to pressurized discharge from the nozzle.

Further, a vent hole is provided at the funnel portion directed at such an angle as to provide relief of high pressure build up while not leaking fluids during normal operation. Such a vent hole provides an air intake point, thus allowing for a smooth gravity feed of fluids to the receiving tank.

The foregoing and other objects, features and advantages of the present invention will become more readily apparent from the following specification and appended claims when considered in conjunction with the drawing in which:

FIG. 1 is a perspective view of the invention mounted for dispensing powered materials stored therein;

FIG. 2 is a view of the apparatus of the invention from behind the surface mounting brackets as shown by section lines 2--2 in FIG. 1;

FIG. 3 is a sectional view of the dispensing apparatus and mounting brackets taken along section lines 3--3 in FIG. 2;

FIG. 4 is a view of a portion of the surface mounting bracket attached to the conveying funnel, taken along section lines 4--4 in FIG. 3.

FIG. 5 is a view of the portion of the surface mounting bracket attached to a fixed surface;

FIG. 6 is a sectional view of the conveying funnel bracket taken along section lines 6--6 in FIG. 4;

FIG. 7 is a view of the invention in combination with a protective shroud provided therefor;

FIG. 8 is a sectional view taken along lines 8--8 in FIG. 7;

FIG. 9 is a sectional view of the conveying funnel and bracket of the invention; and

FIG. 10 is a sectional view of the invention rotated into the replenishment position

Referring to FIG. 1, the present dissolving and dispensing apparatus is generally shown at 10. The apparatus includes a container 12, which is preferably a standardized shipping container, having a threaded opening, and a funnel conveying means 14, hereafter funnel means. The threaded opening may be internally or externally threaded, or both.

The funnel means 14 is rotatably mounted to a support mount 16 which is, in turn, fixedly mounted to a vertical support such as a vertical wall adjacent the washing machine, or to a wall of the washing machine itself. As is best seen in FIG. 3, for example, funnel means 14 is generally funnel shaped and includes a wide opening shown at 18. The opening 18 is shown as part of a substantially cylindrical portion 20. A coupling means 22 is fixed to the funnel means 14. While the present embodiment shows the coupling means 22 as being affixed to the intake opening of the funnel, it is appreciated that the container might be coupled to the funnel other than at the opening. That is, a bracket may be provided for coupling the container to the funnel, and the openings may be otherwise connected. Further, while the presently preferred coupling between the container and the funnel is shown as a threaded coupling, the container being externally threaded and the coupling portion of the funnel internally threaded, it is appreciated that, as previously described, the container might be internally threaded, and that the coupling means be externally threaded. Further, other coupling means might be provided, including but not limited to bayonet sleeves and the like.

It is presently contemplated that an advantage of the invention is attained by the use of standardized shipping containers, which, for example, may be 100 mm containers, and which may be quickly and simply coupled with the funnel means 14 without requiring any operator intervention to scoop out or otherwise contact the powder. The containers are preferably formed of a plastic or other material which is at least somewhat translucent. That is, the material of the container is at least sufficiently translucent to permit external observation of the level of the powder remaining therein so that an operator may quickly determine the need for replacement of containers without disturbing the operation of the system. Of course, glass or other transparent materials might be used for the container to provide more accurate observation of the remaining materials.

Further, the present disclosure contemplates the use of containers having granular detergent material therein. It is possible, however, that the material may be provided in solid form, with a granulating component provided in the apparatus for converting the solid (or other material) to a powder for use as herein contemplated.

The support mount 16 may be fixed to the vertical surface by means of attaching devices, shown in FIGS. 1 and 5 as screws 24. Four holes 26 are provided for the screws, as shown in FIG. 2.

A water supply line 28 provides water to the apparatus for dissolving granules of the material. A vacuum protecting device (not shown) may be provided on water supply line 28 to prevent the occurrence of siphoning.

A rotating portion 30 is attached to the funnel means 14.

Support mount 16 includes an indentation 36 and a housing 38 for a microswitch 40. The rotation portion 30 includes a housing 42 for a ball 44, and a biasing spring 46. Ball 44 thus provides a detent means 45 with indentation 36 of the housing 38 formed in support bracket 16. With the funnel means 14 properly positioned so that container 12 is inverted and substantially vertical, ball 44 snaps into indentation 36 activating microswitch 40 which in turn signals the valve to supply liquid to the apparatus and provides proper positioning for the apparatus in its supply position. In an alternative embodiment, ball 44 depresses a pin or button actively connected to microswitch 40. Additionally, ball 44 is used to depress switching arm 48, thereby completing a circuit between wires 50 and 52 connected to microswitch 40. It is appreciated that a single wire may suffice for this purpose, and that the body of the microswitch 40 may be grounded to the support mount 16 by mechanical contact therewith. The wires 50 and 52 (or one wire and ground) form one of the supply paths from a power supply to a conventional solenoid used in a control valve 100 for water in supply line 28. Thus, only when the apparatus is in an appropriately chosen (substantially vertical) position, is the solenoid 100 activated and the valve opened to permit water to pass through line 28. While other fluids may be used in the invention to dissolve the powdered materials, the preferred embodiment utilizes water, preferably hot water, for that purpose. Such a water supply is typically available in a washing environment and is easily provided to the present apparatus, either as a separate supply or as a part of the rinsing system of the machine.

As seen in FIG. 3, rotating portion 30 rotates about a centrally located spindle 31 secured to support mount 16 (as seen in FIG. 2) through opening 47 containing a passage 59 which transmits water through spray arm 58 to nozzle 60. Arm 43 is connected to funnel means 14 and rotates about stationary spindle 31. Spindle 31 has hollow portions 41 which reduce surface-to-surface contact and resulting friction between spindle 31 and arm 43. Collar 33 is connected for rotation with respect to spindle 31 and has a lip 35 which overlies plate 37 of support mount 16 to allow for rotation of funnel means 14 for loading container 12. Lip 35 maintains collar 33 locked onto support mount 16 by attachment means 39, i.e., a screw as shown.

Sealing rings 32a are contained in annular recess 32b circumferentially arrayed about spindle 31. Sealing rings 41a seal spindle 31 to rotating portion 30 to prevent any leakage of liquid from around the spindle. Sealing rings 41a preferably have a figure eight cross section to provide two sealing surfaces on each O-ring surface to sealingly engage inner cylindrical surface 61 of rotating portion 30 and prevent leakage of liquid past spindle 31.

Upon rotation of the apparatus from the vertical dispensing position, the ball 44 is rotated out of indentation 36 so as no longer to depress switching arm 48, thus opening switch 40 and thereby deactivating the solenoid and closing the valve to shut off the supply of water in line 28. Alternatively, switch 40 may be in the rotating portion 30 and the ball and biasing spring mechanism may be in the fixed portion in support mount 16. Moreover, the microswitch actuating mechanism need not be the same as the detent means 45. That is, a separate indentation and ball, with biasing spring having a stiff spring constant, may be used to provide the positioning detent, while a smaller actuating projection, for example, spring loaded by a softer spring, may be used to operate microswitch 40.

Stop 29a is provided on the front face 16a of support mount 16 offset above and to the side of the center of rotation of rotating portion 30 to allow clockwise rotation of the dispenser and chemical container. Stop 29a is secured to support mount 16 by securement means such as screws 25. Lobe 30a is of a shorter radial dimension 34 than lobes 30b and 30c to allow it to rotate past stops 29. Stop 29a is a reversible cylinder placed above the center of rotation of rotating portion 30 so as to not interfere with the rotation of lobe 30a of rotating portion 30. Stop 29a is seen in FIG. 5 as sitting to the upper left of the center of rotation of rotating portion 30. Lobe 30c is stopped by and rests against stop 29a in its dispensing position. In dispensing position, lobe 30c rests adjacent stop 29a and ball 44 is centered over the microswitch 40 to actuate the water valve to initiate water flow into the dispenser. Rotating portion 30 can be rotated clockwise about its center of rotation until lobe 30c abutts against stop 29a and the powder container is in its replenishment position. The presence of stop 29a also helps retain the dispenser in its upright dispensing position resting against stop 29a. Stop 29a also prevents complete rotation of rotating portion 30 as lobe 30b abutts against the opposite side of stop 29a. Stop 29a can be removed and stop 29b added in a position above and to the right of the center of rotation to allow the dispenser to rotate counterclockwise.

Line 28 is shown in FIG. 2 as being coupled to a terminal 54 by nut 56. Terminal 54 provides a connection to water spray arm 58 as shown in FIG. 3, for example. Spray arm 58 terminates in a nozzle 60 which may threadedly engage the arm and spray water, under pressure, in a generally conical distribution. A screen 62 is provided within the funnel means 14 as shown in FIG. 3. The screen is substantially located at the interface between container 12 and funnel means 14. The screen 62 may be retained in place by any of conventionally known means. As shown in FIG. 3, the present embodiment provides a flange 64 on the coupling means 22 for retaining the screen 62 in cooperation with the upper surface of cylindrical portion 20 of the funnel means 14. Coupling means 22 may be pressed onto cylindrical portion 20, may be bonded or welded thereto, or may be otherwise affixed to funnel means 14. It is possible, of course, that the screen may be retained within a circular notch along the periphery of cylindrical portion 20. In one embodiment of the invention, the screen 62 is flat, thus providing for direct gravity feed of powdered materials which pass perpendicularly through the openings of the screen. In another embodiment, the screen is an inverted cone which allows more perpendicular contact of the spray with the screen.

When water is supplied under pressure to nozzle 60, a spray is directed in a broad cone shaped spray at screen 62 as well as at the sidewalls 21 of cylindrical portion 20. Part of the spray penetrates the screen and wets the granules of material immediately in contact therewith, leaving unwetted the ramaining powdered granules. The remaining spray impacts the side walls of cylinder portion 20. The granules are partially dissolved and form a solution which is gravity fed through the openings of screen 62 to the body of funnel means 14. The openings of the screen are chosen to be sufficiently small so as not to permit passage of the granulated material therethrough, yet to allow the spray mist to penetrate the screen to dissolve the powder. In one embodiment, the flat, substantially horizontal positioning of a screen provides holes therein that are substantially vertically oriented and permit for direct passage of the solution of powder therethrough, thus minimizing the formation of a slurry and the clogging of the pores of screen 62 which may occur in portions of a non-horizontally aligned screen. The wetted powder and partial powder-water solution fall from screen 62 and are further mixed with water of the spray impacting the side walls 21 of cylinder portion 20. This addition of water more completely dissolves the powder in cylinder portion 20. Further, the sidewalls of cylindrical portion 20 are provided with the vertical ribs 66 to provide a direction of flow, support and revolution of spray hitting the wall 21 and direct downwardly the flow of any material which may come in contact therewith. The dual action of water spray impacting both the screen 62 and the side walls 21 allows for complete mixing of the powder in water prior to exit from discharge opening 68. The more complete two stage mixing allows screen 62 to be placed closer to nozzle 60. The cone of spray impacts partially dissolved powder and wets granules on screen 62 to provide for a steady feed without the use of mechanical mixers to provide a steady supply of powder.

In an alternative embodiment, screen 62 is shaped as an inverted cone with the wide opening facing nozzle 60.

The nozzle 60 is selected to provide appropriate amounts of liquid to mix with the powder in container 12 to yield a resulting solution having a desired concentration. The concentrated solution produced by the apparatus is gravity fed to an exit, or discharge opening 68. As seen in FIGS. 3, 7 and 8, the exterior of discharge opening 68 is ribbed, in order better to retain a discharge tube 70 attached thereto. Ribs 72 may provide the only retaining force on tube 70, or may be supplemented or replaced by other retaining means. One alternative or supplemental retaining means could be a clamp surrounding the receiving end of tube 70 and tightening the same around discharge opening 68.

Although the discussion herein is in terms of gravity-fed powder and gravity-fed solution, it is possible, of course, to utilize some form of force feeding in the apparatus without substantially departing from the basic advantages thereof.

The rotation portion 30 permits replacement of the powder materials easily and without operator contact with the materials as follows. Upon detecting by external inspection that container 12 is empty, the operator rotates the entire apparatus about the axis of rings 32 and 34 by grasping funnel means 14. Such rotation by 180.degree. results in the empty bottle being in an upright position below the funnel, with the threaded opening of the container above its cylindrical portion as seen in FIG. 10 wherein reference numerals as used in FIG. 3 indicate the same elements. In this position the empty container is threadedly separated from funnel means 14 and a new container is threaded in its place. With the use of standardized shipping containers it is seen that an operator needs only to remove a shipping cap or other seal provided for the container, and need not tear any package, open any box, nor convey by scoop or other means the caustic chemicals from one container to another. The apparatus including the new container is then rotated in the reverse direction, to avoid kinking of discharge tube 70, back to the dispensing position. Interaction of stop 29a prevents rotation of the apparatus in a manner to kink discharge tube 70. It is thus seen that the present invention provides a significant advantage of avoiding the possibility of spillage of or damage by the materials used therein. A further advantage is provided by the preferred embodiment wherein nozzle 60 is retained in its upward pointing position during the replenishment operation hereinabove described. A locking bar, shown at 74 and arms 75 in FIG. 2, are used to prevent the spray arm and nozzle from rotating during rotation of the apparatus. Consequently, even if switch 40 or its controlled solenoid operated valve were to fail during the replenishment operation and the nozzle were to begin spraying, any spray would be upwardly directed towards the discharge opening 68 and discharge tube 70 away from the caustic chemicals. Also the discharge would gravity feed to the screen 62 as described above. The hot materials thus would not be directed at the operator, and would instead be drained into the receiving tank 102 of the associated washing machine. This added safety factor allows other strong substances to be used. Of course, any of the pressurized spray not entering the discharge opening would be incident upon the funnel and would drop gently towards the opening 18, located below the nozzle while the apparatus is inverted and being replenished with the powdered chemicals. While the nozzle may be permitted to rotate, it is an advantage of the present invention that the spray arm and nozzle are fixed and prevented from rotation. As a further safety feature in another embodiment, a locking means (not shown) automatically engages the coupling means 22 during normal dispensing operations. A spring loaded ball engages a hole in the threaded collar and a matching hole in the threaded container opening when the container is inverted, similar to the spring biased ball 44 as previously described. Such an added safety feature would disengage only when the apparatus is rotated to the proper replenishment position, thus further assuring that a careless operator would not harm himself or herself by attempting to remove a container which might still contain its caustic contents. This feature would further assure that under no circumstance could a nozzle spray a screen and direct a pressurized discharge out through opening 18.

As shown in FIGS. 7 and 8, the apparatus of the invention may be provided with a protective shroud 76, together with holding threads to align the container during loading and to provide protection from bumping once in the loaded position. The use of such shrouds permits the use of softer materials to form the containers since the shroud provides positive reinforcement for the outer surface of the container, and extends above the threaded area, reaching a level sufficiently high to maintain support of the container. With coupling threads provided in the shroud, the conveyor funnel may be as shown in FIG. 9, without a coupling for the container. Alternatively, a number of replaceable coupling collars may be provided for the conveyor funnel which may attached thereto to provide a coupling for different sized containers with differing threaded openings. As previously described, the coupling means may be affixed to or formed as a part of the funnel means 14 permanently.

In order to avoid kinking or twisting of the discharge tube 70 and to assure positive safety switch engagement, a pair of positioning stops may be provided. Collar 33 is provided on spindle 31 and projects through opening 47 of support mount 16. Collar 33 is secured to rotating portion 30 by fastening means 39, shown as a screw. Spindle 31 has a loop 78 projecting through opening 47 secures locking bar 74 which is held in place by arms 75 on the back of support mount 16 to prevent rotation and withdrawal of spindle 31. Locking bar 74 retains the spindle inserted through opening 47 in its position. Funnel means 14 connected to rotating portion 30 rotates about spindle 31 from a dispensing position, 180.degree. to a position to allow the operator to change an empty container for a full one. Rotation other than in the permitted directions is prevented by interaction of the lobes of rotating portion 30 and stop 29a. A further stop may be provided to assure that the dispensing position cannot be `overshot`. That is, the stop aligns the apparatus vertically and at a position wherein ball 44 depresses switching arm 48.

The present dissolving and dispensing apparatus may be controlled by manually or electronically operated valves, the latter operated by devices such as electronic timing means, concentration detectors or sequencing operators. Examples of various possible controls are described in U.S. Pat. No. 4,063,663, for example, with reference to FIGS. 5 and 6, and the related text, hereby incorporated by reference. When operated as an hydraulic unit, the associated washing machine should be turned off for loading. A petcock, in line from the rinse section, should be used to meter water flow and provide titration upon a new water fill.

A vent opening 80, shown in FIG. 3, may be provided in the conveying funnel 14. The opening serves three purposes: first, pressure relief is provided for the interior of the funnel during operation; secondly, the vent serves as an air intake to permit smooth gravity feeding of the solution from the funnel to the discharge tube 70; and, finally, the vent provides a safety relief opening should part of the unit become clogged. The opening is angled to assure that none of the solution will leak outwardly.

A shroud 81 covers the vent opening 80 to guide the exit of material from vent 80. The vent 80 opens to the back of the rotating portion 30 and will spray sipport mount 16 or the wall with dissolved chemicals. In a preferred embodiment, the vent 80 is nonclogging, preferably 3/8" in diameter. By forcing exiting chemicals out the back and not out the front, an individual standing in front of the apparatus will not get sprayed by the chemicals evacuated through the relief vent. The vent 80 also provides a backup to eliminate water buildup in the funnel and prevent clogging of the screen.

The preceding specification describes, by way of illustration and not of limitation, a preferred embodiment of the invention. Several equivalent variations of the described embodiment have been provided herein, and others will occur to those skilled in the art. Such modifications, variations and equivalents are within the scope of the invention as recited with greater particularity in the appended claims, when interpreted to obtain the benefits of all equivalents to which the invention is fairly entitled.