Abstract:
A pump system for small fill volumes having a pump unit with a disposable pump head assembly, a controller, a drive motor, and a transmission between the drive motor and the pump unit. A user may enter pump operational data through a controller on the system housing. Operational data may be monitored remotely and through the controller. Access to the pump system is protected through required usernames, passwords, and electronic signatures of system operators.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application is based upon and claims benefit of copending and co-owned U.S. Provisional Patent Application Ser. No. 60/789,792 entitled “Small Fill Volume Pump,” filed with the U.S. Patent and Trademark Office on Apr. 6, 2006 by the inventors herein, the specification of which is incorporated herein by reference. 
     
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    This invention relates to pumping apparatus, and more particularly to a small fill volume pump having disposable components and configured for accurate monitoring and data collection. 
         [0004]    2. Background 
         [0005]    Certain pumping operations lend themselves to use of disposable pump apparatus, or at least pump systems having disposable components that come in contact with the fluid that is to be pumped. Such pumping operations may include, for instance, dispensing chemicals, reagents, or other fluids in the medical, pharmaceutical, cosmetics, and like industries. In these cases, as the damage that might result from cross-contamination of one pumped fluid with another may be catastrophic, simply cleaning the pump components after pumping operations may not be sufficient; rather, to fully protect against such cross-contamination, system components that come in contact with the pumped fluids would desirably be disposed of after a pumping operation on a single fluid. 
         [0006]    Unfortunately, as making a pump assembly disposable typically requires (for purposes of commercial acceptance) that the pump assembly be priced to allow easy replacement, the lower cost requirement has often resulted in pump systems and components of limited utility. For example, peristaltic pumps having disposable tubing for carrying the pumped fluid have been used in pumping operations. However, as many pumping operations in the pharmaceutical, medical, cosmetics, and like industries can require pumping very small volumes, and since peristaltic pumps lack the accuracy and repeatability of positive displacement pumps, they have not been suitable for pumping of such small volumes often required in these industries. Likewise, hand operated syringes have been used for pumping and/or dispensing extremely small volumes of fluid, but the repeatability and accuracy of such operations depends upon the human operator manipulating the syringe, and furthermore takes significantly more time than would an automated pumping operation. 
         [0007]    Still further, such industries as the pharmaceutical, cosmetics, and medical industries are highly regulated, and require manufacturers to maintain data relating to their manufacturing operations in such a way as to allow for data validation, a clear audit trail, and record retention. Thus, those performing operations such as pumping fluids used in the manufacture of new products in those industries may be required to maintain data relating to, among other things, what is being pumped and dispensed, and when. However, while pump systems have previously been available having electronic control systems for operating pump components, to the knowledge of the inventors, there have been no small fill volume pumps of simplistic construction having disposable components that allow for the automated control of the pumping operation and pump data collection and storage capability on board the pump unit, or the capability to remotely monitor the operation of such a pump system. 
         [0008]    It would therefore be advantageous to provide a pump system for small fill volumes have a simplistic construction that is capable of very fine pumping and dispensing operations while maintaining a simple and relatively low cost construction, and that provides for the automated control and data collection and storage on the pump system, and for the remote operational monitoring of such pump system. 
       SUMMARY OF THE INVENTION 
       [0009]    Disclosed is a pump system for dispensing small volumes of fluid. The pump system is configured for quick, easy replacement of disposable components of the system so as to prevent cross-contamination of various fluids processed by the system. The pump system includes a controller that, when accessed by an authorized user, allows the user to set operational parameters, monitor operational data through the controller and remotely across a network, recall operational profiles for specific fluids being dispensed, provide diagnostic tools, and provide security features for operator intervention and logging. 
         [0010]    The various features of novelty that characterize the invention will be pointed out with particularity in the claims of this application. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    The above and other features, aspects, and advantages of the present invention are considered in more detail, in relation to the following description of embodiments thereof shown in the accompanying drawings, in which: 
           [0012]      FIG. 1  is an elevational side view of a pump system according to a first embodiment of the present invention. 
           [0013]      FIG. 2  is a front elevational view of a pump assembly according to a first embodiment of the present invention. 
           [0014]      FIG. 3  is a cross-section view of the pump assembly of  FIG. 2  taken along line  3 - 3 . 
           [0015]      FIG. 4  is a front elevational view of a pump assembly according to an alternate embodiment of the present invention. 
           [0016]      FIG. 5  is a cross-section view of the pump assembly of  FIG. 4  taken along line  5 - 5 . 
           [0017]      FIG. 6  is a top plan view of a pump system according to the present invention. 
           [0018]      FIG. 7  a front elevational view of a pump system according to the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0019]    The invention summarized above and defined by the enumerated claims may be better understood by referring to the following description, which should be read in conjunction with the accompanying drawings in which like reference numbers are used for like parts. This description of an embodiment, set out below to enable one to build and use an implementation of the invention, is not intended to limit the invention, but to serve as a particular example thereof. Those skilled in the art should appreciate that they may readily use the conception and specific embodiments disclosed as a basis for modifying or designing other methods and systems for carrying out the same purposes of the present invention. Those skilled in the art should also realize that such equivalent assemblies do not depart from the spirit and scope of the invention in its broadest form. 
         [0020]    In a particularly preferred embodiment of the invention, and as shown in the side view of  FIG. 1 , a small volume pump system, indicated generally as  10 , is provided comprising a housing  100  having a controller  30 , with an operator interface  47 , mounted on the side of housing  100 , a mounting flange  4  on a front of housing  100 , and a pump assembly (shown generally at  200 ) attached to mounting flange  4 . Pump assembly  200  comprises a pump mounting base  1 , a disposable pump head  2  removably attached to pump mounting base  1 , an inlet  101 , and an outlet  102 . External valves (not shown) are preferably provided in tubing that is attached to inlet  101  and outlet  102  to control the direction of flow in such tubes, allowing the pump assembly  200  to pull product in from a supply and push product out to a dispensing nozzle. Housing  100  is preferably provided a handle  14  allowing the easy transport of the pump system  10 , and a plurality of feet  11  supporting housing  100  above a surface on which it is intended to be used. 
         [0021]    As shown more particularly in the front and cross-sectional views of pump assembly  200  of  FIGS. 2 and 3 , pump mounting base  1  comprises a generally cylindrical block having a flange  17  at its base. The flange  17  is provided a plurality of openings  205  configured to receive a fastener, such as a thumb screw  207  configured for connection with mounting flange  4  on pump housing  100 , thus allowing the entire pump assembly  200  to be quickly connected to and removed from pump housing  100 . Other fasteners may likewise be used without departing from the spirit and scope of the invention. Pump mounting base  1  has a generally cylindrical bore extending therethrough forming a hollow cylinder  210 , which cylinder  210  is configured to receive a piston  3  and to allow for reciprocal motion of the piston  3  (and the piston rod  18  to which it is attached) through cylinder  210 . A resilient sealing member, such as an o-ring  6 , is preferably positioned in the bottom face of pump mounting base  1  so as to provide an air-tight seal between pump mounting base  1  and mounting flange  4  on housing  100 , such that a vacuum may be applied to the interior of the cylinder  210  (as discussed in greater detail below). 
         [0022]    A disposable pump head  2  is removably mounted to the top face of pump mounting base  1 . Pump head  2  is preferably formed of a polymer so as to allow for easy reproduction and, thus, easy replacement at relatively low cost. Pump head  2  is provided a plurality of openings  215  configured to receive thumb screws  7  (or like configured connectors), which thumb screws  7  are configured to be received in threaded openings in the top face of pump mounting base  1 , thus allowing the removable attachment of disposable pump head  2  to pump mounting base  1 . Another o-ring  26  (or other resilient sealing member) is preferably positioned in the top face of pump mounting base  1  so as to provide a fluid-tight seal between disposable pump head  2  and pump mounting base  1 . 
         [0023]    Disposable pump head  2  is preferably provided a hollow fluid chamber  220 , having an inlet port  222  operationally connected to inlet  101  receiving fluid from a fluid source (not shown) and an outlet port  224  operationally connected to outlet  102  for dispensing fluid from the pump assembly  200 . Fluid chamber  220  is closed at its bottom end by a diaphragm  14 , which diaphragm  14  is configured for reciprocating motion in fluid chamber  220  so as to draw fluid into the chamber  220  and push fluid out of the chamber  220  upon movement of the piston  3  away from and towards the chamber  220 , respectively. Diaphragm  14  is preferably formed of a flexible elastomer. Diaphragm  14  is preferably held in place around the bottom of fluid chamber  220  by way of a retaining clip  5 . Because the diaphragm  14  is permanently secured to the pump head  2 , and thus creates a seal, the fluid being pumped never comes in contact with the piston  3 . This allows a user to remove the pump head  2  from the pump mounting base  1  without contaminating the drive or any other components, and likewise allows the user to dispose of the pump head  2  without having to dispose of the rest of the pump system  10 . 
         [0024]    Using a system in accordance with the instant invention, during intake, fluid is pulled into chamber  220  until the stroke of piston rod  18  stops. The rearward movement of piston rod  18 , and resulting rearward movement of piston  3  causes rearward movement of the diaphragm  14  within chamber  220 , creates a vacuum in the fluid tubing causing the fluid to begin moving through inlet port  222  in the direction of the vacuum source. As the pump head  2  reaches the end of its intake cycle, the piston rod  18  reverses direction and moves the piston  3  against the diaphragm  14  back into the chamber  220  increasing the pressure in chamber  220 . The increased pressure causes the fluid in the chamber to begin moving through outlet port  224  to be discharged from the pump head  2 . 
         [0025]    An alternate embodiment of a pump head  2 ′ is shown in  FIGS. 4 and 5 . The inlet port  222   a  and outlet port  224   a  have been moved to the side of the pump head  2 ′. This allows any air in the chamber  220 ′ to be evacuated automatically from the pump head  2 ′ during priming of the pump. 
         [0026]    As shown in the top-down, sectional view of  FIG. 6 , piston  3  is mounted to piston rod  18 , which in turn is configured for reciprocal movement out of and into housing  100 . A slide mount  12 , generally in the form of a spacer block, is mounted to the interior sidewall of housing  100 . A slide  15  is mounted to a free side of slide mount  12 , and is configured to receive a moveable transition mount  16 . More particularly, slide mount  12  includes a transmission that converts the rotary motion of a drive motor  36  ( FIG. 7 ), which rotary motion is transferred into linear displacement of the transition mount  16  along slide  15  through use of a ball screw and nut of standard configuration. A piston rod mount  19  is attached to transition mount  16  and clamps a portion of piston rod  18 , such that movement of transition mount  16  along slide  15  likewise causes movement of piston rod  18 , and thus piston  3 , forward and backward causing fluid in the pump head  2  to be dispensed and drawn in, respectively. A vacuum exhaust port  22  is provided extending through housing  100  so as to allow air to enter and exit the interior of housing  100  upon extending and retracting the piston  3 , respectively. Further, a vacuum fitting  23  is preferably provided at a free end of piston rod  18 , and is configured (when attached to a vacuum source) to pull a vacuum through the center of piston rod  18  using a vacuum pump  325  ( FIG. 1 ). As shown more particularly in the cross sectional view of  FIG. 3 , piston  3  is provided one or more vacuum ports  301  at its tip to aid in drawing diaphragm  14  against piston  3  as it retracts. 
         [0027]    As shown in the front, sectional view of  FIG. 7 , controller  30  is preferably mounted within a cover  31  that is attached to housing  100  via a hinge  33 . A lanyard  43  is preferably attached to cover  31  and to housing  100  to limit the extent to which cover  31  may be opened, thus reducing the risk of damage to controller  30  when opening the housing  100  to service components of the pump system  10 . As shown in  FIG. 7 , a motor  36  is provided inside of housing  100  and, as mentioned above, rotary motion of the motor  36  is transferred into linear motion of the piston rod  18  and piston  3 . Such transfer of motion may use, for example, a pulley  38  such as by way of a drive belt in which rotary motion of the pulley  38  is ultimately transferred to the piston  3  as linear motion. The controller  30  is in communication with the drive motor  36 , the drive motor  36  being mechanically connected to the piston rod  18 . To ensure control of the linear displacement of piston rod  18 , and thus of the operation of the pump system  10 , motor  36  preferably comprises a high precision servomotor. By way of example only, and not by way of limitation, motor  36  may comprise an Allen Bradley type Y series motor. 
         [0028]    Controller  30  preferably includes at least a processor, a data storage device, a user interface  47 , and a communication device allowing remote monitoring of the operational data of the pump system  10 . The user interface  47  preferably includes a display screen, such as a touch sensitive display allowing a user to enter data and control system operation directly through the screen. In an alternate embodiment, the user interface  47  may comprise a separate keyboard or other input device. In some embodiments, the controller  30  may comprise a remote personal computer having data storage capability to record information concerning operation of the drive unit and attached pump components. Controller  30  preferably allows the user to monitor operational data through the display and from a remote location (such as across a wide area network), store predefined dispensing operation parameters for specific fluids, provide diagnostic tools, and provide security features for operator intervention and logging (such as username and password login requirements for engaging the system, accessing data, printing data, etc.). Controller  30  may be connected to a network for data storage, record keeping, and monitoring. In use, a user may use the user interface  47  to enter information identifying the substance to be pumped, such that the controller  30  may recall preset pumping parameters for such substance. Preferably, before the user may have such access to the pump system  10 , they are required to input a username and password, and preferably an electronic signature confirming their operation of the system. During operation, operational data (including identification of the user, identification of the product being pumped, date of the operation, time of the operation, and the volume of the product being pumped) is recorded in a log file. Product dispense data can be sent to secure database units and can be viewed on a company&#39;s intranet or over a wide area network by authorized users. The controller  30  preferably logs all activities for auditing purposes. After the pumping operation is completed, the user may dispose of the pump head  2  or remove and replace the pump head  2  to begin another pumping operation. By disposing of and replacing the pump head  2 , cross-contamination of the fluid products being dispensed is avoided. 
         [0029]    The invention has been described with references to a preferred embodiment. While specific values, relationships, materials and steps have been set forth for purposes of describing concepts of the invention, it will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the specific embodiments without departing from the spirit or scope of the basic concepts and operating principles of the invention. It should be recognized that, in the light of the above teachings, those skilled in the art can modify those specifics without departing from the invention taught herein. Having now fully set forth the preferred embodiments and certain modifications of the concept underlying the present invention, various other embodiments as well as certain variations and modifications of the embodiments herein shown and described will obviously occur to those skilled in the art upon becoming familiar with such underlying concept. It is intended to include all such modifications, alternatives and other embodiments insofar as they come within the scope of the appended claims or equivalents thereof. It should be understood, therefore, that the invention may be practiced otherwise than as specifically set forth herein. Consequently, the present embodiments are to be considered in all respects as illustrative and not restrictive.