KIT, SYSTEM, AND ASSOCIATED METHOD FOR FILLING SEALED DIRECT INJECT DELIVERY CARTRIDGES WITH REFRIGERANT GAS ADDITIVES

A kit defined by various components, a system, and a method for filling a new direct inject cartridge and for refilling an empty used direct inject cartridge. In various embodiments, the invention provides a kit consisting of valves for selectively providing fluid communication between a canister containing a selected volume of at least one selected refrigerant additive and a direct inject cartridge, and for selectively providing fluid communication between a direct inject cartridge and a vacuum pump for filling a direct inject cartridge, and a method for using the disclosed kit and system for filling a direct inject cartridge.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not Applicable.

Not Applicable

BACKGROUND OF THE INVENTION

1. Field of Invention

The invention relates to direct inject sealed delivery cartridges for injecting refrigerant additives, such as drying agents or sealants, into an air conditioning system, such as the chilling system on a refrigerated appliance or an automotive air conditioning system. More specifically, it relates to a kit, system, and an associated method for filling or refilling a direct inject sealed delivery cartridge for refrigerant additives.

2. Description of the Related Art

In the field of maintaining chilling systems, such as automotive air conditioning systems or chilling systems for refrigerated appliances, it is known that refrigerant additives are commonly added to the refrigerant gases. Such refrigerant additives can include sealants, including conditioners for rubber components such as O-rings, lubricants, dyes, such as UV dyes used for leak detection, system enhancers for reducing energy use or improving heat transfer, and drying agents. Frequently, these additives are sold in pre-measured, sealed delivery cartridges designed to inject these additives directly into the HVAC or automobile A/C system without needing to recharge the system first. These pre-measured, sealed delivery cartridges are commonly referred to as “direct injects”. As used herein, “direct injects” or “direct inject cartridges” refer to canister-style, pre-measured sealed delivery cartridges. As recognized by those skilled in the art, direct injects are typically connected via the low pressure side service port. Because many of the refrigerant additives that are frequently used with direct injects are subject to being polymerized or oxidized upon exposure to air, and can be contaminated by moisture in ambient air, the direct inject cartridge is sealed against exposure to the atmosphere or moisture. Further, to avoid the possibility of air or moisture seeping into the sealed direct inject, direct injects are typically sold in sealed, air-tight packages, as seen in Prior Art FIG. 1A. Typically, this package will also contain a desiccant pack.

Those skilled in the art recognize and understand that direct inject cartridges commonly have a Schrader-Type valve disposed at each end and a cylindrical cartridge body disposed between the two valves. These Schrader-Type valves are adapted to engage the service port on the A/C system and similar valves on hoses and vacuum pumps designed to be compatible with an A/C system and the equipment utilized to maintain such a system. Those skilled in the art understand that with a Schrader-Type Valve, the valve opens when pressed and, once disconnected and the pressure on the valve is released, the valve automatically resets and seals. As understood, when manufactured, direct injects are initially filled with nitrogen which is blown through the direct inject cartridge. This step forces oxygen from the cartridge. Then, the refrigerant additive is blown into the cartridge under pressure. When the cartridge is filled with the refrigerant additive, it is not uncommon for excess refrigerant additive to escape the cartridge as it is being removed from the filling apparatus. This excess refrigerant additive is typically exposed to the atmosphere, thereby potentially exposing those working on the filling process to the refrigerant additives. Further, those skilled in the art will recognize that canister-style direct injects are single-use products and are considered disposable. This results in the metal and plastic components of the direct inject ending up in a landfill and the attendant risk of the landfill being exposed to chemical residue associated with the additives previously contained within the direct inject.

What is missing from the art is a kit and associated system for quickly and efficiently refilling a direct inject cartridge so that the direct inject cartridge can be reused. What is further missing from the art is a method of filling a direct inject cartridge, either filling the direct inject cartridge initially during manufacture or refilling the direct inject cartridge for reuse, that utilizes a closed, or sealed system that minimizes release of refrigerant additive to the atmosphere and that allows used direct inject cartridges to be recycled, refilled, and reused thereby reducing the burden of chemical, plastic, and metal waste currently being disposed and burdening landfills.

BRIEF SUMMARY OF THE INVENTION

The present invention is directed towards various components, assemblies, and methods for filling a new direct inject cartridge and for refilling an empty used direct inject cartridge. In various embodiments, the invention provides a kit of components that may be provided together and used, in conjunction with a vacuum pump for filling a direct inject cartridge, a system in which the components are assembled and interact to facilitate filling a direct inject cartridge, and a method for using the disclosed kit and system for filling a direct inject cartridge.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed towards various components, assemblies, and methods for filling a new direct inject cartridge and for refilling an empty used direct inject cartridge. In various embodiments, the invention provides a kit of components that may be provided together for filling a direct inject cartridge, a system in which the components are assembled and interact to facilitate filling a direct inject cartridge, and methods for filling a direct inject cartridge. The kit and the system are adapted for use in the disclosed method. As used herein, the terms “direct inject” and “direct inject cartridges” refer to canister style pre-measured sealed delivery cartridges having self-sealing Schrader-Type valves, referred to herein simply as Schrader valves and which are designed to inject refrigerant additives directly into an air conditioning system. Such refrigerant additives can include sealants, including conditioners for rubber components such as O-rings, lubricants, dyes, such as UV dyes used for leak detection, system enhancers for reducing energy use or improving heat transfer, drying agents, or a combination of two or more of such additives. As used herein, the phrase “air conditioning system” refers broadly to an HVAC system, a chilling system for a refrigerated appliance such as refrigerators, freezers, room air conditioners, small ice makers, wine coolers, etc., or an automotive air conditioning system.

As illustrated in FIGS. 3 and 4A, 4B, 4C, and 4D kit 10 is provided for filling, or refilling direct inject cartridge 20. It will be appreciated by those skilled in the art that direct inject cartridge 20 has a first end 25 that has a self-sealing valve, which in an exemplary embodiment is an externally threaded Schrader valve and a second end 35 that has a self-sealing valve, which, in an exemplary embodiment, has a Schrader valve with an internally threaded Schrader valve chuck. Direct inject cartridge 20 also includes a cylindrical body 30 which is adapted to contain a selected refrigerant gas additive. As discussed above, such refrigerant additives can include sealants, including conditioners for rubber components such as O-rings, lubricants, dyes, such as UV dyes used for leak detection, system enhancers for reducing energy use or improving heat transfer, drying agents, or a combination of two or more of such additives.

A canister 40 is provided which is filled with the refrigerant additive. In an exemplary embodiment, canister 40 contains only the refrigerant additive under at least a partial vacuum. Canister 40 is under negative pressure, in an exemplary embodiment at least a partial vacuum to ensure that the refrigerant additive within canister 40 is not exposed to atmospheric air which could oxidize or polymerize the refrigerant additive.

As will be understood by those skilled in the art, typically, a state-of-the-art aerosol canister in this art contains the refrigerant gas, or refrigerant gas additive, that is intended to be dispensed along with a pressurized gas or liquified gas, typically, a hydrocarbon gas, compressed air, or a fluorocarbon gas, collectively referred to herein as “the propellant”. The pressure of the propellant is what propels the contents of the aerosol canister out of the canister when the self-sealing valve is actuated. And, it will be recognized by those skilled in the art, that a state-of-the-art hose and can tap valve 4, as illustrated in FIG. 1B, includes a fitting 6, a gauge 5, and an actuator knob 8. When the fitting 6 is threadably connected to the self-sealing valve of a conventional aerosol can, actuator knob 8 is used to selectively drive a moveable piercing pin, or valve depressor, into the self-sealing valve.

However, with the refrigerant additives utilized with the present invention, use of such a propellant creates an attendant risk of oxidizing or polymerizing the additive and also risks the propellant itself being injected into cartridge 40. This is not desirable because the propellant could contaminate the chilling system being worked on by a technician using direct inject cartridges for introducing a refrigerant additive into the chilling system. Unlike typical aerosol cans which utilize a propellant, canister 40 only contains the refrigerant additive, preferably under negative pressure. Canister 40 includes a self-sealing valve 45 adapted to release the refrigerant additive contained therein only when the valve is actuated. In an exemplary embodiment, self-sealing valve 45 is defined by an externally threaded self-sealing valve.

The kit 10 further includes a first valve member 60, which is disposed between canister 40 and direct inject cartridge 20. First valve member 60 includes a first end 62 adapted to threadably engage and actuate self-sealing valve 45. As illustrated in FIGS. 4C and 4D, first valve member 60 serves as a can tap and includes a threaded collar 62, a pin 68, and a Teflon seal O-ring 64 to ensure a proper seal with canister 40. Pin 68 engages, and opens, the self-sealing valve 45 of canister 40. As will be understood, pin 68 is hollow and includes an orifice 69 which allows the contents of canister 40 to flow through pin 69, and first valve member 60. Unlike a conventional can tap, pin 68 is fixed relative to the body of first valve member 60. Flow of the contents of canister 40 is selectively actuated by operation of valve actuator 65.

First valve member 60 further includes a second end 66 defined by a Schrader valve chuck and is adapted to engage first end 25 of direct inject cartridge 20 and actuate the Schrader valve of first end 25. First valve member 60 further includes a valve actuator 65 for selectively opening and closing the valve of first valve member 60. While various types of valves could be utilized, in an exemplary embodiment, first valve member 60 is a ball valve. First valve member 60 is adapted to provide selectively actuated fluid communication between canister 40 and direct inject cartridge 20.

Kit 10 also includes a second valve member 80 which is disposed between direct inject cartridge 20 and a vacuum pump 15. Second valve member 80 includes a first end 82 adapted to threadably engage the Schrader valve chuck of second end 35 of the direct inject cartridge 20 and thereby actuate the Schrader valve of second end 35. Second valve member 80 further includes a second end 86 adapted to engage a vacuum port provided on vacuum pump 15. Second valve member 80 further includes a valve actuator 85 for selectively opening and closing the valve of second valve member 80. While various types of valves could be utilized, in an exemplary embodiment, second valve member 80 is a ball valve. Second valve member 80 is adapted to provide selectively actuated fluid communication between direct inject cartridge 20 and vacuum pump 15.

As seen in FIG. 3B, kit 10 optionally includes a filter 70 as a safety precaution for protection of pump 15. In this regard, filter 70 is adapted to catch any refrigerant additive that may flow through direct inject cartridge 20 inadvertently due to an accidental opening of valve actuator 65 while valve actuator 85 is either completely or partially opened.

In one aspect of the present invention, the disclosure provides a system that utilizes kit 10 for filling a new direct inject cartridge 20 or refilling a used direct inject cartridge 20. In accordance with the disclosed system, the components of kit 10 are assembled together as described above, and the second valve member 80 is connected to the vacuum port provided on vacuum pump 15. The components of kit 10 are assembled and, in cooperation with pump 15, operate in functional cooperation to fill direct inject cartridge 20 as will be described hereinbelow.

An alternate embodiment of the kit of the present invention is illustrated in FIG. 5. As illustrated in FIG. 5, kit 10′ is provided for filling, or refilling direct inject cartridge 20. Kit 10′ is adapted to provide selective fluid communication between direct inject cartridge 20 and either canister 40 or vacuum pump 15. As described above, direct inject cartridge 20 has a first end 25 that, in an exemplary embodiment is an externally threaded Schrader valve and a second end 35 that, in an exemplary embodiment, has a Schrader valve with an internally threaded Schrader valve chuck. Direct inject cartridge 20 also includes a cylindrical body 30 which is adapted to contain a selected refrigerant gas additive. A canister 40 is provided which is filled with the refrigerant additive. In an exemplary embodiment, canister 40 contains only the refrigerant additive under negative pressure. Canister 40 includes a self-sealing valve 45 adapted to release the refrigerant additive contained therein only when the valve is actuated.

The kit 10′ further includes a first valve member 60 which is disposed between canister 40 and a T-fitting 90 that is threadably engaged with direct inject cartridge 20 in order to provide fluid communication between first valve member 60 and direct inject cartridge 20. First valve member 60 includes a first end 62 adapted to threadably engage and actuate self-sealing valve 45. First valve member 60 further includes a second end 66 adapted to engage T-fitting 90. T-fitting 90 includes a Schrader chuck that engages the first end 25 of direct inject cartridge 20 and actuate the Schrader valve of first end 25. First valve member 60 further includes a valve actuator 65 for selectively opening and closing the valve of first valve member 60. First valve member 60 acting with T-fitting 90 provides selectively actuated fluid communication between canister 40 and direct inject cartridge 20.

Kit 10′ also includes a second valve member 80′ which is disposed between T-fitting 90 and vacuum pump 15. Second valve member 80′ is adapted to threadably engage the T-fitting 90 and provide fluid communication between vacuum pump 15 and T-fitting 90 and thereby provide fluid communication between pump 15 and direct inject cartridge 20. A hose 95 is optionally provided between second valve member 80′ and vacuum pump 15. Second valve member 80′ further includes a valve actuator 85′ for selectively opening and closing the valve of second valve member 80′. Second valve member 80′ is adapted to provide selectively actuated fluid communication between direct inject cartridge 20 and pump 15. As discussed above, kit 10′ can also include filter 70. Kit 10′ can also optionally include a filter 70.

Referring to FIG. 6, the method of using kit 10 to fill, or to refill, direct inject cartridge 20 will now be described. At step 110, canister 40 is attached to first valve member 60. As described above, canister 40 contains a selected refrigerant additive, preferably under negative pressure. First valve member 60 is confirmed closed, step 120, by ensuring that valve actuator 65 is in the closed position, as illustrated in FIG. 2A. First valve member 60 is attached to the direct inject cartridge 20; and, second valve member 80 is also attached to direct inject cartridge 20 at step 130. At step 140, the second valve member 80 is attached to vacuum pump 15. Optionally, filter 70 could be positioned between second valve member 80 and vacuum pump 15. Second valve member 80 should be confirmed to be in the open position at step 150. FIG. 2B illustrates first valve member 60 being in the closed position and second valve member 80 being in the open position. It should be understood that so long as steps 110, 120, 130, 140 and 150 are performed, the sequence or order of performing these steps is not critical.

Once steps 110, 120, 130, 140 and 150 are performed, vacuum pump 15 is activated, step 160, and allowed to run for a selected period of time, step 170. The time for running vacuum pump 15 will depend on the size of the direct inject cartridge, however, allowing vacuum pump to run at least ten seconds, in one exemplary embodiment, and for at least between ten seconds and thirty seconds in a further exemplary embodiment, should be sufficient. After this period of time, and while the vacuum pump is still running, second valve member 80 is rotated back to the closed position, step 180, as illustrated in FIG. 2A, and, vacuum pump 15 is deactivated. The actuator 65 of first valve member 60 is then rotated to the open position, illustrated in FIG. 2C, step 190, and direct inject cartridge 20 is allowed to fill with refrigerant additive. Once direct inject cartridge 20 is filled with refrigerant additive, actuator 65 of first valve member 60 is rotated to the closed position, step 200, and first valve member 60 and second valve member 80 are removed from direct inject cartridge 20, step 210.

It will be appreciated that while a technician could use the system of the present invention, including kit 10, and associated method 100 to fill used direct inject cartridges 20 while on a job site, a technician could also refill used and empty direct inject cartridges 20 in a workshop environment prior to going to a jobsite or upon returning from a jobsite. Alternatively, the technician could perform the second part of step 130, i.e., connecting second valve member 80 to direct inject cartridge 20, and perform steps 160, 170, 180, to a plurality of direct inject cartridges in one location. Then the technician could perform steps 110, 120, the first part of 130, and steps 190 and 200, to this plurality of previously evacuated direct inject cartridges 20 in a different location.

Further, the kit 10 and associated method 100 also provide flexibility and allow the technician to be prepared for a variety of scenarios. Rather than carrying a large variety of direct inject cartridges of various capacities and with various refrigerant additives, a technician could carry a plurality of empty direct inject cartridges 20 that have already been evacuated by steps 110 through 180 of method 100. The technician could also carry a plurality of canisters 40 that contain a variety of refrigerant additives. Once the technician has diagnosed the problem at the jobsite and identified the necessary refrigerant additive, the technician could then fill the evacuated direct inject cartridges 20 with the appropriate refrigerant additive by attaching the appropriate canister 40 to the first valve member 60 and attaching the first valve member 60 to the direct inject cartridge 20 and executing steps 190 and 200 of method 100 and removing the first valve member 60 from the direct inject cartridge 20 and the canister 40.