Injection system

An injection system for injecting one or more additives into a pressurizable container for use with a filling system providing a flow of fluid into the pressurizable container, the injection system comprising: (a) a delivery system adapted for transferring at least one additive from a source of the additive to at least one portal; and (b) at least one portal operatively connectable between the delivery system and the filling system, the portal defining an internal space and having at least a first configuration and a second configuration, in the first configuration, the internal space being adapted to receive additives from the delivery system while being fluidly isolated from the filling system, in the second configuration, the internal space being in fluid communication with the filling system such that any additive deposited therein is carried into the container by the flow of fluid provided by the filling system.

FIELD OF INVENTION
 The present invention relates generally to the filling of pressurizable
 containers. More specifically, the present invention relates to the
 introduction of additives, such as oils, surfactants, stabilizers, dyes
 and odor agents, during the filling of pressurizable containers.
 BACKGROUND OF THE INVENTION
 Containers of pressurized fluid are ubiquitous in a modern society and
 include, for example, jugs of refrigerant for charging refrigeration
 systems and tanks of propane for heating. Such containers typically are
 charged under pressure using a filling system. A conventional filling
 system comprises a central tank for storing the fluid, conduit for
 connecting the central tank to one or more filling stations, one or more
 pumps to motivate fluid flow toward the fill station(s), and typically a
 programmable controller for controlling the filling system's operation. A
 conventional filling system tends to be a specialized apparatus, and, as
 such, tends to represent a significant capital expenditure. Therefore, to
 maximize its utility, a filling system usually is configured to
 accommodate a number of fill stations, thereby increasing the number of
 containers that can be filled at a given time. To this end, the conduit
 usually comprises a common section from which a number of leader sections
 extend, each leader section supplying a particular fill station. In
 operation, the filling system initially pulls a vacuum to evacuate
 residual fluids, impurities and/or air from each container connected to a
 fill station. Once the containers have been evacuated, the system
 transfers fluid from the central tank to the individual containers at
 relatively high pressure, for example, usually between 50 psi and 2000
 psi.
 Aside from the fluid, it is often preferable to introduce one or more
 additives to the container. As used herein, an "additive" is any substance
 that is added to the container to render the fluid detectable to the
 senses, to improve the performance of the fluid, or to improve performance
 of apparatus using the fluid. Such additives are well known in the art.
 For example, dyes may be added to refrigerants and other fluids used in
 circulating systems to provide operators with a visual indication of a
 leak so as to avoid an unnecessary atmospheric release of the fluid and to
 keep the system operational. In situations where the fluid is explosive or
 toxic and the early detection of a leak thereof is critical to minimizing
 danger, an odor agent such as a mercaptan can be added to the container.
 It also may be preferable to add oil or other lubricants to fluids used in
 machinery having wearing components such as refrigeration units.
 One approach to introducing an additive to a pressurizable container is to
 mix it in the central tank of a filling system and then use the filling
 system to distribute the fluid/additive mixture through the conduit to the
 various containers. Such an approach is appealing because it uses the
 existing filling system to pump the additives to all the containers.
 Additionally, it allows the additives to be mixed with the fluid in bulk
 fashion and distributed among the individual containers during the course
 of ordinary filling. Unfortunately, although efficient, this approach
 tends to contaminate the filling system with the additives. This is
 particularly problematic since a common filling system usually is employed
 to fill containers with a variety of different fluids, some of which not
 only do not require such additives, but are compromised by such additives.
 For example, it is generally preferred that fluids such as alcohol,
 kerosene, and water remain crystal clear so as to ensure their purity.
 Color in the fluid may serve to mask or suggest an impurity.
 Another approach to introduce additives in pressurizable containers is to
 have a dedicated fill station for a particular fluid and a combination of
 additives. Although this takes advantage of a centralized facility for
 injecting additives and avoids the problem of contamination mentioned
 above, the expense of a dedicated system is prohibitive and renders such
 an approach impractical. Also, seasonal products, such as refrigerants and
 propane tanks, are commonly filled during "campaigns," in which many
 cylinders are filled in a relatively short time span, thus necessitating
 many filling stations.
 Therefore, a need exists for a system and method of supplying additives to
 a pressurizable container that can be used with an existing system, but
 which avoids contaminating the filling system. The present invention
 fulfills this need among others.

DESCRIPTION OF THE INVENTION AND PREFERRED EMBODIMENTS
 The present invention provides for the introduction of one or more
 additives in a container by introducing the additives through a portal in
 a filling system. The portal functions to receive one or more additives
 and then to facilitate their transfer into one or more containers by
 exposing them to the flow of fluid provided by the filling system. Thus,
 the present invention uses ordinary fluid flow in the filling system to
 carry the additives into the container. Furthermore, the invention uses
 the fluid flow to flush the filling system clean of the additives, thereby
 eliminating any contamination resulting from the filling system's exposure
 to the additives. Contamination can be reduced further by locating the
 portal near the container to minimize the filling system's exposure to the
 additives.
 One aspect of the invention is an injection system for delivering one or
 more additives into a pressurizable container for use with a filling
 system adapted for providing a flow of fluid into the pressurizable
 container. In a preferred embodiment, the injection system comprises: (a)
 a delivery system adapted for transferring at least one additive from a
 source of the additive to at least one portal; and (b) at least one portal
 operatively connectable to the filling system and the delivery system, the
 portal defining an internal space and having at least a first
 configuration and a second configuration, in the first configuration, the
 internal space is in fluid communication with the delivery system to
 receive additive therefrom while being fluidly isolated from the filling
 system, in the second configuration, the internal space is in fluid
 communication with the filling system such that any additive deposited
 therein is carried into the container by the fluid flow provided by the
 filling system.
 Another aspect of the invention is a portal as described above adapted for
 integration with an existing filling system. In a preferred embodiment,
 the portal comprises an upstream connection point adapted for connection
 to conduit of a filling system and a downstream connection point adapted
 for connection to the conduit downstream of the upstream connection point.
 Still another aspect of the invention is a delivery system adapted for
 interfacing with one or more portals. In a preferred embodiment, the
 delivery system comprises: (a) a tank adapted to store one or more
 additives; (b) delivery conduit adapted to connect the tank to one or more
 portals; and (c) a transfer device adapted to transfer the additives from
 the tank to the portal(s).
 Yet another aspect of the invention is a mobile delivery system adapted for
 interfacing a portal. In a preferred embodiment, the portable delivery
 system comprises: (a) a movable platform; (b) a tank mounted on the
 platform and adapted to store one or more additives; (c) delivery conduit
 adapted to connect the tank to a portal; and (d) a transfer device adapted
 to transfer the additives from the tank to the portal.
 A further aspect of the invention is a method for injecting one or more
 additives in a container using an existing filling system. In a preferred
 embodiment, the process comprises: (a) configuring a portal in a first
 configuration such that its internal space is sealed from the filling
 system and is in fluid communication with the delivery system; (b)
 facilitating deposition of the additive in the internal space of the
 portal preferably by maintaining the portal in the first configuration for
 a sufficient time to allow the delivery system to deposit the additive
 into the internal space; and (c) configuring the portal in a second
 configuration such that it is sealed from the delivery system and in fluid
 communication with the filling system, thereby allowing any additive
 deposited in the internal space to be carried into the container by the
 flow of fluid provided by the filling system.
 Further, another aspect of the invention is a controller configured to
 control the configurations of a portal to effect the process described
 above.
 Referring to FIG. 1, a preferred embodiment of the present invention is
 shown integrated with a conventional filling system 10. As mentioned
 above, a conventional filling system typically comprises one or more tanks
 for blending and storing the fluid(s). The fluid is pumped from the
 storage tanks to the filling stations via a conduit system. A typical
 conduit system comprises a main conduit line operatively connecting to the
 central tank(s), the pumps, and a plurality of leader sections. Each
 leader section is connectable to a single container. A filling system also
 comprises a programmable controller to control the evacuation of the
 containers and to transfer the fluid from the central tank through the
 conduit system and into the individual containers.
 The injection system of the present invention interfaces with the filling
 system along the leader section 17 as shown in FIG. 1. The injection
 system comprises a portal 12 operatively connected to a leader section 17
 and a delivery system 13 operatively connected to the portal 12. Although
 the injection system of the present invention may be interfaced with the
 filling system at any point along the conduit system, preferably it is
 connected to a leader section to minimize the filling system's exposure to
 the additives. In other words, rather than systemically exposing the
 filling system to the additives, only the portion of the leader section
 17a downstream of the portal is exposed. Additionally, this configuration
 allows other fill stations (not shown) to be used independently from the
 injection system.
 The portal 12 functions to receive the additives from the delivery system
 and then to facilitate their transfer into the container(s) by exposing
 them to the flow of fluid provided by the filling system. Suitable portals
 include any device capable of interfacing a certain volume between two or
 more systems without, at any time, connecting the systems. This way, the
 systems remain separate, allowing them to contain different materials at
 different conditions (e.g., pressure and temperature). To achieve this
 functionality, the portal preferably has an internal space and at least
 two configurations. In the first configuration, the internal space is
 adapted to receive additives from the delivery system while being fluidly
 isolated from the filling system. In the second configuration, the
 internal space is in fluid communication with the filling system such that
 any additive deposited therein is carried into the container by the fluid
 flow provided by the filling system. The following is merely
 representative of suitable portals having the above-mentioned
 functionality:
 (1) Devices having: (a) a chamber connected to two or more systems; and (b)
 valving for alternately connecting the chamber to one of the systems.
 (2) Devices having (a) a vessel having a circular cross-section and one or
 more radially-disposed orifices therein; and (b) a sleeve rotatably
 mounted around the vessel and having radially-disposed ports connected to
 two or more systems. The vessel being in fluid communication with a system
 when the vessel or the sleeve is rotated such that an orifice of the
 vessel aligns with the port of the sleeve connected to the system.
 (3) Devices having (a) a vessel having a circular cross section and a
 plurality of radially-disposed ports connected to two or more systems; and
 (b) a rotor disposed within the vessel defining one or more fluid channels
 within the vessel depending upon its radial position relative to the
 vessel. The vessel being in fluid communication with a system when the
 fluid channel defined by the rotor includes the port(s) connected to the
 system.
 (4) Devices having (a) a vessel connected to two or more systems; and (b)
 interlocking, movable partitions therein for alternately connecting the
 vessel to one of the systems to facilitate fluid communication
 therebetween.
 In FIG. 1, a preferred embodiment of the portal 12 is shown. A preferred
 embodiment of portal 12 comprises a chamber 20, which defines an internal
 space 20a and is connected at an upstream end 5 by a first valve 32 and at
 a downstream end 6 by second valve 35. In this embodiment, the first valve
 32 is a three-way valve connected to the delivery system 13, the filling
 system 10 along the leader section 17, and the chamber 20. The first valve
 32 has two positions. In the first position, delivery system 13 is in
 fluid communication with the chamber 20, and, in the second position, the
 filling system 10 is in fluid communication with the chamber 20. Although
 a three-way valve is shown in FIG. 1, it is well known that two two-way
 valves can accomplish the same function. Specifically, one two-way valve
 can connect the filling system to the chamber, another two-way valve can
 connect the delivery system to the chamber, and the two valves can be
 interlocked such that only one is opened at a given time. Referring back
 to FIG. 1, the second valve 35 is a two-way valve having an open and
 closed position. In the open position, the internal space 20a is in fluid
 communication with a downstream portion of the leader section 17a
 connected to an individual container 18. In the closed position, this
 fluid communication is interrupted. Although the three-way valve and the
 two-way valve are shown at the upstream and the downstream ends of the
 chamber 20, respectively, it is known that their positions may be switched
 such that a two-way valve connects the upstream end 5 of the chamber with
 the filling system and the three-way valve connects the downstream end 6
 of the chamber with the pressurizable container and the delivery system
 without affecting the portal's operation.
 The portal configuration depicted in FIG. 1 facilitates: (a) the evacuation
 of the container(s); (b) the introduction of additives into the filling
 system; and (c) the injection of additives and fluid into container.
 Specifically, container 18 is evacuated by opening the second valve 35 and
 disposing the first valve 32 in the second position thereby facilitating
 fluid communication between the filling system 10 and the container and
 enabling the filling system to evacuate the container 18. Once the
 container 18 is evacuated, the second valve 35 is closed and the first
 valve 32 is switched to the first position thereby establishing fluid
 communication between the delivery system 13 and the chamber 20 and
 enabling the delivery system to transfer the additive into the internal
 space 20a. Next, the first valve 32 is switched to the second position
 thereby reestablishing fluid communication between the filling system 10
 and the chamber 20 and the second valve is switched to an open position,
 thereby allowing the flow of fluid provided by the filling system 10 to
 carry the additive deposited in the internal space 20a into the individual
 container 18.
 The delivery system 13 is configured to deliver the additive to portal 12.
 Suitable delivery systems include conventional fluid handling systems
 which are well known in the art. A preferred delivery system 13 is shown
 in FIG. 1. As shown, a central tank 14 holds the additive and a conduit 15
 operatively connects the tank to the portal 12. To transfer the additive
 from tank 14 to portal 12, a transfer device 16 may be used. In situations
 where the additive may separate or where mixing is otherwise desirable,
 the delivery system 13 also may comprise an agitator (not shown) within
 tank 14 for mixing the additive.
 The transfer device 16 may be any known device for moving fluid. Suitable
 devices include, for example, centrifugal pumps, positive displacement
 pumps, and any other device which effects a flow of fluid toward the
 portal 12. Preferably, the transfer device 16 is a pump (either
 centrifugal or positive displacement) for moving the fluid from tank 14 to
 portal 12.
 The conduit 15 may be any conventional conduit for directing the fluid
 therein. Preferably, conduit 15 is suitable to be pressurized. More
 specifically, in the preferred embodiment transfer device 16 is a pressure
 increasing device, for example, a pump, which pressurizes the conduit
 downstream thereof. By pressurizing the conduit 15, the additive readily
 fills the internal space when access to the portal is provided.
 Pressure-rated conduits are well known in the art.
 In a preferred embodiment, especially where the additive benefits from
 mixing, a return conduit 22 is used to form a circuit with the conduit 15
 for unused additive to return to the tank 14. This way, additive is
 continuously circulated down conduit 15 and back to the tank through
 conduit 22 where it is reintroduced to the tank 14. Mixers or agitators
 may be added to achieve more intense mixing.
 It also may be preferable to configure the delivery system 13 to handle a
 plurality of fill stations. More specifically, the delivery system 13 can
 be configured to interface with two or more of the fill stations supplied
 by filling system 10. The advantage of this is the same as with the
 filling system in that a central tank or tanks and transfer device(s) can
 be used to accommodate a plurality of fill stations, thereby achieving
 economies of scale.
 FIG. 1 is a schematic diagram of the injection system of the present
 invention adapted to accommodate two or more fill stations 43. More
 specifically, drum pump 16 is configured to pump the additive from tank 14
 through conduit 15 to a plurality of fill stations 43. Each fill station
 43 is connected to conduit 15 through a branch conduit 51. The branch
 conduit 51 comprises a check valve 29 to prevent the back flow of fluid
 into the delivery system 13 in the event valve 32 malfunctions. An inlet
 valve 28 downstream of check valve 29 controls the flow of additive in a
 portion of the branch conduit 51 and a high pressure indicator 30 ensures
 that the injection system is not over pressurized. The portal 12 is
 connected at the downstream end of the branch conduit 51. A downstream
 leader section 17a extends from the portal 12 and is operatively
 connectable to a container 18.
 As shown in FIG. 1, conduit 15 connects two or more fill stations and then
 returns to tank 14 through return conduit 22. Although the fill stations
 may be connected in series, it is preferable for the fill stations to be
 connected in parallel. To this end, the delivery system comprises a first
 manifold 38 having an inlet 24 for receiving additive from the drum pump
 and a plurality of outlets 25 for supplying branch conduit 51. Each branch
 conduit 51 supplies a fill station 43 as described above. As mentioned
 above, it may be preferable in certain circumstances to employ a delivery
 system which circulates the additive. As shown in FIG. 1, a second
 manifold 40 is used which has a plurality of inlets 26, each inlet
 connected to a branch conduit 51, and an outlet 27 connected to a return
 conduit 22. Accordingly, additive is pumped from tank 14 into the first
 manifold 38 where the flow is split into branch conduit 51. A portion of
 the flow passes through the check valve 29 as described above while the
 remaining portion flows into second manifold 40 where it is combined in
 return conduit 22 and pumped back to the tank where it can be
 re-circulated.
 Rather than configuring the delivery system 13 to accommodate a plurality
 of fill stations, a single, mobile delivery system may be used to
 accommodate a number of individual fill stations. FIG. 2 shows a preferred
 embodiment of a mobile delivery system. As shown, the mobile delivery
 system comprises a cart 47 or other known mobile platform on which is
 mounted a tank 46 operatively connected to a pump 45 by a connector 55.
 The tank 46 may have a level gauge 56 so that the operator can readily
 determine the amount of available additive remaining in the tank. A hose
 48 is used to connect the pump to the portal 12.
 It may be preferable to control the amount of additive introduced into the
 individual containers. To this end, a metering system may be employed.
 Suitable metering systems are known in the art and include, for example,
 devices for controlling flow of fluid, such as a metering pump, and
 devices for measuring a predetermined amount of fluid, such as a
 calibrated vessel or a syringe pump.
 In a preferred embodiment, a metering system comprises a calibrated portal.
 More specifically, as depicted in FIG. 1, portal 12 comprises a chamber 20
 calibrated such that it delivers a known quantity of additive to the
 individual containers. The chamber may be calibrated in different ways.
 For example, graduated marks may be inscribed on the chamber such that an
 operator can determine the amount of additive deposited therein.
 Preferably, however, the entire volume of the chamber is calibrated such
 that, when filled, it contains the desired amount of additive.
 Alternatively, a metering pump can be used to limit the flow of additive
 into the portal to a predetermined amount. For example, the pump 45
 equipped with the mobile delivery system 57 depicted in FIG. 2 may be a
 metering pump.
 It may be preferable for the injection system of the present invention to
 comprise a controller 70 for automatically controlling the injection of
 additive into the containers. The control functionality may be housed in a
 discrete controller dedicated to the injection system, but preferably is
 integrated with the filling system's programmable controller described
 above. Accordingly, the controller may be adapted to control the filling
 system, the delivery system, the various configurations of the portals and
 combinations thereof depending upon the specific structure of the
 injection system and its integration with the filling system.
 As mentioned above, in a preferred embodiment, the delivery system is
 pressurized such that additive enters the internal space as soon as fluid
 communication between the portal and the delivery system is established.
 This embodiment of the delivery system requires little control and
 operates on demand like tap water. Accordingly, the control of the
 injection system may be focused on the portal.
 For illustrative purposes, the configuration of controller will be
 described in greater detail with respect to a preferred embodiment
 depicted in FIG. 1, in which the portal comprises a three-way valve 32
 connected to a chamber 20 which in turn is connected to a two-way valve
 35. To facilitate remote control of the valves by the controller, valves
 32 and 35 have actuators 32a and 35a, respectively, as shown. Valves
 actuators are well known in the art and include, for example, air-operated
 actuators, and electrical solenoid valves. The controller is operatively
 connected to the actuators and has logic which is integrated or otherwise
 interfaces with the logic of the filling system to perform the following
 steps:
 (a) configuring the portal 12 in the second configuration by opening the
 second valve 35 and positioning the first valve 32 in the second position:
 (b) facilitating evacuation by maintaining the portal in the second
 configuration for a time sufficient for the filling system to evacuate the
 container 18;
 (c) configuring the portal 12 in the first configuration by closing the
 second valve 35 switching the three-way valve 32 to a first position;
 (d) facilitating the deposition of additive in the portal by maintaining
 the portal in the first configuration for a sufficient time to allow the
 delivery system to fill the calibrated section 20; and
 (e) facilitating injection of the additive into the container by
 configuring the portal in the second position by switching the first valve
 to the second position and opening the second valve, thereby exposing the
 additive in the chamber to the flow of fluid provided by the filling
 system such that the flow carries the additive into the container while
 filling the container.
 Accordingly, the injection system of the present invention can be automated
 such that it accommodates a plurality of fill stations by automatically
 actuating the valving necessary to configure the portal and inject the
 additive.
 Optionally, a scale 37 or other level indicator may be used to monitor the
 amount of available additive. Such a level indicator may be integrated
 with the controller to sense when levels are running low or to control the
 amount of additive being injected.
 As described above, the system of the present facilitates the injection of
 additives into pressurizable containers. Although the system is suitable
 for use with most fluids, it has been found to be particularly effective
 for use with halogenated compounds, especially refrigerants, such as
 tetrafluoroethane (HFC-134a). Furthermore, although any known additive may
 be injected with the system, the injection of dyes, lubricants, and/or
 odor agents is particularly convenient.