Flowable material dispenser with automatic shutoff and vessel for receiving flowable material

A flowable material dispensing system that will dispense a flowable material into a container and stop dispensing when the proper level is reached in the container. The container has an actuating device that is used to open the valve on the container. As the flowable material flows into the container and reaches the top, flow stops.

FIELD OF THE INVENTION 
The invention is directed generally to dispensing flowable materials and 
specifically to dispensing predetermined amounts of flowable materials. 
The invention is directed more specifically to automatic limit control for 
dispensing a predetermined volumes of flowable material. 
BACKGROUND OF THE INVENTION 
A large number of different chemicals are available as flowable materials, 
which can include liquids, granules, pellets and powders. A variety of 
products can be formulated in these product formats. Examples of powders 
and granules include laundry detergents, presoak materials, floor cleaners 
and fertilizers. Pellets can comprise compressed alkaline detergent 
formulations for warewashing or laundry. Although these materials are 
commonly used in dilute aqueous form, they are frequently stored and 
shipped as solids in order to conserve considerable space and weight 
during transportation and warehousing. Because these materials generally 
need to be dissolved in water to create a dilute use solution, dispensing 
precise and accurate predetermined quantities is needed. Materials can 
also be stored as concentrated liquids. In this case, the dispensed 
material must be diluted to form the concentrate prior to final dilution 
at the end use. If the material in question is under-dispensed, the 
resulting use solution will be excessively dilute and possibly 
ineffective. Conversely, if too much material is dispensed, the resulting 
use solution will be too concentrated, which wastes material and possibly 
represents an unsafe condition. For example, if the flowable material is 
fertilizer, a too-concentrated use solution can burn the plants being 
fertilized. 
Because these materials represent a significant expense, it is important to 
be able to dispense them without waste or spillage. In addition, it should 
be noted that many materials are restricted in their permitted release to 
the environment. Since spills can contribute to the amount of material 
released, it is important to minimize them. A substantial need exists for 
an accurate, easy-to-operate flowable material dispensing system which is 
capable of repeated accurate and precise dispensing of various 
predetermined amounts of material without spillage. 
SUMMARY OF THE INVENTION 
We have found a flowable material dispensing system which consists of a 
valved gravity-flow container suitable to hold a volume of flowable 
material. The system comprises a stand suitable to hold the gravity-flow 
container in a dispensing position for gravity-flow, a valve which fits 
into an aperture in the container; and a receiving vessel that interacts 
with the valve via an actuating device in order to permit dispensing of 
the flowable material until said vessel is full. A limiting portion of the 
valve terminates dispensing of the flowable material when the vessel 
becomes full. The term "flowable material" means any material, liquid, 
powder, granule or pellet, that can be readily transferred by action of 
gravity feed through an opening of about 0.5 to 5 in.sup.2. 
The flowable material dispenser system of the invention comprises a 
flowable material container with a sufficient capacity of flowable 
material for multiple dispensing cycles. The flowable material is 
dispensed into a material vessel having a predetermined volume. Such 
volume is adapted to diluting the flowable material with a predetermined 
volume of water at a fixed predetermined dilution ratio to form a use 
solution comprising the dissolved flowable material in an aqueous or 
non-aqueous liquid. If the flowable material itself is a liquid, the use 
solution is formed by diluting said material. 
The bulk flowable material container comprises mounting apertures or 
grooves that cooperate with the stand to maintain the container in a 
dispensing mode for gravity-feed purposes. The bulk material container is 
valved to permit easy dispensing of the flowable material into the vessel. 
The valve comprises a disc with a valve seat and a movable circular valve 
closure. The closure has a closed position in contact with the valve seat 
in an open position in which the valve is moved inwardly with respect to 
the container into the flowable material volume permitting the 
free-flowing material volume to flow around the circular closure through 
the valve seat opening and into the vessel. 
Movement of the valve is obtained using a valve actuator probe on the 
flowable material vessel. The valve actuator probe contacts an actuator 
post connected to the circular valve closure. The vessel having the 
actuator probe is moved against the actuator post which moves the valve 
closure from the seat opening the seat opening permitting flow of the 
flowable material from the container into the vessel. The valve assembly 
also contains a skirt member which extends from the exterior of the 
container for a distance such that the end of the skirt penetrates the 
opening of the vessel by at least one millimeter, preferably 5 to 10 
millimeters. This distance is necessary to ensure that material is not 
dispensed if the skirt configuration fails to fit within the confines of 
the receiving vessel. As the flowable material is transferred through the 
valve into the vessel, the flowable material fills the vessel. As the top 
of the material in the vessel approaches the skirt, the flowable material 
can flow unimpeded. When the top of the material contacts the bottom of 
the skirt, flow from the container is prevented. This self-limiting 
function of the valve skirt is an important aspect of the invention and 
permits the easy and convenient dispensing of a predetermined volume of 
flowable material for dissolution or dilution in the predetermined volume 
of liquid. 
The circular closure and post is spring biased to maintain the valve in a 
closed position. The actuator probe moves the circular closure against the 
action of the spring to open the valve for material dispensing. When 
flowable material dispensing is completed due to the self-limiting nature 
of the skirt, the spring can then move the circular aperture to a closed 
position. The circular closure has a lower conical portion which 
cooperates with the seat to close the valve. The upper portion of the 
circular closure also has an upper conical surface that permits easy flow 
of the flowable material around the circular closure. 
In order to obtain secure contact between the actuator probe and the 
actuator post, the post contains a receiving surface comprising a 
cylindrical mating surface that accepts and holds the actuator probe in 
place during dispensing. The valve is commonly manufactured in the form of 
a valve member with a threaded closure that mates with a threaded opening 
in the container. The flowable material vessel receiving the flowable 
material from the flowable material container may be a substantially 
cylindrical vessel with a movable platform that defines a predetermined 
volume. The flowable material vessel is not limited to cylindrical shapes, 
however. The vessel can have a variety of shapes and a variety of 
apertures which correspond with a variety of complementary skirt 
configurations. A preferred stand member comprises a wire stand that holds 
the container in a dispensing mode. 
In a particular embodiment, the flowable material is a powder.

DETAILED DISCUSSION OF THE INVENTION 
The invention is directed to a flowable material dispensing system which 
comprises a gravity-feed valved container suitable to hold a volume of 
flowable material. The container cooperates with a stand to hold the 
container in a dispensing attitude. The valved system comprises a valve 
assembly which fits onto a threaded aperture in the container that 
controls gravity-feed dispensing. A receiving vessel that interacts with 
the valve assembly via an actuating device initiates dispensing of the 
flowable material while said cup is not full and terminates dispensing of 
the flowable material when the cup becomes full. Each major element of the 
invention will be discussed in turn. 
Material Container 
The invention utilizes a container suitable to hold a volume of flowable 
material. The container further defines a round aperture whereby the 
flowable material can depart the container when the container is in a 
gravity-feed or dispensing attitude. The container may be designed in such 
a way that product can be sealed into the container via a cap or sealing 
apparatus and shipped. There may be an optional handle molded into the 
bottom surface of the container to ease handling. In another embodiment of 
the invention, the flowable material container is a refillable hopper. 
This hopper is open at the top to facilitate refilling. In other 
embodiments, the container could also be a bottle, pail or even a drum. 
There are no specific limitations on container volume. Said volume would 
depend on the nature of the material being dispensed. The cap or sealing 
apparatus can be replaced with a valved assembly or while intact prior to 
product use can be equipped with a round knock-out which permits 
installation of a gravity-feed valve assembly. The cap or apparatus is 
then used (minus center knock-out) to hold the valve assembly in place on 
the container. Preferably, the container is transparent, translucent or 
includes a viewing port, permitting the end user to see the contents. The 
container has means, slots or inserts that cooperate with a stand to 
position the container for flowable material dispensing. 
Stand 
The present embodiment of the invention includes a stand which is suitable 
to hold the container in a gravity-feed attitude. Preferably, the stand is 
constructed of metal wires, permitting easy container installation and 
removal. The stand is able to be mounted onto a vertical surface such as a 
wall for convenience. Depending on the size of the container used, the 
stand may be freestanding on the floor. Further, a user is able to easily 
see the container and its contents, thereby judging when replacement is 
necessary. 
Valve Assembly 
The heart of the claimed invention is the valve assembly that dispenses a 
predetermined volume of the flowable material. The valve can be fitted 
onto a threaded aperture of the material container and includes three 
individual components (i.e.) the disc and seat, the closure and the skirt, 
as described below: 
Disc and Seat 
This is a flat cylindrical disc of diameter equal to the aperture in the 
material container, wherein the top surface of the disc is slightly 
concave and defines a round aperture or valve seat, wherein the bottom 
surface comprises a skirt acting as a flow stopper with an inner diameter 
approximately equal to the round seat or aperture. The skirt can take many 
possible shapes and is not limited to a cylindrical shape. This flow 
stopper operates in concert with the valve to control flow. The disc 
further comprises a support piece extending across the round aperture, 
said support piece defining a smaller round aperture through which a metal 
stem can slide and further providing support for a spring. The bottom 
surface of the disc further comprises a lip slightly larger in diameter 
than the aperture in the container. This lip serves to hold the valve 
assembly within the container aperture without falling into the container. 
The cap serves to prevent the valve assembly from falling out. 
Actuator Post or Stem 
A metal stem which protrudes through the aperture through the support 
piece; wherein the bottom end of the stem forms a larger diameter cup 
suitable for engaging with the actuating device within the receiving 
vessel and the upper end of the stem is attached to a double cone shaped 
stopper. The stem is encased in a spring to hold the stopper in position. 
Circular Valve Closure or Stopper 
The closure is a double cone shaped stopper with a lower conical region 
which consumes approximately one quarter of the length of the stopper and 
an upper conical region which consumes approximately three quarters of the 
length of the stopper. The lower conical region has a diameter which 
decreases while moving closer to the bottom of the cone and serves to plug 
the round aperture in the cylindrical disc. Further, the conical shape of 
the lower conical region essentially makes the stopper self-guiding. It 
will seat properly into the round aperture in the disc even if not at the 
correct initial angle. The upper conical region decreases in diameter 
while moving upward and serves to promote and direct material flow. 
Receiving Vessel 
Another key feature of the invention is a receiving vessel that can 
interact with the valve via an actuating device in order to permit 
dispensing of the flowable material while said vessel is not full, and 
terminates dispensing of the flowable material when the vessel becomes 
full. Individual receiving vessel are designed and precalibrated for a 
particular predetermined volume of material. Consequently, an individual 
dispenser container can be used to dispense a nearly limitless number of 
different predetermined volumes of the flowable material. 
The receiving vessel has several key features which render it useful in the 
claimed invention. In a current embodiment, the vessel itself is not 
required to be of any particular volume. Rather, the vessel holds an 
insert which serves both to control the dispensing volume and to anchor 
the actuating device. This insert consists of a cylindrical disc which 
forms a threaded aperture in its center suitable to secure the actuating 
device. The volume limiting disc is of a diameter less than the maximum 
diameter of the receiving vessel. Consequently, it will only penetrate a 
certain distance vertically into the vessel. Therefore, the sides of the 
vessel serve to hold the insert in place vertically. 
The receiving vessel must have an aperture suitable to permit the inflow of 
the flowable material. In the simplest embodiment, said vessel has an open 
top. This easily permits flow into the receiving vessel. However, it does 
not place any limitations on what particular material flows into the 
vessel. In some cases, however, it is important to control the identity of 
the material dispensed. For example, a series of dispensing devices 
according to the claimed invention could be utilized to dispense a variety 
of different and incompatible chemicals. 
Control is provided via a system of complementary configurations between 
valve seat, cap and receiving vessel. In short, a shaped skirt is provided 
which complements the shape of the respective aperture in the top of the 
receiving vessel. The skirt is of sufficient depth to prevent contact 
between the actuating device and the post or stem, thereby preventing 
dispensing of the material if the skirt configuration fails to match the 
receiving vessel. 
In another embodiment, the actuating device can be in threaded attachment 
to the volume limiting disc. This permits the end user to modify the 
volume of the receiving vessel. Consequently, a single receiving vessel 
can be used for dispensing an infinite number of different volumes. 
The actuating device protrudes through the aforementioned round aperture 
and extends down to the bottom surface of the cup. There, it is held in an 
indentation provided in the vessel for that purpose. Because the actuating 
device is permanently bonded to the insert, this serves to locate and hold 
the insert in place within the vessel. 
Detailed Discussion of the Figures 
FIG. 1 is a perspective view of the apparatus 100 showing the major 
components of the invention. The container 110 is held in a 
gravity-dispensing mode or upside down by the stand 120, which is of a 
metal wire design. The bottle 110 contains the flowable material 160 to be 
dispensed through valve assembly 140 into receiving cup or flowable 
material vessel 150. The valve assembly 140 is held in place in the 
aperture of the container 110 by a cap 130. 
Several features can be seen in this figure. The container 110 contains 
indentations 111 (only one seen) on each side of the container which serve 
to hold the bottle in the stand 120. The top of the container 110 includes 
a handle 112 for handling ease. The stand 120 has several additional 
features as well. There are two protrusions 121 (only one seen), which 
serve to hold the bottle 110 in place by fitting into the indentations 
111. Further, the stand 120 also includes several hanging brackets 122 for 
the purpose of mounting the apparatus 100 on a vertical surface such as a 
wall. The receiving cup 150 contains a volume limiting disc 151 and an 
actuating device or probe 152. 
FIG. 2 is an expanded side view of a portion of the apparatus 100 which 
shows the relationship between the container 110, valve assembly 140 and 
receiving cup 150. This view clearly shows how the valve assembly 140 
protrudes through and is held in place by cap 130. The valve assembly 140 
is seen to include a throat 171, a circular closure or stopper 210, a disc 
and seat 220 and an actuator post or stem 230. One end of the stem 230 is 
seen to be threaded for the purpose of attaching the stopper 210. Further, 
the valve assembly also includes a spring 240 which serves to bias or hold 
the valve closed when not in use, and a receiving surface 250 which 
interacts with the actuating device 152. This figure shows the threaded 
attachment or support apparatus 280 which traverses the aperture and lip 
270 and provides guidance and support for the stem 230. Further, this 
diagram shows the actuating device holder 153 which is formed into the 
bottom of receiving cup 150 that cooperates with the volume limiting disc 
151 to calibrate the vessel 150. The flowable material 160 is shown within 
the container 110. Further, the passage of material through the valve 
assembly 140 and into the receiving cup 150 can be explained via this 
diagram, which is drawn with the valve 140 in the closed position. The 
stopper 210 is clearly shown blocking the aperture 270 and throat 171 
through the valve assembly 140. In this position, no flowable material 160 
may flow. The receiving cup 150 is clearly shown as being empty of 
flowable material 160. When an empty receiving cup is brought into 
position directly beneath the valve assembly 140, the actuating device 152 
engages the cup guide 250 and forces the stem 230 upward. This forces the 
stopper 210 upward (shown in FIG. 4) and permits the flowable material 160 
to flow into the receiving cup 150. 
When the receiving cup 150 is full, the flowable material 160 level within 
the cup will make contact with the skirt or flow stopper 260. This stops 
the flow of free-flowing material 160 into the receiving cup 150. When the 
receiving cup 150 is pulled away, the spring 240 forces the stopper 210 
back into the closed position and prevents flow of any additional flowable 
material 160. 
FIG. 3 is an exploded view 300 of the valve assembly 140 and container cap 
130 which shows the vertical arrangement of these components. Most of the 
individual components in this figure have been described previously. 
However, this figure does provide a much better view both of the support 
apparatus 280 itself and its orientation both within the valve assembly 
140 and to the stem 230. This figure also shows the screw 310 which serves 
to attach the receiving surface 250 to the post or stem 230, thereby 
capturing the spring 240. Finally, this figure shows the center knockout 
320, located in the center of the cap 130. The circular closure having the 
dual conical surfaces 210 is shown. The circular closure 210 cooperates 
with seat 221 to seal the throat 171 in the valve. Seat 221 is formed in 
the disc 220. Disc 220 contains a lip that cooperates with a threaded 
opening in the container. The disc 220 contains a skirt or flow stopper 
260 which contacts the flowable material as it fills the vessel thus 
stopping free-flowing material transfer from the container to the vessel. 
The cup guide or probe receiver means 250 is attached to the post or stem 
230 using a screw 310 in a preferred mode. The guide 250 holds the spring 
240 on the post 230. The spring 240 biases the circular closure or stopper 
closed against the seat 221. The valve assembly is held in the threaded 
opening to the container using the cap 130 with the optional knock-out 
320. When the circular closure 210 is positioned in an open location, the 
flowable material flows around the circular closure 210 through the 
aperture 270 and the knockout opening 320 into the vessel for the flowable 
material. 
FIG. 4 shows vessel 150 in contact with the valve assembly 130 at the edge 
270 using the actuator probe 152 in contact with the actuator post 
receiving surface 250. The probe 152 and the volume limiting disc 151 
cooperate to calibrate the volume of the vessel 150. Flowable material 160 
flows through the throat 171 and has filled the vessel 150 such that the 
flowable material 160 level reaches the skirt 260 stopping the flow of the 
flowable material. When vessel 150 is withdrawn from the valve, the 
actuator post 230 returns the closure 210 to the seat 221 preventing 
dispensing substantially more flowable material 160. This feature is a 
self-limiting feature in the flowable material dispenser apparatus. 
FIG. 5 shows several possible embodiments of the skirt 260, cap 130 and 
receiving vessel 150. In each case, the skirt 260 and the flowable 
material receiving vessel 150 possess complementary shapes and fit 
together in a lock-and-key manner. The invention is not limited to the 
particular embodiments displayed. Any suitable configuration of skirt and 
receiving vessel top could be used. These embodiments are intended only to 
illustrate the idea. 
FIG. 5A shows a portion of the valve assembly 140 bearing a particular 
skirt embodiment 260', a particular receiving vessel 150' and cap 130'. 
This figure clearly shows the idea of a complementary skirt and receiving 
vessel configuration and further demonstrates that the cup guide 250' can 
not make contact with the actuating device 152' unless the skirt 260' 
penetrates the top 154 of the receiving vessel 150'. 
FIG. 5B shows another possible embodiment. Pictured is a skirt 260" and cap 
130". The complementary receiving vessel top (not pictured) would comprise 
an aperture suitable to permit penetration by skirt 260". 
FIG. 5C shows another possible embodiment. Pictured is a skirt 260'" and 
cap 130'". The complementary receiving vessel top (not pictured) would 
comprise an aperture suitable to permit penetration by skirt 260'". 
Virtually any flowable chemical useful for dilution in a liquid diluent can 
be dispensed using the apparatus of the invention. Preferably, the 
flowable chemical is aqueous dispersible or soluble. Typically in use, the 
chemical is measured into a volumetric cup, calibrated for appropriate 
dilution ratios until the cup is accurately and precisely filled with a 
measured volume of chemical. The chemical is then transferred to a mixing 
or storage tank in which it is combined with diluent to form an active 
aqueous or non-aqueous solution. The volume in the measuring cup is 
matched to the volume of the mixing or storage tank. 
Chemical flowable materials can include flowable liquid, powder, granule, 
pellet, etc., laundry detergents, dishwashing detergents, antimicrobial or 
sanitizing materials, manual dish, pot or pan cleaners, oxidant bleaches, 
flowable products used for forming treatment materials for dairy animals 
including teat dips, utter washes, etc., floor cleaners, hard surface 
cleaners, fertilizers, insecticides, fungicides, herbicides and any other 
flowable material having an active water soluble or dispersible 
ingredient. 
Warewashing detergents typically have a source of alkalinity, a 
sequestering agent, and a variety of optional ingredients including 
chlorine sources, anticorrosion ingredients, wetting agents or 
surfactants, dyes, perfumes, anticorrosion agents, etc. Sources of 
alkalinity can include carbonate salts, silicate salts, alkali metal 
hydroxides and other inorganic materials. Chlorine sources can include 
encapsulated chlorine sources, sodium chlorite and others. The other 
ingredients are commonly available and can provide associated activities 
with an effective concentration in the detergent composition. 
Laundry detergents are typically mildly or highly alkaline materials 
containing a substantial proportion of anionic and/or nonionic surfactants 
for soil removal. The laundry detergents can also contain a variety of 
other ingredients including hardness sequestrants, bleaches, 
antiredeposition agents, inorganic diluents or fillers, water or fabric 
softening agents, etc. Such laundry detergents are typically manufactured 
by dosing the organic materials onto and absorbing the organic materials 
into the organic components and then dry blending the combined inorganic 
organic materials to form uniform laundry detergent. 
Flowable material sanitizers that can be dispensed with the apparatus of 
the invention include materials containing chlorine containing compounds 
such as hypochlorite, chlorine dioxide, quaternary ammonium sanitizer 
compounds, iodophors, acid anionic materials and others. Such compositions 
if unstable can be encapsulated and can be combined with diluent salts 
such as sodium sulfate, sodium carbonate, sodium bicarbonate, etc. 
Similarly, chlorine bleaches and oxygen bleaches can be formulated in 
free-flowing material form and dispensed using the apparatus of the 
invention. In such compositions, typically a chlorine source is 
encapsulated with inorganic, organic or mixed or layered coatings, to 
render the chlorine source compatible with diluent materials. Less 
oxidizing peroxygen or oxygen bleaches such as perborate and others can be 
formulated with bleach activators and a diluent salt in useful 
compositions. 
Other fertilizers, floor cleaners, hard surface cleaners, insecticides, 
fungicides, herbicides, etc. can be obtained from sources of such 
materials and can be diluted with appropriate proportions according to bag 
instructions. In the case of use of a liquid material, the liquid material 
can be blended with a flowable diluent such as sodium sulfate, sodium 
carbonate, sodium bicarbonate, etc. in a ribbon blender prior to 
dispensing from the apparatus of the invention. 
Many flowable materials are hygroscopic, i.e., they can absorb water from 
the atmosphere. Exposure of these materials to moisture can result in 
caking which may disrupt flow. If the invention is used with a sealable 
flowable material container, the exposure to ambient air is minimized. 
This is important because an equilibrium exists between water vapor in the 
air and water absorbed by the hygroscopic material. Constant exposure to 
ambient air would disrupt this equilibrium, causing excessive water 
absorption. 
The above specification, examples and data provide a complete description 
of the manufacture and use of the composition of the invention. Since many 
embodiments of the invention can be made without departing from the spirit 
and scope of the invention, the invention resides in the claims 
hereinafter appended.