Abstract:
A feeder is disclosed for dissolving a chemical and mixing it with a liquid. The feeder includes a hopper adapted to hold the chemical, a nozzle located in the hopper, and a supply of the liquid to the nozzle to dissolve the chemical on contact with the liquid from the nozzle to form a solution. A solution basin is disposed under the hopper and a drain is provided from the hopper into the solution basin. An outlet from the solution basin has an outlet valve which opens when a solution level in the solution basin rises.

Description:
FIELD OF THE INVENTION 
     Several embodiments of the invention pertain to the field of chemical solution feeding devices and methods. More particularly, some aspects pertain to feeders that dissolve solid chemical material, using a liquid, to create a solution and feed the solution to systems such as, for example, swimming pool systems. 
     BACKGROUND OF THE INVENTION 
     Feeder systems for chemical solutions are in wide use in industry. For example, one application for a chemical solution feeder is a system that will dissolve chemicals into water to create a solution that can be fed to an environment such as a swimming pool. Further, it is known to provide chemical solution feeders which will dissolve solid materials such as, for example, calcium hypochlorite, and other chemicals, which are in tablet or pellet form. In one example, tablets are dissolved by being contacted by a stream of water directed at the tablets in a hopper. This creates a liquid solution which can be drawn from the hopper and fed into a swimming pool water recirculation system. 
     The known chemical feeders have been quite satisfactory. However, it is always desirable to provide systems which may be more efficient, and/or which may provide better flow regulation of the solution supply. 
     SUMMARY OF THE INVENTION 
     An embodiment of the present invention discloses a feeder for dissolving a chemical and mixing it with a liquid, that includes a hopper adapted to hold the chemical, a nozzle located in the hopper, a supply of the liquid to the nozzle to dissolve the chemical on contact with the liquid from the nozzle to form a solution in a solution basin with a drain from the hopper into the solution basin, and an outlet from the solution basin having an outlet valve which opens when a solution level in the solution basin rises. 
     Another embodiment includes a swimming pool chlorinating system, with a feeder for dissolving a chemical and mixing it with a liquid. In addition, the present invention describes a hopper adapted to hold the chemical, a nozzle located in the hopper, a supply of the liquid to the nozzle to dissolve the chemical on contact with the liquid from the nozzle to form a solution in a solution basin, with a drain from the hopper into the solution basin, and an outlet from the solution basin having an outlet valve which opens when a solution level in the solution basin rises. A loop feeds pool return water to the feeder and sends it from the feeder basin to the pool. 
     Yet another embodiment of the present invention discloses a feeder for providing a dissolved chemical with a tank adapter to contain the dissolved chemicals, a solution basin with a drain from the tank into the solution basin, and an outlet from the solution basin having an outlet valve which opens when a solution level in the solution basin rises. 
     A feeder for dissolving a chemical and mixing it with a liquid is also disclosed which comprises means for dissolving the chemical into the liquid to form a solution, a solution basin for receiving the dissolved solution, an outlet from the solution basin having means for controlling the rate of solution outlet based on the solution level in the solution basin. 
     A further embodiment includes dissolving a chemical and mixing it with a liquid to form a dissolved solution in a solution basin. The dissolved solution is outputted from the solution basin and the rate of solution outlet is controlled based on the solution level in the solution basin. 
     There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto. 
     In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting. 
     As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side view of a chemical solution feeder according to a preferred embodiment of the invention. 
         FIG. 2  is a front view of the chemical solution feeder of  FIG. 1 . 
         FIG. 3  is a detailed schematic view of a solution outlet float valve used in the arrangement of  FIG. 1 . 
         FIG. 4  is an exploded view of various components of the feeder of  FIG. 1 . 
         FIG. 5  is a perspective view showing some components of the feeder of  FIG. 1 . 
         FIG. 6  is a diagrammatic view of the system of  FIG. 1  installed in a swimming pool water handling system. 
         FIG. 7  is a diagrammatic view of the system of  FIG. 1  installed in another swimming pool water handling system. 
         FIG. 8  is a side view of a mining nozzle. 
         FIG. 9  is a diagram showing a spray pattern of the mining nozzle of  FIG. 8 . 
     
    
    
     DETAILED DESCRIPTION 
     Referring initially to  FIGS. 1 and 2 , a chemical solution feeder  10  is illustrated. The feeder  10  will now be further described along with other embodiments, with reference made to the drawing figures, in which like reference numerals refer to like parts throughout. 
     Reference will now be made especially to  FIGS. 1-4 , taken together, since some components are feasible to show only in some of these views. The feeder  10  includes an upper hopper  2 , also referred to as a tablet hopper, which is a container that holds solid chemical tablets and receives water to dissolve the tablets, as is described in more detail below. The tablet hopper  2  rests upon a lower basin or tank, also referred to as a solution mixing basin  4 . An intermediate top plate  6  separates the tablet hopper  2  above the solution mixing basin  4 , and also supports other valves, switches, solenoids, and/or other components as seen in the drawings and as described further below. 
     The feeder  10  receives water from a water inlet/supply line  14 . In some installations, this may be clean municipal water, or alternatively it may be pool water that is being re-circulated from the pool water return. A purpose of receiving this inlet water is to use at least part of it to dissolve chemical tablets, such as, for example, calcium hypochlorite tablets, to produce a chlorinated and otherwise chemically treated water solution that can be returned to the swimming pool. 
     The inlet water from the inlet supply  14  is directed to an inlet water solenoid valve  16 . The inlet water supply solenoid  16  operates in a normally opened position, but can be closed to provide a safety cutoff when it is detected that malfunction, or overly high levels, or overflow of the system is occurring. During normal operation the inlet water supply solenoid  16  is open and permits the inlet water to feed through it. A solution level switch  18  is provided inside the solution mixing basin  4  utilizing a float arm  20  and a float  22 . When the water/solution level L 2  in the solution basin  4  becomes too high, the float  22  rises and the solution level switch  18  is triggered and sends a signal via a signal line  19  to the inlet water supply solenoid  16  to reduce or close the supply of inlet supply water. Main power is supplied to the solution level switch  18  via a power cable  21 . 
     Water fed through the inlet water supply solenoid  16  can be directed out from the inlet water supply solenoid  16  in two paths. At all times, any inlet water from the inlet water supply solenoid  16  is available to travel in a first path down a rinse down pipe  24  to a rinse nozzle jet  26  located in the bottom of the solution tank  4 . Also, a portion of the inlet water from the inlet water supply solenoid  16  can be selectively directed in a second path to a chemical feed solenoid  30 . If chemical feed solenoid  30  is closed, the inlet supply water only takes the first path, and therefore exits the rinse nozzle jet  26 , filling up the solution tank  4  and being returned to the pool via the outlet of the solution tank in a method described more below. However, if the chemical feed solenoid  30  is open, a portion of the inlet water is fed via tube  32  which receives water from the chemical feed solenoid  30  and directs it to a mining nozzle  34 . A dome  23  covers a T-shaped splitter that splits water fed out of the inlet water supply solenoid  16 . 
     The chemical feed solenoid  30  when open thus allows a portion of the inlet water to travel through a tube  32  to the mining nozzle  34 . The chemical feed solenoid  30  is controlled by an external electric or electronic switch or controller via a control line  33  (shown in  FIG. 4 ). In some cases, the chemical feed (supply to the nozzle) is performed intermittently based on a pre-set schedule or by measured chemical levels. The pre-set measured chemical levels turn on and off the chemical feed solenoid  30 . In the case of a swimming pool application, the chemical feed may include a chloride addition function and be performed based on a pre-set schedule and/or measured chlorine levels. 
     It will be appreciated that when the chemical feed solenoid  30  is closed, then the feeder  10  essentially receives inlet water  14  which is all ejected out the rinse nozzle jet  26 , and can be returned to the pool system. The return method is discussed in more detail below. However, for example, when it is desired to add chemicals to swimming pool water by creating a chemical solution, the chemical feed solenoid  30  will be opened by a signal from the control line  33  (shown in  FIG. 4 ). Water will be supplied through the conduit line  32  to the mining nozzle  34 . 
     Assuming that the tablet hopper  2  has been filled with tablets, for example to a level shown at L 1 , then water that is ejected horizontally through holes in the mining nozzle  34  will impact and dissolve the tablets to form a solution in the lower part of the tablet hopper  2 . This solution will drop through a sieve plate  36  and collect at the bottom of the tablet hopper  2 , where it will drain out a solution supply drain pipe  39  and into the solution basin  4 . The sieve plate  36  is a flat disc with holes in it that serves as a strainer. Spacers  37  space the sieve plate above the bottom of the tablet hopper  2 . Because the solution basin  4  is also receiving rinse water from the rinse nozzle  26 , the liquid in the solution basin  4  forms a batter that dilutes the solution from drain pipe  29 . The solution from the drain pipe  39  can be fairly highly concentrated. 
     In case the sieve plate  36  should become clogged, a hopper overflow pipe  38  is provided. The hopper overflow pipe  38  can be a vertical pipe with an opening  38 A near its bottom so that, as the liquid level rises beyond a desired level then liquid will bypass the sieve plate by flowing into the hopper overflow pipe  38 . This hopper overflow water will be directed by the hopper overflow pipe  38  through and under the sieve plate  36  and still enter the solution supply drain pipe  39 . The overflow opening  38 A thus prevents water from building up in the tablet hopper  2 , and minimizes submerging of the tablets in water. 
     From the above it will be clear that the feeder  10  can operate in one mode where water arriving at the water inlet is simply re-circulated straight down into the solution mixing basin  4  via the rinse nozzle jet  26 , and another mode where some of the water is diverted to the mixing nozzle  34  and will dissolve the chemical tablets to provide a relatively concentrated solution that enters the solution mixing basin  4  via the solution supply pipe  39 . The relatively concentrated solution is continually diluted by mixing with rinse water from the rinse nozzle  26 . As the relatively concentrated solution may still have some particulate material in suspension, it is desirable that the rinse nozzle  26  jet be located or oriented as shown, with a lateral output near the bottom of the solution mixing tank  4 , so that the jet output will provide some turbulence and mixing action continually in the overall solution that is present in the solution mixing tank  4 . The provision of a laterally terminating rinse nozzle jet  26  can thus prevent the buildup of sediment over time in the bottom of the solution mixing basin  4 . 
     From the above it will also be seen that the solution mixing basin  4  during operation will generally be full to some extent with a solution, which is either primarily simply inlet water being recycled, or which may be inlet water that is being mixed therein with a concentrated solution (when the chemical feed solenoid  30  is open). 
     This liquid solution in the solution mixing basin  4  is drawn out from the solution mixing basin  4  via a solution outlet  40 . The solution outlet  40  is connected to some form of low pressure inducing device, such as a venturi, that will draw the solution out of the solution mixing basin  4 . In an illustrated example, an outlet control valve  41  is provided. In particular, as illustrated in  FIG. 3 , the control valve solution outlet  41  is provided via a valve body  42  that has an internal port  44  therethrough. The valve body  42  also has an end  46  leading to an inlet port  47 , by which fluid can be drawn from the tank up into the internal port  44 . 
     The valve body  42  operates in combination with a valve proportioning hinge pin  50 , which is a rotatable cylinder having its own port  52  extending therethrough. The valve proportioning hinge pin  50  is rotated with respect to the valve body  42  by being attached to a float  54  by an arm  56 . As can be seen, for example, in  FIG. 3 , when the float  54  is relatively lower towards the bottom of the solution mixing tank  4 , the outlet control valve  41  will be in a fully or nearly fully closed position and in this position, the removal of solution via the solution outlet  40  is inhibited or prevented so that the solution mixing basin  4  will tend to fill up. In some embodiments, even if the float reaches its lowest position the valve  41  will be nearly, but not fully, closed. As the solution level rises, the float  54  moves upward, thereby opening the outlet control valve  41  more fully so that the solution outlet  40  can draw the solution out at a higher flow rate. If the rate of input into the solution mixing basin  4  is exceeding the rate of output via the solution outlet  40 , the solution level will tend to rise, thereby opening the outlet control valve  41  even more fully. Therefore, in a range of normal flow conditions, the outlet control valve  41  will tend to equalize the outlet flow to preserve a relatively consistent solution level L 2  in the solution mixing basin  4 . In this way, the outlet valve system  41  provides at least some degree of equalization which can maintain a relatively constant level L 2  in the solution tank  4 , even if the flow output demand  40  varies to some degree. 
     In case the solution outlet  40  becomes clogged, or the solution outlet control valve  41  is otherwise not operable, an overflow port  59  is provided in the side of the solution mixing basin  4 , which can be connected to a drain or sewer or the like. Also, turning to  FIG. 4 , it will be appreciated that a lid  12  can be secured onto the hopper  2  by a lock pin  55  and lock ring  57  engaging various securing holes  58 . 
     The above described system and other embodiments of the system can thus be used to receive inlet water (or another liquid) to dissolve a chemical material using at least part of the received liquid, and return a solution including the dissolved chemical into the feeder. This can have many industrial applications. 
     One example of an industrial application used in this specification is shown in  FIGS. 6 and 7 , in the context of installing the feeder  10  in connection with a swimming pool water system. This system receives a water flow  112  from the pool, and pumps it using a pump  114 , so that some of it goes through a filter  116  and a heater  118  before being ejected into a pool return  120 . When the isolation valves  122  are open, some of the water from the pump  114  will pass to a diversion element having an inlet valve  130 , a strainer  132 , a flow meter  134  and a flow control valve  136 . When the flow control valve  136  is open, the water is fed to an inlet line  14  to the feeder system  10 . This water will pass through the feeder, as described above, and will be outlet as a solution at the outlet  40  and be drawn through a tube  142  by low pressure created at a venturi  146 . From there it will be directed back to the pool return  120 .  FIG. 7  depicts the configuration of  FIG. 6  with the addition of a booster pump  150  to facilitate creation of pressure for flow through the feeder  10  and/or facilitate water flows and pressures necessary for proper operation of the low pressure inducting device such as a venturi. 
     Another example of a use for some feeders according to some various preferred embodiments is for drinking water or wastewater applications. One example of a chemical for use with the feeder in drinking water and wastewater applications is the chemical trichloro isocyanurate. 
     Various preferred embodiments of the invention are described above. References above to water are intended to encompass not only clean water, but also water that may be treated, thereby already having some chemicals in it, pool water, or any liquid. Further, references to chemical material and to tablets in the description of the specification are also intended to be used generically, with respect to some embodiments of the invention, in that the chemical being dissolved into the water may be in a solid or partially solid-state, but could also be in liquid form. Therefore, while some embodiments utilize a nozzle that directs water onto solid pellets, it will be appreciated that other mixing of materials may occur, within the scope of some embodiments of the invention, including for example, applying the water to a cake, powder, gel, or any other chemical material that is intended to be put into solution. Also, references to tablets of some embodiments are not intended to be limiting, but can also include briquettes, powders, cakes and other chemical forms. Further, additional optional features may be added to the feeder  10  described above to provide additional functionality, while still being within the scope of at least some embodiments of the invention. 
     The exemplary nozzle  34  is an upwardly projecting substantially cylindrical structure, having a plurality of individual nozzle jet ports therein. In one preferred embodiment seen in  FIGS. 8 and 9 , there are twenty-four jets total. The jet ports are in four vertical rows  201 ,  202 ,  203 ,  204 , each row spaced above each other, and there are six of them spaced circumferentially around the nozzle in each row. Each row is offset 15° compared to the row beneath, so that a radial jet pattern (see  FIG. 9 ) is provided including circumferentially spaced outward radial jets, each projecting outward from the center, with each of these radial jets spaced above each other in horizontal rows by vertical spacing. The circumferential position of the jets provides a jet at each 15° interval. Fluid sprayed from these jets tends to consume the tablets of material. Also, it will be appreciated that in the illustrated preferred embodiments, the nozzle extends upward a height that is only a portion of the height of the entire tablet hopper. Since the spray pattern described above is essentially in the horizontal direction when taken as a whole, the benefit of this arrangement is that a lower portion of the tablets can be dissolved without wetting the upper section of the tablets in the top of the hopper. As the tablets are dissolved, the overall height level of the tablets will decrease. 
     The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.