Abstract:
An apparatus for creating a use solution of a concentrate diluted, with a dilution rate of not more than 1:130, into a diluent flowing under pressure in a line. A normally-closed, user activatable valve is operatively coupled in the line allowing the diluent to flow in the line upon user activation. A flow regulator is operatively coupled in the line downstream of the valve, configured to maintain a constant flow rate for the diluent in the line. A constant flow rate pump having an inlet and an outlet is operatively coupled to the valve. The inlet is adapted to be operatively fluidly coupled to the concentrate. The outlet is fluidly coupled to the line downstream of the flow regulator.

Description:
TECHNICAL FIELD  
         [0001]    This invention relates to product dilution apparatus and methods and, more particularly, to product dilution apparatus and methods having low dilution rates.  
         BACKGROUND  
         [0002]    Often apparatus and methods are used to add a concentrate to a diluent in order to create an effective use solution. Diluting a concentrate with water flowing in a water line is one example. Using an active ingredient in concentrated form and relying on-site dilution of the active ingredient allows more efficient use of shipping and storage of the active ingredient. The volume and weight of the water diluent need not be shipped to the point of usage nor stored at the point of usage.  
           [0003]    In the cleaning environment, it is common to dilute a concentrate of a sanitizer or cleaner on-site with locally supplied water. Apparatus and methods are commonly used to dilute the concentrated sanitizer or cleaner, for example, to form a commercially suitable use solution.  
           [0004]    Aspirators are commonly used for this purpose. An aspirator is essentially a pipe (the water line) with a narrowing in it. As water flows through that narrowing, the velocity of the water increases and the water pressure drops. An opening on the side of line is connected to a hose which, in turn, is connected to the concentrate. Since the water pressure in the high speed water flow is lower than atmospheric pressure, atmospheric pressure pushes the concentrate through the connected tube into the water flowing through the line.  
           [0005]    Such aspirators work well to add concentrate to water flowing in a line at certain amounts of dilution. At dilution rates down to approximately 1:130 (that is, a dilution rate of one part concentrate to 130 parts diluent), the amount of concentrate being added to the water diluent can be controlled by varying the size of the opening on the side of the line. Making the opening larger increases the amount of concentrate added to the line. Making the opening smaller decreases the amount of concentrate added to the line.  
           [0006]    However, at dilution rates lower than approximately 1:130 (that is, one part concentrate to more than 130 parts diluent), it is difficult to control the amount of concentrate added to the line by simply varying the size of the opening in the side of the line. At low dilution rates, i.e., small amounts of concentrate added to the line, variations in the water pressure, flow rate, temperature of the water can all result in significant variations in the amount of concentrate added to the water (diluent) in the line. Further, it is easy to plug the opening into the line with foreign material limiting the amount of concentrate which is added to the diluent flowing in the line or completely eliminating any concentrate to the line. Thus, it is difficult to accurately use an aspirator to add concentrate to a diluent flowing in a line with the use of an aspirator.  
           [0007]    However, many applications require just such low dilution rates. An example is the addition of a sanitizer to form a use solution for a warewashing application. If highly concentrated sanitizer is utilized, dilution rates of approximately one part in one hundred thirty to one part in one hundred fifty or less may be desired. An aspirator is often unreliable and unworkable in this situation.  
           [0008]    Thus, there is needed an apparatus and method to accurately control the addition of a concentrate to a diluent flowing in a line at dilution rates not more than 1:130.  
         SUMMARY OF THE INVENTION  
         [0009]    The present invention solves this problem, in part, by using a pump with a constant flow rate, such as a peristaltic pump, to add a specifically controlled amount of concentrate to the diluent flowing in the line. A flow control valve provides ensures that the diluent flowing in the line has a known rate of flow. By precisely controlling the constant flow rate pump, a variable amount and precisely known amount of diluent can be added to the line. Variations in water pressure and water temperature have little effect of the combination of concentrate and diluent forming the use solution in the line.  
           [0010]    In one embodiment, the present invention provides an apparatus for creating a use solution of a first product diluted, with a dilution rate of not more than 1:130, and a second product diluted, with a dilution rate of more than 1:130, into a diluent flowing under pressure in a line. A normally-closed, user activatable valve is operatively coupled in the line allowing the second product to flow in the line upon user activation. A flow regulator is operatively coupled in the line downstream of the valve, configured to maintain a constant flow rate for the diluent in the line. An aspirator is adapted to be fluidly coupled to the second product and operatively coupled in the line downstream of the flow regulator. A constant flow rate pump having an inlet and an outlet is operatively coupled to the valve. The inlet is adapted to be operatively fluidly coupled to the first product. The outlet is fluidly coupled to the line downstream of the flow regulator.  
           [0011]    In a preferred embodiment, the diluent is water.  
           [0012]    In a preferred embodiment, the constant flow rate pump is a peristaltic pump.  
           [0013]    In a preferred embodiment, a pressure-operated electrical switch is fluidly coupled in the line downstream of the valve and is electrically coupled to the pump configured to activate the pump when the diluent flows in the line.  
           [0014]    In a preferred embodiment, a vacuum break is operatively coupled in the line between the valve and the flow regulator.  
           [0015]    In a preferred embodiment, the valve is a latching solenoid valve which opens for a predetermined period of time upon user activation.  
           [0016]    In a preferred embodiment, the outlet of the pump is coupled in the line downstream of the aspirator.  
           [0017]    In a preferred embodiment, the first product is a fragrance.  
           [0018]    In another embodiment, the present invention provides a method of creating a use solution of a first product diluted, with a dilution rate of not more than 1:130, and a second product diluted, with a dilution rate of more than 1:130, into a diluent flowing under pressure in a line. A normally-closed, user activatable valve operatively coupled in the line is opened allowing the second product to flow in the line. The flow in the line downstream of the valve is regulated to maintain a constant flow rate for the diluent in the line. The second product is aspirated into the line downstream of the flow regulation. The first product is pumped into the line downstream of the flow regulation using a constant flow rate pump.  
           [0019]    In a preferred embodiment, the first product is pumped into the line downstream of where the second is aspirated into the line.  
           [0020]    In an alternative embodiment, the present invention provides a method of distributing a product to each of a plurality of customers. The product is constituted from a base concentrate and a customizable concentrate selectable from a plurality of customizable concentrates. The base concentrate is distributed to each of the plurality of customers. A different selected one of the plurality of customizable concentrates is distributed to each of the plurality of customers. The base concentrate is diluted with a locally obtained diluent. The selected one of the plurality of customizable concentrates is diluted at a dilution rate of not more than 1:130 with the locally obtained diluent.  
           [0021]    In a preferred embodiment, the diluent is water.  
           [0022]    In a preferred embodiment, the customizable concentrate is a fragrance.  
           [0023]    In a preferred embodiment, the base concentrate is a sanitizer.  
           [0024]    In a preferred embodiment, the base concentrate is a cleaner. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWING  
       [0025]    [0025]FIG. 1 is a block diagram of an embodiment of the present invention diluting one ingredient;  
         [0026]    [0026]FIG. 2 is a block diagram of an alternative embodiment of the present invention also diluting one ingredient; and  
         [0027]    [0027]FIG. 3 is a block diagram of another embodiment of the present invention diluting a plurality of ingredient. 
     
    
     DETAILED DESCRIPTION  
       [0028]    In FIG. 1, apparatus  10  is coupled to a source of supply of water by water supply line  12 . A water pressure regulator  14  and, preferably, pressure gauge  16 , control the pressure in water supply line  12  so that the water pressure is maintained relatively constant, e.g., having a deviation of plus or minus five percent (5%). Preferably, the water pressure is maintained in within that tolerance in the range of 35 to 50 pounds per square inch (241 to 345 kilopascals).  
         [0029]    Latching solenoid valve  18  is coupled into water line  20  downstream of water pressure regulator  14 . Latching solenoid valve  18  is manually operable by a user. Water flow through latching solenoid valve is normally prevented. When a user operates latching solenoid valve  18 , water is allowed to flow through water line  22 . Once activated by a user, latching solenoid valve  18  allows water to flow through water line for a predetermined or selectable period of time. This time period is set based on the volume of use solution desired to be produced, e.g., the volume of a container or containers into which a use solution created by apparatus  10  is to be placed. At dilution ratios in the range of 1:130 or lower, most of the volume of the use solution will consist of water flowing through latching solenoid valve  18 . Once latching solenoid valve  18  times out, water flow through water line  22  is again halted. Thus, latching solenoid valve  18  operates, once activated by a user, to allow a predetermined or selectable amount of water to pass through water line  22 .  
         [0030]    Vacuum break  24  is positioned in water line  22  downstream from latching solenoid valve  18 . Plumbing codes in many jurisdictions require a vacuum break, such as vacuum break  24 , to ensure that water downstream of vacuum break  24  does not flow backwards in water line  22  in the event of loss of water pressure in water supply line  12 , possibly contaminated the water source supplying water supply line  12 . Vacuum break  24  can be any of a number of conventional vacuum breaks, such as incorporating a one inch (2.54 centimeters) air gap.  
         [0031]    Flow control  26  maintains a constant rate of flow of water in water line  22 . In a preferred embodiment, flow control  26  maintains a flow rate of one gallon (3.8 liters) per minute. Having an accurate and consistent rate of flow in water line  22  enables apparatus  10  to produce an accurate and consistent dilution rate. If the volume of water flowing in water line  22  is known, a precise amount of concentrate added to water line  22  will produce a known dilution rate.  
         [0032]    Concentrate  28  is fluidly coupled to inlet  30  of constant flow rate pump  32 . Outlet  34  is fluidly coupled, via tee  36 , to water line  22 . Constant flow rate pump  32  is electrically power and is electrically activated by latching solenoid valve  18 . Thus, when a user manually activates latching solenoid pump  18  to allow water flow through water line  22 , constant flow rate pump  32  is also activated. Thus, whenever water is flowing through water line  22 , constant flow rate pump  32  is also pumping concentrate  28  into water line  22 .  
         [0033]    Constant flow rate pump  32  may be manually or automatically adjustable to vary the rate at which concentrate  28  is pumped into water line  22 , or constant flow rate pump can simply pump concentrate  28  in water line  22  at a predetermined rate.  
         [0034]    Since the rate of flow of water in water line  22  is known and the rate at which concentrate  28  is pumped into water line  22  can be controlled by constant flow rate pump  32 , the dilution rate of concentrate  28  to water in water line  22  can not only be known but can also be controlled very accurately.  
         [0035]    A peristaltic pump is an example of a pump that can be used as constant flow rate pump  32 . A peristaltic pump operates with a roller or rollers compressing a tube containing the liquid being pumped, in this case, concentrate  28 . The flow rate through a peristaltic pump can be precisely controlled by controlling the rate of rotation of the roller or rollers, the inside diameter of the tubing used in the peristaltic pump and the distance between rollers. The distance between rollers and the inside diameter of the tubing creates a known volume of material being pumped. The rate of rotation of the rollers determines the rate at which that known volume of material is delivered. The advantage of a peristaltic pump is the control on the amount of material being pumped and the rate at which that material is pumped.  
         [0036]    In a preferred embodiment, constant flow rate pump  32  is commercially available model 300 peristaltic pump manufactured by Tate Western, a SHURflo company, 36 Aero Camino, Santa Barbara, Calif. Seven different tube sizes resulting in pump volumes from ⅛ cubic centimeters per revolution to 3 cubic centimeters per revolution are available. Pressures from 25 to 60 pounds per square inch (172 to 414 kilopascals) are possible depending on tube size. A preferred tubing size is ¼ cubic centimeters per revolution.  
         [0037]    Fluid then flowing in outlet pipe  38  is a precisely diluted mixture of water (diluent) and concentrate  28 . Outlet pipe  38  may be operatively coupled to a use solution container (not shown) or may otherwise be coupled, e.g., directly, to a location where the desired use solution is to be used.  
         [0038]    [0038]FIG. 2 illustrates an alternative embodiment of apparatus  10  of the present invention. Incoming water supply line  12  is directly coupled to push button water valve  40 . In contrast to latching solenoid valve  18  used in the embodiment illustrated in FIG. 1, push button water valve  40  operates to deliver water from water supply line  12  to water line  20  whenever a user pushes a button on push button water valve  40 . Water flows in water line  20  whenever a user pushes and holds a button on push button water valve  40 . Water stops flowing in water line  20  when a user ceases to push a button on push button water valve  40 . Thus, push button water valve operates to make as much use solution as desired by the user by simply pushing and holding push button water valve  40  until the desired volume of use solution is obtained.  
         [0039]    Vacuum break  24  connected in water line  20  downstream of push button water valve  40  performs the same function as in the embodiment illustrated in Figure 1. Tee  42  in water line  22  downstream of vacuum break  24  allows pressure switch  44  to be fluidly coupled to water line  22 . Flow control  26  and tee  36  also perform the same function as in the embodiment illustrated in FIG. 1.  
         [0040]    Electrical outputs  46  and  48  of pressure switch  44  are electrically connected through voltage regulator  50  and battery pack  52  to constant flow rate pump  32 . Inlet  30  of constant flow rate pump  32  is fluidly coupled to concentrate  28 . Outlet  34  of constant flow rate pump  32  is fluidly coupled into outlet pipe  38  via tee  36 . Container  54  is positioned to receive use solution from outlet pipe  38 .  
         [0041]    In operation, when water pressure exists in water line  22 , pressure switch  44  makes continuity between outputs  46  and  48  allowing battery pack  52  to energize constant flow rate pump  32 . Thus, no direct electrical connection is required between push button water valve  10  and constant flow rate pump  32 . Whenever a user pushes a button of push button water valve  40  to activate the flow of water in water line  22 , water pressure against pressure switch  44  will electrically activate constant flow rate pump  32 . Thus, whenever diluent (water) is flowing through water line  22 , constant flow rate pump  32  is adding concentrate  28  to outlet pipe  38  ensuring that the resulting use solution has the proper ratio of concentrate  28  and diluent (water). When a user obtains a sufficient amount of use solution in container  54 , the user releases the button on push button water valve  40  stopping the flow of water (diluent) and stopping the pumped addition of concentrate  28  into outlet pipe  38 .  
         [0042]    [0042]FIG. 3 illustrates an embodiment of apparatus  10 ″ of the present invention in two concentrates. A first concentrate  28  and a second concentrate  56  are diluted with diluent, in this case, water, to form a use solution. In this embodiment, first concentrate  28  is diluted into diluent at a dilution ratio lower than 1:130 making the use of an aspirator unreliable and second concentrate  56  is diluted into diluent at a dilution ratio exceeding 1:130 allowing the use of an aspirator.  
         [0043]    Water supply line  12 , water pressure regulator  14 , water pressure gauge  16 , water lines  20  and  22 , latching solenoid valve  18 , vacuum break  24 , constant flow rate pump  32  along with inlet  30  and outlet  34 , tee  36  and outlet pipe  38  operate exactly as described with respect to FIG. 1. These components ensure that concentrate  28  will be accurately diluted into the diluent (water) to form a use solution in outlet pipe  38  at a dilution ratio not more than 1:130.  
         [0044]    Concentrate  56  is also conventionally aspirated into outlet pipe  38  by conventional aspirator  58  at a dilution ratio typically exceeding 1:130.  
         [0045]    Thus, apparatus  10 ″ operates to add two concentrates ( 28  and  56 ) to the diluent flowing in water supply line  12  on demand from a user at differing dilution ratios. Concentrate  28  can be added at relatively low dilution rate while, at the same time, concentrate  56  can be added at a relatively high dilution rate. The addition of dual concentrates ( 28  and  56 ) may be advantageous to prepare use solutions using an active ingredient, such as a detergent, using concentrate  56  and, at the same time, using an added fragrance using concentrate  28 . Fragrance from concentrate  28  is added at a higher dilution ratio than the active ingredient from concentrate  56 .  
         [0046]    The separation of fragrance from the active ingredient and the ability to add them separately to the resulting use solution allows use solutions having common active ingredients but with individualized fragrances. This separation allows individual accounts purchasing active ingredient to have an individualized fragrance specific to their use and needs. It is economically feasible because multiple varieties of the active ingredient do not need to be produced, stocked, shipped and stored for each separate individualized account.  
         [0047]    Apparatus  10 ″ can be used to distribute a product using concentrates and a locally obtained diluent from water supply line  12 . A product diluted from a base concentrate, such as a cleaner or a sanitizer, can be distributed to a plurality of customers. The product, however, can be customized with the addition of a customizable concentrate, such as a fragrance. Thus, while many customers may get the base product with the base concentrate, the product may be individualized for individual customers by selecting a different customizable concentrate. Since only a small amount of the customizable concentrate may be required, e.g., with a fragrance, storage and distribution costs can be minimized with a common base concentrate utilized by many customers. Apparatus  10 ″ is useful in this environment due to the ability to add a customizable concentrate, e.g., a fragrance, with a dilution rate of not more than 1:130.  
         [0048]    In this embodiment, base concentrate can be utilized for second concentrate  56  in FIG. 3 which is aspirated into a locally obtained diluent, such as water, and customizable concentrate can be utilized for first concentrate  28  in FIG. 3. Since customizable concentrate is usually diluted at a relatively low dilution rate, e.g., not more than 1:130 while base concentrate usually has a lower dilution rate, apparatus  10 ″ is an ideal mechanism to achieve distribution of a product of this type.  
         [0049]    Various modifications and alterations of this invention will be apparent to those skilled in the art without departing from the scope and spirit of this invention. It should be understood that this invention is not limited to the illustrative embodiments set forth above.