Abstract:
A mixing apparatus and system includes a hub, a plurality of blades, and a respective hinge for each blade to pivotally secure each blade to the hub. Each hinge including a lock having a tab and a detent to secure the respective blade in an operating conformation.

Description:
FIELD OF THE INVENTION 
     The present disclosure generally relates to an impeller. More particularly, the present disclosure pertains to a folding impeller for use in a mixing system or assembly that utilizes containers or vessels having relatively small openings for mixer insertion. 
     BACKGROUND 
     Mixing and blending applications, in particular the mixing and blending of liquids, liquid suspensions and gases, are often constrained by the diameter of the tank in which the mixing is being carried out and by the diameter of the impeller. Moreover, the size and diameter of the manway through which the impeller and shaft is inserted can further constrain the mixing application and the impeller employed. 
     The impeller blades need to be inserted through the manway in the vessel for installation. In some covered mixing vessels, manways are commonly 24″ in size and can pass impeller blades of up to 23″ in width at best. Therefore, in order to insert larger blades, operators either have to install an oversized manway, or the blades must be supplied in a longitudinally split configuration and then assembled inside the vessel. Splitting the impeller blades is an expensive operation, especially for blades having a rounded, leading edge, twist and curvature. In addition, multiple bolts are required along with match marking to assure proper, gap free re-assembly. This process can be very difficult and time consuming because the inner and outer blade components must be aligned correctly so that the impeller balance and blade geometry will not be compromised. 
     Thus for vessels or containers with relatively small manways, it may be advantageous to utilize a folding impeller as an alternative to splitting the impeller blades or employing an oversized manway. However, conventional folding impellers suffer from a variety of deficiencies. For example, folding impellers must be held well away from the bottom of the container to reduce damage to the container and/or blades in the folded position. Also, the folding mechanism of conventional impellers causes serious disturbances in laminar flow of fluid around the impeller blades. Accordingly, it is desirable to provide an impeller that is capable of overcoming the disadvantages described herein at least to some extent. 
     SUMMARY 
     The foregoing needs are met, to a great extent, by embodiments the present disclosure, wherein in one respect an impeller is provided that is capable of mixing fluids in a container. 
     An embodiment of the present invention relates to an attachment assembly for attaching an impeller system to a vessel or the like, comprising: a frame comprising: a first end and a second end generally opposing one another; a first side that extends between said first and second ends; a second side that extends between said first and second ends generally parallel to the said first side; a first rotational rod having first and second ends that extends between said first and said second sides; and a second rotational rod having first and second ends that extends between said first and said second sides; a base plate disposed on said frame, wherein said base plate extends between said first and said second sides and has a bore extending therethrough; a locking lever; a first bracket connected to said locking lever and said first rotational rod; a second bracket connected to said locking lever and said second rotational rod; a first latch mounted to said first rotational rod; and a second latch mounted to said second rotational rod. 
     Another embodiment pertains to an impeller drive assembly for driving a mixing impeller or the like, comprising: an attachment assembly comprising: a frame comprising: a first end and a second end generally opposing one another; a first side that extends between said first and second ends; a second side that extends between said first and second ends generally parallel to the said first side; a first rotational rod having first and second ends that extends between said first and said second sides; and a second rotational rod having first and second ends that extends between said first and said second sides; a base plate having a bore disposed on said frame, wherein said base plate extends between said first and said second sides; a locking lever; a first bracket connected to said locking lever and said first rotational rod; a second bracket connected to said locking lever and said second rotational rod; a first latch mounted to said first rotational rod; and a second latch mounted to said second rotational rod; and a motor releasably mounted to said attachment assembly. 
     Yet another embodiment relates to a method for attaching an impeller assembly to a vessel or the like, comprising: connecting an attachment assembly to the vessel, the attachment assembly comprising: a frame comprising: a first end and a second end generally opposing one another; a first side that extends between said first and second ends; a second side that extends between said first and second ends generally parallel to the said first side; a first rotational rod having first and second ends that extends between said first and said second sides; and a second rotational rod having first and second ends that extends between said first and said second sides; a base plate having a bore disposed on said frame, wherein said base plate extends between said first and said second sides; a locking lever; a first bracket connected to said locking lever and said first rotational rod; a second bracket connected to said locking lever and said second rotational rod; a first latch mounted to said first rotational rod; and a second latch mounted to said second rotational rod; translating the locking lever to a first position, urging the first and second latch to engage the vessel; and mounting a motor to the base plate of the attachment assembly. 
     In yet another embodiment of the present invention, an attachment assembly for attaching an impeller system to a vessel or the like, comprising: means for connecting an attachment assembly to the vessel, the attachment assembly comprising: a frame comprising: a first end and a second generally opposing one another; a first side that extends between said for and second ends; a second side that extends between said first and second ends generally parallel to the said first side; a first rotational rod having first and second ends that extends between said first and said second sides; and a second rotational rod having first and second ends that extends between said first and said second sides; a base plate having a bore disposed on said frame, wherein said base plate extends between said first and said second sides; a locking lever; a first bracket connected to said locking lever and said first rotational rod; a second bracket connected to said locking lever and said second rotational rod; a first latch mounted to said first rotational rod; and a second latch mounted to said second rotational rod; means for translating the locking lever to a first position, urging the first and second latch to engage the vessel; and means for mounting a motor to the base plate of the attachment assembly. 
     In another embodiment of the present invention, an impeller assembly, is disclosed comprising: a hub; a first blade; a second blade; a first hinge having a first tab and first detent connected to said hub, wherein said first hinge pivotally secures said first blade to said hub; a second hinge having a second tab and a second detent connected to said hub, wherein said second hinge pivotally secures said first blade to said hub. 
     In an embodiment of the present invention, an impeller assembly is disclosed, comprising: a hub comprising: a first hinge integral thereto having a first tab and first detent; and a second hinge integral thereto having a first tab and first detent connected a first blade connected to said first hinge; and a second blade connected to said first hinge. 
     Another embodiment discloses a method of positioning an impeller into an operating position, comprising: inserting the impeller in to a mixing vessel or the like, wherein the impeller comprises: a hub; a first blade; a second blade; a first hinge having a first tab and first detent connected to said hub, wherein said first hinge pivotally secures said first blade to said hub; a second hinge having a second tab and a second detent connected to said hub, wherein said second hinge pivotally secures said first blade to said hub; translating the first blade to the operating position by pivoting the first blade whereby the first tab engages the first detent such that the first blade extends outwardly from the hub; and translating the second blade to the operating position by pivoting the second blade whereby the second tab engages the second detent such that the second blade extends outwardly from the hub. 
     In still another embodiment of the present invention, an impeller assembly is disclosed, comprising: means for inserting the impeller in to a mixing vessel or the like, wherein the impeller comprises: a hub; a first blade; a second blade; a first hinge having a first tab and first detent connected to said hub, wherein said first hinge pivotally secures said first blade to said hub; a second hinge having a second tab and a second detent connected to said hub, wherein said second hinge pivotally secures said first blade to said hub; means for translating the first blade to the operating position by pivoting the first blade whereby the first tab engages the first detent such that the first blade extends outwardly from the hub; and means for translating the second blade to the operating position by pivoting the second blade whereby the second tab engages the second detent such that the second blade extends outwardly from the hub. 
     In another embodiment of the present invention, an impeller assembly is disclosed, comprising: a sleeve having a first end and a second end; a bung hole closure sealingly disposed at the first end; and an impeller disposed at the second end, the impeller comprising: a hub; a first blade; a second blade; a first hinge having a first tab and first detent connected to said hub, wherein said first hinge pivotally secures said first blade to said hub; and a second hinge having a second tab and a second detent connected to said hub, wherein said second hinge pivotally secures said first blade to said hub. 
     In yet another embodiment, a mixing apparatus and system is disclosed comprising: a vessel having a bung hole disposed on an upper surface thereof; a motor attached to said vessel, wherein said motor has a having a shaft; an attachment assembly to attach the motor to the vessel; and an impeller assembly comprising: a sleeve having a first end and a second end, the shaft being configured to slide within the sleeve; a bung hole closure disposed at the first end, the bung hole closure being configured to mate with the bung hole; and a sleeve having a first end and a second end; a bung hole closure sealingly disposed at the first end; and an impeller disposed at the second end, the impeller comprising: a hub; a first blade; a second blade; a first hinge having a first tab and first detent connected to said hub, wherein said first hinge pivotally secures said first blade to said hub; and a second hinge having a second tab and a second detent connected to said hub, wherein said second hinge pivotally secures said first blade to said hub. 
     In still yet another invention of the present invention, a method for mixing multiple components within a mixing vessel is disclosed, comprising: inserting an impeller assembly into the vessel, wherein the impeller assembly comprises: a motor attached to said vessel, wherein said motor has a shaft; an attachment assembly to attach the motor to the vessel; and a sleeve having a first end and a second end; a bung hole closure sealingly disposed at the first end; and an impeller disposed at the second end, the impeller comprising: a hub; a first blade; a second blade; a first hinge having a first tab and first detent connected to said hub, wherein said first hinge pivotally secures said first blade to said hub; and a second hinge having a second tab and a second detent connected to said hub, wherein said second hinge pivotally secures said first blade to said hub; translating the first blade to an operating position by pivoting the first blade whereby the first tab engages the first detent such that the first blade extends outwardly from the hub; and translating the second blade to the operating position by pivoting the second blade whereby the second tab engages the second detent such that the second blade extends outwardly from the hub. 
     And finally, another embodiment of the present invention discloses a mixing system apparatus, comprising: means for inserting an impeller assembly into the vessel, wherein the impeller assembly comprises: a motor attached to said vessel, wherein said motor has a shaft; an attachment assembly to attach the motor to the vessel; and a sleeve having a first end and a second end; a bung hole closure sealingly disposed at the first end; and an impeller disposed at the second end, the impeller comprising: a hub; a first blade; a second blade; a first hinge having a first tab and first detent connected to said hub, wherein said first hinge pivotally secures said first blade to said hub; and a second hinge having a second tab and a second detent connected to said hub, wherein said second hinge pivotally secures said first blade to said hub. means for translating the first blade to an operating position by pivoting the first blade whereby the first tab engages the first detent such that the first blade extends outwardly from the hub; and means for translating the second blade to the operating position by pivoting the second blade whereby the second tab engages the second detent such that the second blade extends outwardly from the hub. 
     There has thus been outlined, rather broadly, certain embodiments of the disclosure 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 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 in detail, it is to be understood that the disclosure 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 disclosed device and method 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 various embodiments. 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 various embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a cutaway perspective view of an impeller system in accordance with an embodiment of the present invention. 
         FIG. 2  is a detailed view of  FIG. 1 . 
         FIG. 3  is a perspective view of a mounting bracket assembly in accordance with an embodiment of the present invention. 
         FIG. 4  is a cross sectional view of the impeller system in a first position. 
         FIG. 5  is a cross sectional view of the impeller system in a second position. 
         FIG. 6  is a side view of an impeller assembly in accordance with an embodiment of the present invention. 
         FIG. 7  is another side view of the impeller assembly depicted in  FIG. 6 . 
         FIG. 8  is a cross sectional view of a drive shaft engaged to an impeller head in accordance with an embodiment of the present invention. 
         FIG. 9  is a cross sectional view of a locking mechanism for the impeller system in accordance with an embodiment of the present invention. 
         FIG. 10  is a more detailed view of the locking mechanism illustrated in  FIG. 9 . 
         FIG. 11  is a plan view of the impeller hub in accordance with an embodiment of the present invention. 
         FIG. 12  is a more detailed view of the impeller the impeller hub. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     An embodiment will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout.  FIG. 1  is a cutaway perspective view of a mixing system generally designated  10 . The mixing system  10  comprises a container or mixing vessel  12  having support frame or cage  14  extending at least partially around the mixing vessel  12 . As illustrated in  FIG. 1 , the mixing system  10  includes an impeller assembly  16  that includes an impeller  18 , sleeve  20  through which a drive shaft  21  extends, and bung closure  22 . The impeller assembly  16  further includes a mounting bracket assembly  24 , which will be discussed in further detail below, motor mount  26 , motor  28 , and an output shaft  30 . 
     In general, the motor  28  is configured to rotate the drive shaft  21 . The drive shaft  21  is configured for insertion down through the bung closure  22  and sleeve  20  to engage with the impeller  18 . Rotation of the drive shaft  21  urges the impeller  18  to rotate. 
     Turning specifically to  FIGS. 2 and 3 , a more detailed view of  FIG. 1  is set forth illustrating the mixing assembly  16  which includes the mounting bracket assembly  24  and the motor mount  26 . As shown in  FIG. 2 , the mixing assembly  16  comprises upper and lower flanges,  32  and  34  respectively, wherein the upper flange  32  is attached the output shaft  30  while the lower flange  34  is attached to the drive shaft  21 . As depicted in  FIG. 2 , the upper flange  32  has a series of slots  36  positioned about its periphery while the lower flange  34  has a series of dogs  38  positioned about its periphery extending therefrom. During operation, the upper flange  32  and lower flange  34  are releasably connected to one another via the above-described dogs and slots. For example, the dogs  38  mate with the slots  36  wherein the dogs  38  are inserted into the respective slot  36 , and the shafts are rotated such that the dogs engage the upper flange  32  and retain the upper  32  and lower  34  flanges in place. 
     Turning now to  FIG. 3 , a perspective view of the mounting bracket assembly  24  in accordance with an embodiment of the present invention is illustrated. As shown in  FIG. 3 , the mounting bracket assembly  24  may be generally rectangular in geometry having first and second opposing sides  40  and  42  along with opposing ends  44  and  46 . The mounting bracket assembly further includes rods  41  that extend generally parallel to one another between the opposing sides  40  and  42  along with a base plate  48  upon which the motor mount  26  and impeller assembly  16  is attached. The base plate  48  extends between the first and second sides  40 ,  42  and has a circular bracket  50  that assists in aligning the mounting bracket assembly  24  to the motor  28 . The base plate  48  has a circular opening that aligns the bracket to the vessel. The circular bracket  50  has at least two dogs  52  disposed thereon attaching the motor to the bracket. The mounting bracket assembly  24  further includes latching connectors  54  that releasably attach the mounting bracket assembly  24  and thus the motor mount  26  (shown in  FIGS. 1 and 2 ) to the vessel via the cage  14 . The bracket assembly  24  attaches the motor mount via a sling lever action that comprises a pair of side brackets  43  mounted to the sides  40 ,  42  that are actuated via a single lever action  58  that operates to rotated the latching connectors  54  into the locked and unlocked position. The side brackets  43  engage the latching connectors  54  at the rods  41 . Depending upon the embodiment, the rods  41  may rotate with the latching connectors  54  or otherwise remain stationary. 
     Turning now to  FIG. 4 , a cross sectional view of the impeller system  10  in a first position or operating position is depicted. By operating position, it is meant that the upper flange  32  and lower flange  34  are mated to one another via the slots  36  and dogs  38 , therefor mating the drive shaft  21  to the output shaft  30  of the motor. Moreover, due to the aforementioned mating, the drive shaft  21  is translated upward and thus the bung hole  31  of the vessel  12  is open because the bung closure  22  is disposed relatively above the bung hole  31  of the vessel. This described disposition of the closure  22  is due to the previously described translation of the drive shaft  21 . 
     In this first position, threads  60  disposed upon the bung closure  22  are not mated to or engaged with threads  62  disposed within the bung hole  31  allowing for the drive shaft  21  to freely rotate. Also shown in  FIG. 4 , the drive shaft  21  extends down through the sleeve  20 . 
     Moving on to  FIG. 5 , whereas  FIG. 4  illustrated the assembly in a first or operating position,  FIG. 5  depicts a cross sectional view of the impeller system  10  in a second position or closed, shipping position. By closed position it is meant that the upper flange  32  and lower flange  34  are no longer mated to one another via the slots  36  and dogs  38  and disconnected from one another and in turn, disconnecting the drive shaft  21  from the output shaft  30  of the motor  28 . Moreover, due to the aforementioned disconnection, the drive shaft  21  is removed from the sleeve  20 . Furthermore, as illustrated in  FIG. 5 , the bung closure  22  is now disposed within the bung hole  31 . As illustrated in this second position, threads  60  disposed upon the bung closure  22  are mated to or engaged with threads  62  disposed within the bung hole  31  thus sealing the vessel. As such, the impeller assembly  16  is secured to the container and may be shipped without the likelihood of spillage. 
     Turning to  FIGS. 6 and 7 , each is a side view of a portion of the impeller assembly  16  in accordance with an embodiment of the present invention. More particularly,  FIGS. 6 and 7  illustrate the portion of the impeller assembly extending from the bung hole  31 , into the vessel  12 . As shown in  FIG. 6 , the impeller assembly  16  is a single sealed unit with the various components being friction welded or otherwise permanently affixed to one another. The impeller assembly  16  may be made from any suitable material or materials. Suitable materials include those with sufficient structural rigidity and strength to withstand being rotated in fluid and other such loads placed upon the impeller assembly  16 . Specific examples of suitable materials include polymers such as polyethylene terephthalate (PETE), high-density polyethylene (HDPE), and the like. 
     Also shown in  FIGS. 6 and 7 , the impeller  18  includes a plurality of blades  70  that are substantially air foil in shape. That is, the blades  70  are configured to generate a laminar flow as they are driven through a fluid. In this manner, efficient mixing of the fluid within the container  12  may occur. This smooth and airfoil shape is particularly surprising given that the embodiment shown in  FIGS. 6 and 7  is a folding impeller to facilitate ingress and egress from the bung hole  31 . In this regard, each of the blades  70  includes a respective hinge  72 . 
     Optionally, the impeller assembly  16  includes a post  74  to rest upon the bottom of the container  12  when the impeller assembly  16  is in the second position or shipping position. 
     Turning now to  FIG. 8 , a cross sectional view of the drive shaft  21  connected to the impeller  18  in accordance with an embodiment of the present invention is illustrated. As depicted in  FIG. 8 , the drive shaft  21  includes detents  80  to receive and retain clips  82  in the impeller  18 . In this manner, the shaft  21  is detachably secured to the impeller  18  and thus, the impeller assembly  16 . 
     As illustrated in  FIG. 8 , the sleeve  20  encompasses the drive shaft  21  and is plastic welded to the impeller  18 . Also, as depicted in  FIG. 8 , the end of the drive shaft  21 , generally designated  84  has a two machined flats geometry that assists with the connection to the impeller  18 . Moreover, the shaft end  84  has a preferred length to enable the impeller  18  to disengage from the shaft  21  and sleeve  20  if the drive shaft  21  were to detach from the drive shaft  21  or translate or shift downward during operation of the mixer assembly  10  preventing engagement of the bung threads  60 ,  62  while the motor  28  is rotating the output shaft  30 . 
     Turning now to  FIGS. 9 and 10 , cross sectional views of the prior discussed hinge  72  are depicted. Specifically, the locking mechanism, each generally designated  90 , for the blades  70  of the impeller  18  is depicted in detail. Whereas  FIG. 9  shows the hinge  72  in combination with the mounting to the shaft  21  and the related connection thereto,  FIG. 10  is a detailed depiction of the locking mechanism  90 . As shown in both  FIGS. 9 and 10 , the blade  70  is oriented in the operating position. By operating position, in general, it is intended that the blades  70  are locked or retained in the operating position by a locking mechanism  90  of varying designs that are capable of retaining the blade  70  in the operating position, however in one embodiment of the present invention, the locking mechanism is preferably retained by a snap-lock. 
     As illustrated, in the particular example shown, the locking mechanism  90  of the hinge  72  includes a detent or snap down  92  that engages a sear or positive ramp  94 . The detent  92  and sear  94  ‘snap’ lock to retain the blade  70  in the operating position. Moreover, the aforementioned locking mechanism  90  is a single, one time use connection. By one time use it is meant that when the blade  70  is rotated from the operational position as illustrated, downward or upward as preferred, “shaving” or otherwise removal the sear  94  occurs, preventing the blade  70  from being locked in the operating position again. Thus, once the blade  70  is forced from the operating position, removing the sear  94 , the snap-lock locking mechanism  90  may not be utilized again. Also shown in  FIGS. 9 and 10  is a shaft  96  upon which the blade  70  pivots is shown. The shaft  96  appears oblong because the cross sectional view is taken at an oblique angle relative to the axis of the shaft  96 . 
     Referring now to  FIGS. 11 and 12 , isometric plan views of the impeller  18  in a folded position or non-operational position. For example, in this position, the impeller assembly  16  and accompanying impeller  18  may be inserted or removed from the vessel  12 . As shown in  FIGS. 11 and 12 , the locking mechanism  90  comprises the detent  92  that engages the sear  94 . 
     Also depicted in  FIGS. 11 and 12 , the impeller  18  includes a fitting  104  disposed in a hub  106  of the impeller  18  that receives the end portion  84  of the drive shaft  21 . As previously discussed, the end of the drive shaft  21 , generally designated  84  has a two machined flats geometry that assists with the connection to the impeller  18 . Moreover, the shaft end  84  has a preferred length to enable the impeller  18  to disengage from the drive shaft  21  and sleeve  20  if the drive shaft  21  were to detach from the output shaft  30  or translate or shift downward during operation of the mixer assembly  10  preventing engagement of the bung threads  60 ,  62  while the motor  28  is rotating the output shaft  30 . Thus, in the particular example shown, the fitting  104  is a double D type fitting. In other examples, the fitting  104  may include a square drive, hexagonal, or the like. The clips  82  are configured to retain the drive shaft  21  within the fitting  104 . 
     The many features and advantages of the various embodiments are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages that fall within the true spirit and scope of the embodiments. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the embodiments 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 various embodiments.