Abstract:
The invention relates to a container assembly that includes a built-in follow plate for loading a viscous fluid into the barrel of a dispensing device. The assembly includes a drum for holding a viscous fluid therein and a lid for fitting over the drum open top to effect closure of the drum. The assembly includes a horizontally oriented follow plate detachable from the lid. The follow plate includes a central hub arranged for receiving the barrel of a dispensing device. The follow plate moves in response to a change in the level of fluid in the drum as it is drawn into the barrel of the dispensing device.

Description:
[0001]    This application claims the benefit under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 61/723,349, filed on Nov. 7, 2012 entitled CONTAINER ASSEMBLY INCLUDING A DETACHABLE FOLLOW PLATE FOR LOADING BULK MATERIAL THEREFROM, the disclosure of which is incorporated by reference herein. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    This invention relates generally to dispensing materials from a container (drum, barrel, pail, etc.) using apparatus including a follower plate which is lowered into the drum housing the material to be dispensed. In particular, the invention relates to a follow plate that is detachable from a drum lid and is low cost and disposable. 
         [0003]    The viscosity of materials to be dispensed using apparatus of the present invention varies depending upon the specific application, and it is not unusual to find materials which are not particularly viscous and are substantially free flowing. On the other hand in certain applications such materials may be extremely viscous and require the application of considerable heat and/or pressure in order to render such materials dispensable. The present invention is applicable to apparatus for dispensing highly viscous materials and also useful with substantially free flowing materials. 
         [0004]    In one form of apparatus of the type contemplated by the present invention a follow plate is caused to be lowered into open end of a drum-like container housing the material to be dispensed. In operation, as the follow plate enters the drum it engages the inside surface of the drum and the material therein. As the follow plate travels towards the closed base of the drum it causes the material sandwiched or pressured therebetween to be dispensed, as for example, by forcing the material through an opening in the follow plate. The follow plate fits within the end of the drum and “follows” the fluid level in the drum as the fluid is withdrawn from the drum. The follow plate is often used for loading bulk caulking material or epoxy into the barrel of a device or gun for dispensing such materials. The barrel defines a cylindrical chamber into which the caulking material or epoxy is drawn prior to dispensing. The barrel is attached to an opening in the follow plate and by retracting a piston rod within the barrel of the dispensing device, the caulking material or epoxy may be drawn from the drum into the barrel for dispensing. 
         [0005]    There are a number of problems associated with the use of such follow plates. Usually, such follow plates are made of metal parts, and/or multiple components, and therefore can be costly. For this reason, disposal of the follow plate after a single use is not preferred. Rather, it is necessary to remove the follow plate from the spent drum for reuse in the next drum. Often this can be a difficult and time consuming effort because residual viscous material remaining in the drum that may have begun to cure will impede easy removal of the follow plate. Often the follow plate will be provided with a hook or a tab to facilitate such removal of the follow plate from the drum for reuse. Removal of the follow plate from the drum can be also difficult due to the weight of the follow plate. Accordingly, it is an object of the present invention to overcome these difficulties by developing a low cost follow plate that is detachable from a container lid and can be disposed of with the drum when the contents of the drum has been emptied. 
       BRIEF SUMMARY OF THE INVENTION 
       [0006]    The invention relates to a container assembly having a lid that includes a built-in follow plate for loading a viscous fluid into the barrel of a bulk dispensing device. Alternatively, the follow plate may be arranged for attaching to a hose, pipe, tubing, etc., for dispensing. The assembly includes a drum for holding a viscous fluid therein, the drum including an open top, a central axis, and an inner side wall. The assembly includes a lid having a peripheral channel arranged for fitting over the drum open top to effect closure of the drum. The lid also includes an annular skirt extending inwardly from the peripheral channel to define a central opening. The assembly also includes a horizontally oriented follow plate detachable from the lid by means of a pull tab. The follow plate includes an opening, e.g., a central hub, arranged for receiving the barrel of a bulk dispensing device. Alternatively, the central hub could be arranged for attaching to a hose, pipe, tubing or other useful attachment for dispensing. The follow plate is movable by external means along the central axis of the drum in response to a change in the level of fluid in the drum as it is drawn into the barrel of the bulk dispensing device. The follow plate includes an outer periphery that is in sliding engagement with the drum inner side wall. 
     
    
     
       BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS 
         [0007]    The invention will be described in conjunction with the following drawings in which like reference numerals designate like elements and wherein: 
           [0008]      FIG. 1  is an isometric view of prior art container assembly of the present invention; 
           [0009]      FIG. 2  is an isometric view of a prior art container assembly of the present invention; 
           [0010]      FIG. 3  is a sectional view taken along line  3 - 3  of  FIG. 2 ; 
           [0011]      FIG. 4  is sectional view illustrating the prior art follow plate “following” the material downwardly as material is being suctioned into the barrel of a bulk dispensing device or other attachment; 
           [0012]      FIG. 5  is a perspective view of an embodiment of the container assembly of the present invention illustrating the follow plate assembly integral with the pail or drum lid; 
           [0013]      FIG. 6  is an isometric view of a portion of an embodiment of the container assembly of the present invention illustrating the follow plate assembly integral with the pail or drum lid; 
           [0014]      FIG. 7  is a sectional view of an embodiment of the container assembly of the present invention showing the follow plate attached to the lid in contact with material inside the pail or drum; 
           [0015]      FIG. 8  is a sectional view taken along line  8 - 8  of  FIG. 6 ; 
           [0016]      FIG. 9  is a cross sectional view of a container assembly of the present invention illustrating a second embodiment of the follow plate assembly integral with the pail or drum lid; 
           [0017]      FIG. 10  is a cross sectional view of the container assembly of  FIG. 9  illustrating the second embodiment follow plate illustrating the manner for separating the follow plate assembly from the lid of the pail; and, 
           [0018]      FIG. 11  is a cross sectional view of the container assembly of  FIG. 9  illustrating the second embodiment follow plate during loading of viscous material into the barrel of a bulk dispensing device. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0019]    Under the prior art, illustrated in  FIGS. 1-4 , a container assembly  10  is provided to the user in a pre-filled condition with the viscous material  18  located within the drum  14 . A lid (not shown) is removed and a follow plate  19  of the prior art is inserted to contact the viscous material  18 . Next, as shown in  FIGS. 1-4 , the user attaches a barrel  53  of a bulk dispensing device to a central hub  21  of the follow plate  19  and applies downward pressure as indicated by arrow  17  in  FIG. 4 . As best illustrated in  FIGS. 3 and 4 , as a result of this downward pressure, the viscous material  18  will begin to flow upwardly through the central hub  21  of the follow plate  19  and into the barrel  53  of the dispensing device. Simultaneously, the user pulls back on the piston rod  23  of the dispensing device in the direction indicated by arrow  24  to draw the viscous material  18  into the dispenser barrel  53  until the barrel  53  is filled. Once filled, the barrel  53  can be removed from the central hub  21  and bulk material can be dispensed from the dispensing device. As bulk viscous material  18  is repeatedly drawn from the drum  14 , the follow plate  19  moves towards the bottom of the drum  14 . Once the follow plate  19  reaches the bottom of the drum  14 , the follow plate  19  is removed from the bottom of the drum  14  for re-use, which can be difficult and time-consuming for reasons stated above. 
         [0020]    Referring now to an embodiment of the present invention, there is shown in  FIGS. 5 through 8  a container assembly including a drum  14  for containing and dispensing therefrom a viscous material  18  such as an epoxy or caulking material. The drum  14  includes a base  22  and a side wall  26  extending upwardly from the outer periphery of the base  22  to an upper edge  30  ( FIGS. 7 and 8 ). A lid  34  is provided for covering the drum  14  during sale, shipping, and use. The lid  34  includes an annular upper wall  38  and an annular lower wall  42 . An inner annular lip  46  protrudes downwardly from an inner circumference of the annular upper wall  38  to connect the annular upper wall  38  to the annular lower wall  42 . An annular outer wall  50  extends downwardly from the annular upper wall  38 . Together, the outer wall  50 , annular wall  38  and annular lip  46  form a peripheral channel for fitting over the upper edge  30  of the drum  14 . The annular lower wall  42  defines an opening  52  ( FIG. 8 ). By providing the opening  52 , the lid  34  may remain in place over the drum  14  during loading of the viscous material  18  from the drum  14  into the barrel of a bulk dispensing device (not shown). 
         [0021]    The annular lower wall  42  includes a bottom surface to which a disposable follow plate  54  is attached by any suitable means. In one embodiment shown in  FIGS. 5 through 7 , a “break away” mechanism or “pull-tab”  58  is interposed in the form of a strip between the lower wall  42  bottom surface and the follow plate  54 . The pull tab  58  may be attached to the bottom surface of the lower wall  42 , as well as to the follow plate  54  by any suitable method, e.g., overmolding. As best illustrated in  FIG. 6 , a pulling force  59  may be applied to the pull tab  58  to remove the follow plate  54  from the lid  34  when it is desired to load a barrel  53  of a bulk dispensing device (not shown) with viscous material  18  provided in bulk within the drum  14 . 
         [0022]    The follow plate  54  may be made of any suitable material, such as a nitrile rubber, neoprene, metal, plastic, or another suitable chemical resistant material. In another embodiment, the material forming the follow plate  54  may be of any suitable material hardness, e.g., (Shore A) in the range of 70A to 90A. The follow plate  54  may be provided with an integral central hub  62  in the form of a cylinder having an open top and an open bottom to enable a user to draw viscous material  18  from within the drum  14 . The follow plate  54  includes a plurality of reinforcement ribs  64  that extend radially from the central hub  62  to the periphery thereof, or can be made of another suitable design for reinforcement. 
         [0023]    As the follow plate  54  is lowered into the drum  14  and engages the viscous material  18 , there is a tendency for the viscous material to flow from the bottom of the follow plate  54  over the top of the follow plate  54  at the peripheral surface or edge thereof where the follow plate abuts the inside surface of the drum  14 . For example, in those instances where the follow plate  54  is cylindrical and is caused to extend into a cylindrical drum  14  for purposes of dispensing viscous material  18  from within the drum  14 , there is a tendency for the viscous material  18  to flow or leak between the outer periphery of the follow plate  54  and the inside surface of the drum  14 . In order to prevent such leakage and to direct substantially all of the viscous material  18  through the central hub  62 , for example, the follow plate  54  discussed above may be encircled with one of more resilient sealing means which serve to scrape the inside surface of the drum  14  and also to prevent or reduce leakage at the interface between the inside surface of the drum and the periphery of the follow plate. Alternatively, as best shown in  FIGS. 7 and 8 , towards its periphery, the follow plate  54  is reduced in thickness to facilitate sliding engagement with the inner side wall of the drum  14 . 
         [0024]    In one embodiment, the central hub  62  may include an outer diameter that is sized to fit within the inner diameter of a barrel  53  of a dispensing device ( FIGS. 1-4 ). A cap  66  arranged to be fitted over the central hub  62  and may be removed from the central hub  62  by applying a pulling force to a pull tab  70  integral with the cap  66 , the pull tab  70  that is similar to a “tamper-evident” ring commonly used on a plastic milk container. In one embodiment, once the cap  66  has been removed from the central hub  62 , the barrel  53  of a dispensing gun ( FIGS. 1-4 ) may be placed over the central hub  62  of the follow plate  54  to provide an interference fit between the inner diameter of the dispensing device barrel (not shown) and the outer diameter of the central hub  62  to create a seal for drawing viscous material  18  into the dispensing device barrel (not shown). Under this embodiment there are no internal or external threads utilized for securing the barrel (not shown) to the central hub  62 . Alternatively, the central hub  62  of the follow plate  54  could be sized to enable the bulk dispensing device (not shown) to be placed within the central hub  62  to provide an interference fit between the outer diameter of the barrel (not shown) and the inner diameter of the central hub  62  to create a similar seal for drawing viscous material  18  into the barrel (not shown). In an alternative embodiment (not shown) the internal surface of the barrel (not shown) could be provided with threads and the central hub  62  provided with external threads to enable threaded engagement between the dispensing device barrel (not shown) or any other connection meant for dispensing, and the central hub  62 . 
         [0025]    In use, the container assembly  10  is provided to the user in a pre-filled condition with the viscous material  18  located within the drum  14 . The container assembly  10  is provided with the lid  34  fitted over the upper edge  30  of the drum  14  and the removable pull tab  58  attaching the follow plate  54  to the underside of the lid  34 . Without removing the lid  34  from the drum  14 , the user may remove the pull tab  58  to separate the follow plate  54  from the underside of the lid  34 . Next, the cap  66  may be removed by pulling pull tab  70  to expose the central hub  62  of the follow plate  54 . Next, as best shown in  FIGS. 7 and 8 , the user applies downward pressure (indicated by arrow  72 ) on the follow plate  54  until it makes contact with the viscous material  18  within the drum  14 . As a result of this downward pressure, viscous material  18  will begin to flow upwardly through the central hub  62 . Once material reaches the tip of the central hub  62 , the user will extend the bulk dispenser barrel (not shown) through the lid opening  54  and install the barrel directly over the central hub  62  to create a positive seal between the barrel (not shown) and the central hub  62 . Next, using the bulk dispensing device, the user pushes down on the follow plate  54  while simultaneously pulling up on the piston rod (not shown) of the bulk dispenser to draw viscous material into the dispenser barrel (not shown) until the dispenser barrel is filled. Once filled, the barrel can be removed from the central hub  62  and bulk material can be dispensed from the dispensing device. As bulk viscous material  18  is repeatedly drawn from the drum  14 , the follow plate  54  moves towards the bottom of the drum  14 . Once the follow plate  14  reaches the bottom of the drum  14 , it can be disposed of along with the drum  14  and attached lid  34 . Alternatively, the user can install a connection device to the follow plate hub (such as a hose, pipe, or tube) to dispense material from the drum. 
         [0026]    Referring now to  FIGS. 9-11 , there is shown a second embodiment  100  of the present invention including an alternative follow plate  154  which is shown attached by any suitable means to the bottom surface of a lower annular wall  142  of a lid  134  provided for covering a drum  114  containing a viscous material during sale, shipping, and use. The lid  134  is substantially the same as that of the first embodiment, in that it includes an annular upper wall  138 , the annular lower wall  142 , and an annular lip  146  extending at an inclined angle to connect the upper and lower annular walls,  138 ,  142  respectively. Together, the outer wall  150 , annular upper wall  138  and annular lip  146  form a peripheral channel for fitting over an upper edge  130  of the drum  114 . The annular lower wall  142  defines an opening  152  ( FIG. 11 ) to enable the lid  134  to remain in place over the drum  114  during loading of the viscous material  118  from the drum  114  into a barrel  115  of a bulk dispensing device. 
         [0027]    A “break away” mechanism or “pull-tab”  158  ( FIG. 9 ) is interposed in the form of a strip between the lower wall  142  and the follow plate  154 . The pull tab  158  may be attached to the lower annular wall  142 , as well as to the follow plate  154  by any suitable method, e.g., overmolding. As described in the earlier embodiment, a pulling force may be applied to the pull tab  158  to detach the follow plate  154  from the lid  134  when it is desired to load the barrel  115  of the bulk dispensing device with viscous material  118  provided in bulk within the drum  114 . 
         [0028]    The follow plate  154  of this embodiment  100  includes a disk member  156  which is generally circular and includes a centrally-located hub  160 , which is generally cylindrical in shape. As in the first embodiment, the follow plate  154  may include a plurality of ribs  164  extending radially from the hub  160  to outer periphery  156   a  of the disk member  156  to provide added stiffness to the disk member  156 . The disc member  156  may be formed of any suitable rigid plastic material such polypropylene. Attached to and extending radially from the outer periphery  156   a  of the disk member  156  is a relatively soft and flexible overmold  168 , which extends to the inside wall of the drum  114 . 
         [0029]    The overmold  168  may be formed of any suitable material, such as PVC or TPE (thermoplastic elastomer), and as demonstrated in  FIGS. 9-11 , actually reduces in thickness as it extends radially and approaches the inside wall of the drum  114 . As is often the case, the rigid plastic drum  114  may reduce slightly in circumference as it extends from its upper edge  130  downwardly to the bottom surface of the drum  114 . As best shown by comparing  FIGS. 10 and 11 , during use, once detached from the lid  134 , the follow plate  154  incrementally advances downwardly towards the bottom of the drum  114  to enable repeated loadings of the barrel  115 . During this movement, the outer edge  168   a  of the overmold  168  actually bends or flexes upwardly against the inside wall of the drum  114  to permit the follow plate  154  to continue its downward advancement into the drum  114  during incremental loadings of viscous material  118  into the barrel  115 . In this manner, the substantial majority of viscous material  118  contained within the drum  114  may be withdrawn into the barrel  115  of the dispensing device resulting in only a minimal amount of waste and leakage across the follow plate  154 . Due to the stiffness of the disk member  156 , during use, the disk member  156  in combination with the overmold  168  serves to prevent adhesive or caulk material within the drum  114  from leaking across the follow plate  154  as the follow plate  154  is pressed down into the drum  114  during loading of the barrel  115 . 
         [0030]    A gasket  172  is provided to encircle the centrally-located hub  160  of the disk member  156 . Like the overmold  168 , the gasket  172  may be formed of any suitable material such as PVC or TPE (thermoplastic elastomer) and serves to provide a seal between the barrel  115  and the hub  160 . Under this embodiment, the gasket  172  may be sized to fit over the outer diameter of the hub  160  of the follow plate  154  during loading. Prior to loading, a cap  173  ( FIGS. 9 and 10 ) is arranged to be fitted over the gasket  172  surrounding the central hub  160  and may be removed from the gasket  172  by applying a pulling force to a pull tab  175  integral with the cap  173 . The pull tab  175  may be similar to a “tamper-evident” ring commonly used on a plastic milk container. In one embodiment, once the cap  173  has been removed from the gasket  172  surrounding the central hub  160 , the barrel  115  may be placed within the hub  160  to provide an interference fit between the outer diameter of the barrel  115  and the inner diameter of the hub  160  to create a seal for drawing viscous material  118  into the dispensing device barrel  115 . The gasket  172  prevents leakage across the follow plate  154  during loading. Under this embodiment, there are no internal or external threads utilized for securing the barrel  115  to the hub  160 , although such a mechanism for attachment is contemplated under this invention. 
         [0031]    It is understood that the container assembly including a detachable follow plate and its constituent parts described herein is an exemplary indication of a preferred embodiment of the invention, and is given by way of illustration only. In other words, the concept of the present invention may be readily applied to a variety of preferred embodiments, including those disclosed herein. While the invention has been described in detail and with reference to specific examples thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.