Patent Abstract:
A powdered and liquid chemical distribution system for distributing powdered and liquid chemicals. The system includes a transport module having a plurality of chambers arranged in series to automatically distribute both a powdered chemical and a liquid chemical to a point of use along a single line, wherein the plurality of chambers share a chamber wall.

Full Description:
RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 13/483,675, filed May 30, 2012, which is a continuation of U.S. patent application Ser. No. 12/293,745, now U.S. Pat. No. 8,240,514, filed Sep. 19, 2008, which is a U.S. national phase application filing of International Patent Application No. PCT/US2007/064200, filed Mar. 16, 2007, which claims the benefit of and priority to U.S. Provisional Patent Application No. 60/787,583, filed Mar. 30, 2006, the entire contents of each of which are incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The embodiments disclosed herein relate to chemical distribution systems and in particular to a system and method for dispensing and distributing liquid and powdered chemicals to washers. 
     BACKGROUND 
     Many industries require the frequent use of accurate dosages of chemicals. These industries include the on premise laundry (OPL) and machine ware wash (MWW) industries, where large volumes of chemicals are used daily. As these chemicals are consumed, new chemicals must be shipped to the user and distributed to their eventual point of use, such as to washing machines (“washers”). 
     Typically, automated chemical distribution systems distribute liquid chemicals, as it is relatively easy to distribute liquids, as compared to non-liquids like powder, to their eventual point of use. However, transporting liquid chemicals to the end user presents a number of drawbacks. For example, liquid chemicals occupy a large volume, are heavy, and, therefore, are expensive to ship and transport to the end user. Furthermore, certain chemicals are more easily manufactured and stored as a non-liquid form, e.g., a powder, and, therefore, manufacturing and shipping these chemicals in a liquid form increases the complexity and cost, and decreases the usability, of such liquid chemicals. 
     On the other hand, non-liquid chemicals, e.g., powders, are easier to store and ship. Non-liquid chemicals are also generally less complex and expensive to manufacture. However, a non-liquid chemical is not easy to automatically distribute to its eventual point of use. However, those few automated chemical distribution systems that distribute powdered chemicals require separate automated chemical distribution systems for liquid chemical distribution. In other words, existing automated chemical distribution systems that distribute liquid chemicals to their point of use are not compatible with powdered chemicals. Such duplication of automated chemical systems substantially increases the overall complexity and cost of automatically distributing chemicals to their points of use. 
     In light of the above, it would be highly desirable to provide a single chemical distribution system that can distribute accurately dosages of both liquid and powdered chemicals. 
     SUMMARY 
     According to some embodiments, there is provided a powdered and liquid chemical distribution system including a transport module having a plurality of chambers arranged in series to automatically distribute both a powdered chemical and a liquid chemical to a point of use along a single line, wherein the plurality of chambers share a chamber wall. 
     According to some other embodiments, there is provided a powdered and liquid chemical distribution system including a transport module having a first chamber positioned to receive powdered chemical and a second chamber aligned with and fluidly connected to the first chamber and positioned to receive a liquid chemical such that the transport module automatically distributes both the powdered chemical and the liquid chemical to a point of use along a single line, wherein the second chamber fluidly connects the first chamber to the single line, and wherein the second chamber is positioned to receive the liquid chemical and to receive the powdered chemical from the first chamber. 
     According to some other embodiments, there is provided a powdered and liquid chemical distribution system having a transport module including a plurality of vertically arranged chambers to automatically distribute both a powdered chemical and a liquid chemical to a point of use along a single line, wherein the chambers are fluidly connected to a manifold, and wherein the chambers and manifold are aligned and positioned relative to each other such that fluid gravitationally flows from the chambers to the manifold. 
     According to some embodiments there is provided a method for distributing powdered and liquid chemicals. Water is introduced into an upper end of a measuring chamber. A liquid chemical is then injected into a chemical chamber that is fluidly coupled to a lower end of the measuring chamber until a desired volume of the liquid chemical has been introduced. The desired volume of liquid chemical and at least some of the water is pumped to a washer. Water and a desired dose of a powdered chemical may then be inserted into the upper end of the measuring chamber, and thereafter transported to the washer. 
     According to some other embodiments there is provided a method for distributing powdered and liquid chemicals. Water is introduced into an upper end of a chamber. A desired volume of liquid chemical is introduced into a bottom end of the chamber. The desired volume of liquid chemical and at least some of the water is then pumped to one washer of multiple washers. A desired dose of a powdered chemical and water is then introduced into an upper end of the chamber. The powdered chemical and at least some of the water is subsequently pumped to the one washer. 
     According to some other embodiments there is provided a method for distributing powdered and liquid chemicals. Water is introduced into an upper end of a chamber. A desired volume of liquid chemical is introduced into a bottom end of the chamber. The desired volume of liquid chemical and at least some of the water is then pumped to one washer of multiple washers. A desired dose of a powdered chemical and water then introduced into an upper end of the chamber. The powdered chemical and at least some of the water is subsequently pumped to the one washer. 
     In many of these various systems and methods flow of liquid is achieved with gravity feed only, where each subsequent lower chamber or tubing has a smaller size or diameter than the chamber above it. Not only does this keep liquid chemicals, powdered chemicals, and/or other chemicals from sticking to the walls of the system (which can damage the system or cause harmful chemical reactions within the system), the downsizing of chambers, and or tubing, produces a higher velocity at the exit point to help clean out or flush the system of chemicals. Also, the system is continually flushed with water before, during and after the liquid or powdered chemicals are introduced into the system. This also helps to keep the unit clean and free of harmful residue. 
     Accordingly, the above described systems and methods provide a single chemical distribution system and method, whereby accurate dosages of both liquid and powdered chemicals can be distributed along a single line to each of multiple washers. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a better understanding of the nature and objects of the invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings, in which: 
         FIG. 1  is a block diagram of a powdered and liquid chemical distribution system, according to an embodiment of the invention; 
         FIG. 2  is a partial cross-sectional view of the chemical distribution hub of the chemical distribution system shown in  FIG. 1 ; 
         FIG. 3  is a partial cross-sectional view of another chemical distribution hub, according to another embodiment of the invention; 
         FIG. 4  is a perspective view of the chambers component of a chemical distribution hub, according to another embodiment of the invention; 
         FIG. 5  is a top view looking into the third chamber of  FIG. 4 ; and 
         FIG. 6  is a perspective view of additional components of the hub shown in  FIG. 4 . 
     
    
    
     Like reference numerals refer to the same or similar components throughout the several views of the drawings. 
     DETAILED DESCRIPTION 
     The following describes various embodiments of chemical distribution systems and methods. These systems are particularly well suited for on premise laundry (OPL) and machine ware wash (MWW) applications. However, it should be appreciated that the systems and methods described herein may be used for any suitable chemical distribution applications. 
       FIG. 1  is a block diagram of a powdered and liquid chemical distribution system  100 . The system  100  includes a chemical distribution hub  104  (sometimes referred to as a transport module) that dispenses and/or distributes water and one or more chemicals to devices, such as washers  102 ( a ) and  102 ( b ), along tubes or lines  116 . In some embodiments, only a single tube or line is run to each device, unlike current systems which typically require more than one line to each device, as will be explained in further detail below. 
     Water is supplied from one or more water sources  110 , such as a municipal or city water supply. One or more powdered chemicals may be provided by one or more powdered chemical sources  106  that are coupled to the hub  104  via one or more tubes or lines  112 . In some embodiments, the water from the water source  110  is also provided to the hub  104  along the same lines  112  that supply the powdered chemical(s). Also in some embodiments, the powdered chemical sources receive disposable powdered chemical refill containers  118 . A suitable powdered chemical source and/or container is disclosed in Applicant&#39;s US Patent Publication No. US 2005/0247742A 1 entitled “Metering and Dispensing Closure,” the entire contents of which are incorporated herein by reference. 
     In addition, one or more liquid chemicals may be provided by one or more liquid chemical sources  108  that are coupled to the hub  104  via one or more tubes or lines  114 . In some embodiments, the powdered chemical sources receive disposable liquid chemical refill containers  120 . In other embodiments, one or more liquid chemicals may be supplied from a tank that is refilled, or the like. 
       FIG. 2  is a partial cross-sectional view of the chemical distribution hub  104  of the chemical distribution system  100  shown in  FIG. 1 . In some embodiments, the hub  104  includes three chambers. It should however be appreciated that more or less chambers may be used. The three chambers include a measuring chamber (“first chamber”)  208 , a chemical chamber (“second chamber”)  210 , and a transport chamber (“third chamber”)  206 . In some embodiments, the three chambers are aligned with one another in use so that the third chamber  206  is disposed vertically above the first chamber  208 , and the first chamber  208  is disposed vertically above the second chamber  210 , i.e., aligned along a vertical line that is perpendicular to the horizon. In some embodiments, the three chambers are aligned with one another such that fluid can flow under a gravitational force from the third chamber  206  to the first chamber  208 , and from the first chamber  208  to the second chamber  210 . 
     The first chamber  208  is defined by at least one first chamber wall. In some embodiments the first chamber wall is a circular wall that defines a cylinder having a first diameter D1. The volume of the chamber is selected such that any change in fluid level in the chamber is great enough to allow easy sensing of the change in pressure by a sensor, described below, while retaining the water volume low enough to allow rapid flushing at the end of a dose cycle. A suitable range of first diameters and heights of the first chamber are 0.5-2 inches and 4 to 10 inches, respectively. The first chamber  208  has a first chamber first end  242 , an opposing first chamber second end  244 , and a port  228 . The first chamber first end  242  is configured to receive into the first chamber  208 : (i) water  202 , from a water source  110  ( FIG. 1 ), and/or (ii) one or more powdered chemicals  204 , from one or more powdered chemical sources  106  ( FIG. 1 ). The port  228  is formed in the first chamber wall. In some embodiments, the port  228  is situated near the first chamber second end  244 . Also in some embodiments, the port has a diameter that is significantly larger than the pressure sensor input tube to create a trapped air pocket between the chamber and the pressure sensor input tube. Also in some embodiments, the diameter of the port  228  is chosen so that water is not drawn or held in the port by a capillary action. In some embodiments, the height of the first chamber that is used for calibration is in the range of 2 to 6 inches above the port  228 . 
     The port  228  allows fluid communication into the first chamber  208 . The port  228  is configured to be coupled to a sensor  236 . In some embodiments, the sensor  236  is a pressure sensor, such as an absolute pressure sensor, that measures the head of fluid in the first chamber  208  above the port  228 . In some embodiments, the sensor  236  is disposed within a controller  214 . The controller  214  is configured to calibrate the chemical distribution system, control the flow of water and chemicals into the hub  104 , and control the flow of water and chemicals to the various devices  102  ( FIG. 1 ), as described in further detail below. 
     The second chamber  210  is defined by at least one second chamber wall. In some embodiments the second chamber wall is a circular wall that defines a cylinder having a second diameter D2. In some embodiments, the first diameter D1, i.e., the diameter of the first chamber is larger than the second diameter D2, i.e., the diameter of the second chamber. The second diameter is chosen to be large enough to allow liquid chemicals to be injected into the second chamber, but small enough to facilitate high velocities of water to flush any liquid chemical residue from the second chamber. A suitable range second diameters and heights of the second chamber are 0.25 to 1.75 inches and 5 to 11 inches, respectively. The second chamber  210  has a second chamber first end  246 , an opposing second chamber second end  248 , and one or more chemical inlets  230  in the at least one second chamber wall. The second chamber first end  246  is configured to be coupled to the first chamber second end  244 . Each of the one or more chemical inlets  246  allows fluid communication into the second chamber  210 . In some embodiments, each of the chemical inlets is configured to be coupled to a different liquid chemical source  108  ( FIG. 1 ). Where multiple chemical inlets are provided, but fewer chemical sources are provided, the additional inlets may be capped. Each chemical inlet  230  coupled to a chemical source, is coupled to a tube or line  114 , such as a flexible plastic tube, that is coupled to the chemical source. In some embodiments, each of these chemical inlets  230  chemical source via a chemical pump  216 , as shown. For example, a flexible plastic tube transporting a liquid chemical may be inserted through a positive displacement pump, such as a peristaltic pump. In some embodiments, each chemical pump  216  is located within a respective liquid chemical source  108 . 
     The manifold  212  has a manifold inlet  250  fluidly coupled to the second chamber second end  248 . In some embodiments, the manifold may be coupled to the second chamber second end via a tube or line (see  FIG. 6 ). The manifold also includes one or more manifold outlets  232  each configured to be coupled to a different device  102  ( FIG. 1 ). Where multiple manifold outlets  232  are provided, but fewer devices are provided, the additional outlets may be capped. Each manifold outlet  232  coupled to a device, is coupled to a tube or line  116 , such as a flexible plastic tube, that is coupled to the chemical source. In some embodiments, each of these manifold outlets  232  is coupled to a respective device via a transport pump  218 , as shown. For example, a flexible plastic tube transporting water and a chemical to a device may be inserted through a positive displacement pump, such as a peristaltic pump. 
     The third chamber  206  is defined by at least one third chamber wall. In some embodiments the third chamber wall is a circular wall that defines a cylinder having a third diameter D3. Also in some embodiments, the third diameter D3, i.e., the diameter of the third chamber is larger than the first diameter D1, i.e., the diameter of the first chamber. The third chamber  206  has a larger diameter to facilitate larger volumes of, particularly of water, to be transported once calibration has taken place. The larger diameter also provides an overflow volume in case of failure of the sensor  236 , i.e., if the sensor fails, the water entering the third chamber can rise without overflowing until the flow of water is automatically stopped by the controller after a predetermined time period. A suitable range of third diameters are 3 to 7 inches. The third chamber  206  includes a third chamber first end  252  and a third chamber second end  254 . The third chamber first end  252  is configured to receive water  202  and chemicals  204  into the third chamber  206 . For example, water  202  is received from at least one water source  110  ( FIG. 1 ) and one or more powdered chemical(s)  204  are received from the powdered chemical source(s)  106  ( FIG. 1 ). The third chamber second end  254  is located opposite the third chamber first end  252 . The third chamber second end  254  is fluidly coupled to the first chamber first end  242 . 
     In use, the chemical distribution system may first be initialized to: ensure that the water level is known and ready for feed or distribution, to measure sensor offset, and to compensate for drift of the sensor output. First, the controller  214  may verify communication with the remote chemical sources, valves, pumps, etc. One or more of the transport pump(s)  218  are then run until the sensor  236  measures that the level in the first chamber has stopped dropping, i.e., the fluid in the first chamber has dropped below the port  228 . The controller then records the sensor output as zero offset, which is used to adjust all readings during feed or distribution to the devices. If the sensor continues to report that the level is dropping after a predetermined time period, then an error exists and the user is notified. 
     Next, the system checks that the transport pump and water supply are operational before starting to pump chemicals. The water supply  110  ( FIG. 1 ) is turned on and the system waits for the level to rise above the sensor to a predetermined level. One or more of the transport pumps  218  are then turned on and the controller  214  waits for the level in the first chamber  208  to drop to just above the port  228 . At that time, the transport pump is turned off. 
     To dispense a liquid chemical, all flow out of the manifold is stopped, e.g., pumps  216  and  218  are turned off. If water is not already present in the first chamber, then water is injected from the water source  110  ( FIG. 1 ) into the third chamber  206 . The water flows into the first chamber  208  and is filled to a level just above the port  228 . 
     The chemical(s) to be dispensed (typically a liquid chemical) are introduced into the second chamber  210  via one or more of the chemical inlets  230 . This may be accomplished by turning on the chemical pump(s)  216 . The entry of the chemical(s) into the second chamber  210  causes the water in the first chamber  208  to rise. The resulting change in water level in the first chamber is detected by the sensor  236 , i.e., the sensor detects the change in head (pressure) in the first chamber. As the volume of the first chamber is known, the increase in pressure is used to determine the volume of chemical(s) being injected. When the desired volume has been reached, flow of the chemical(s) into the second chamber  210  is stopped, e.g., the chemical pump(s)  216  are turned off by the controller  214 . The chemical(s) and water are then distributed to a desired device  102  ( FIG. 1 ). This may be accomplished by, for example, turning on one of the transport pumps  218  for a predetermined amount of time sufficient to pump the chemical(s) and water to a desired device  102  ( FIG. 1 ). The water that follows the chemical(s) to the device has the added advantage of flushing the chemical distribution system of the chemical(s). 
     Where larger dosages of liquid chemicals are to be dispensed and distributed, the chemical to be dispensed (typically a liquid chemical) is introduced into the second chamber  210  via one or more of the chemical inlets  230 . This may be accomplished by turning on the chemical pump  216 . The entry of the chemical into the second chamber  210  causes the water in the first chamber  208  to rise. The resulting change in water level in the first chamber is detected by the sensor  236 , i.e., the sensor detects the change in head (pressure) in the first chamber. As the volume of the first chamber is known, the increase in pressure is used to determine the volume of chemical being injected. When a predetermined volume has been injected, flow of the chemical into the second chamber  210  is stopped by the controller  214  turning off the chemical pump  216 . The controller  214  also measures the time that it takes the chemical pump  216  to inject the predetermined volume. The controller  14  uses the predetermined volume and the measured time to determine the flow rate of the liquid chemical being injected by the chemical pump  216 . Using this calculated flow rate, the controller turns on the chemical pump  216 , a flow of water, and the transport pump  218  until the larger dosages of liquid chemical has been dispensed and distributed. During this dispensing and distributing phase, the controller maintains the level of water in the third chamber by measuring the pressure and turning on or off the transport pump  218  and/or water flow into the third chamber. The larger volume of the third chamber allows for some variation in water volume in the third chamber as the level is maintained. In this way larger dosages of liquid chemicals may be distributed to a desired device  102  ( FIG. 1 ). As described above, the water that follows the chemical(s) to the device has the added advantage of flushing the chemical distribution system of the chemical(s). 
     To dispense a powdered chemical, a known dose of powdered chemical  204  and water  202  is introduced into top of the third chamber  206 . The water and powdered chemical mix is then distributed to a desired device  102  ( FIG. 1 ). An advantage of this system is that the powdered chemicals may be distributed to each device along the same single line as the liquid chemicals. This may be accomplished by, for example, turning on one of the transport pumps  218 . More water may then be injected into the third chamber  206  to flush the chemical distribution system of the chemical. 
     The above described chemical distribution system and method allows the controller  214  to accurately dispense a desired dose of powdered and/or liquid chemicals to a ware wash or laundry washer along a single tube or line  116 . 
       FIG. 3  is a partial cross-sectional view of another chemical distribution hub  300 . Chemical distribution hub  300  is configured to receive water  302 , one or more powdered chemicals  304 , and one or more liquid chemicals  305 . Unlike the hub  104  shown in  FIG. 2 , the hub  300  includes only a single chamber  307 . The chamber  307  is defined by at least one chamber wall. In some embodiments the chamber wall is a circular wall that defines a cylinder having a predetermined diameter D. The volume of the chamber is selected such that any change in fluid level in the chamber is great enough to allow easy sensing of the change in pressure by a sensor, while retaining the water volume low enough to allow rapid flushing at the end of a dose cycle. A port  308  is formed in the chamber wall that allows fluid communication into the chamber. The port  308  is coupled to a sensor. In some embodiments, the sensor is a pressure sensor, such as an absolute pressure sensor, that measures the head of fluid above the port  308 . In some embodiments, the sensor  236  ( FIG. 2 ) is disposed within a controller (not Shown), which calibrates the chemical distribution system, controls the flow of water and chemicals into the hub, and controls the flow of water and chemicals to the various devices  102  ( FIG. 1 ). 
     The chamber  307  also includes one or more liquid chemical inlets  310  in the chamber wall below the port  308 , and one or more outlets  312  that are each configured to be coupled to a different device  102  ( FIG. 1 ). In use, liquid chemicals  306  are introduced into the chamber through the chemical inlets  310 , and powdered chemicals  304  are introduced into the chamber through the top of the chamber  322 . The water and chemicals are distributed to the devices through the outlets  312 . Calibration, dosage, measurement, distribution and other control occurs in a similar manner to that described above in relation to  FIG. 2 . 
       FIG. 4  is a perspective view of the chambers component of a chemical distribution hub  400 , according to another embodiment of the invention. The hub  400  includes many of the same components as described above in relation to  FIG. 2 . For example, hub  4  includes a first chamber  404  that is similar to the first chamber  208  ( FIG. 2 ), a second chamber  408  that is similar to the second chamber  210  ( FIG. 2 ), a third chamber  402  that is similar to the third chamber  206  ( FIG. 2 ), three chemical inlets  410  that are similar to the chemical inlets  230  ( FIG. 2 ), and a port  406  coupled to a sensor that is similar to the port  228  ( FIG. 2 ). In some embodiments, the port  406  is disposed at an acute angle to the first chamber wall so that the port drains as the water level drops during flushing of water and chemical(s) to the devices  102  ( FIG. 1 ). Although each of the first, second, and third chambers are shown in  FIG. 2  as having stepped boundaries, in this embodiment the boundaries between chambers are graduated, e.g., the diameters of the chambers change gradually so that fluid easily drains from the chambers and there is no powder build-up. The hub  400  also includes an outlet port  412  that is coupled to a manifold via tube or line, as shown and described in relation to  FIG. 6 . A suitable range of diameters for the outlet port  412  is ⅛ to 1 inches. 
       FIG. 5  is a top view looking into the third chamber  402  of  FIG. 4 . To prevent false readings of the sensor that may occur when water or chemicals entering the first chamber  402  pass directly over the port  406 , a baffle  502  is positioned in the first chamber  402  above the port  406 . The baffle  502  may be coupled to the wall of the first chamber. In some embodiments, the baffle  502  is formed in an angled shape to deflect water and chemicals away from the port  406 . The baffle  502  may be formed from the same material as the first, second, and third chambers, and in some embodiments may be injection molded together as a single piece together with the first, second, and third chambers, port, and chemical inlets. 
       FIG. 6  is a perspective view of additional components of the hub  400  shown in  FIG. 4 . This view of the hub  400  includes the chambers shown in  FIG. 4 . The outlet  412  is fluidly coupled to a manifold  604  via a flexible tube or pipe  602 . The three outlets from the manifold are in turn fluidly coupled to three separate transport pumps  608  via flexible tubes or lines. In some embodiments, the transport pumps are peristaltic pumps. Each of the flexible tubes or lines exiting the manifold is configured to be fluidly coupled to a separate device, such as a washer. In some embodiments, the chambers, manifold  604 , and pumps  608  are coupled to a mounting plate  606  to allow the hub  400  to be wall mounted. The hub  400  may also house the controller  214  ( FIG. 2 ). A housing (not shown) may connect to the mounting plate  606  to enclose the above described components. 
     While the foregoing description and drawings represent the preferred embodiments of the present invention, it will be understood that various additions, modifications and substitutions may be made therein without departing from the spirit and scope of the present invention as defined in the accompanying claims. In particular, it will be clear to those skilled in the art that the present invention may be embodied in other specific forms, structures, arrangements, proportions, and with other elements, materials, and components, without departing from the spirit or essential characteristics thereof. For example, it should be appreciated that while the above described systems and methods are directed to dispensing and distributing chemicals to washers, such as fabric washers or dishwashers, the above described systems and method may be used equally well to dispense and distribute chemicals to any other suitable devices or applications, such as water conditioners, swimming pools, etc. The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims, and not limited to the foregoing description.

Technology Classification (CPC): 3