DIAPHRAGM PUMP UTILIZING DUCKBILL VALVES, MULTI-DIRECTIONAL PORTS AND FLEXIBLE ELECTRICAL CONNECTIVITY

Abstract

Diaphragm pump features upper/lower diaphragm pumping assemblies (U/LDPAs) for pumping fluid and a manifold assembly arranged therebetween. The manifold assembly include a manifold body having an inlet with dual inlet ports and an inlet chamber to receive the fluid from a source; an inlet check valve assembly channel having an inlet duckbill check valve assembly (DCVA) arranged therein to receive the fluid from the dual inlet ports; U/LDPAs orifices having the U/LDPA arranged therein to receive the fluid from the inlet DCVA via first upper/lower manifold conduits and provide the fluid from the U/LDPAs via second upper/lower manifold conduits; an outlet check valve assembly channel having an outlet DCVA arranged therein to receive the fluid from the U/LDPAs; and an outlet having dual outlet ports and an outlet chamber to receive the fluid from the U/LDPAs and provide the fluid from the pump to a outlet source.

Claims

1-18. (canceled)

19. A dual diaphragm pump (10), comprising: upper and lower diaphragm pumping assemblies (12, 14); and a manifold assembly (20) arranged between the upper and lower diaphragm pumping assemblies (12, 14), the upper and lower diaphragm pumping assemblies (12, 14) configured to pump a particle medium having solids and particulates with up to four millimeters in diameter through the manifold assembly (20) without fouling or clogging, the manifold assembly (20) having a manifold body that is a plastic injection molded integral structure and includes: an inlet having at least one inlet port (20a (1), 20a (2)) and an inlet chamber (20a) configured to receive the particle medium from at least one fluid source, an inlet check valve assembly channel formed therein and being in fluidic communication with the inlet chamber (20a) and both of the upper and lower diaphragm pumping assemblies (12, 14), an inlet duckbill check valve assembly having two input duckbill check valves (30, 32) arranged in the inlet check valve assembly channel (20d), each input duckbill check valve configured to allow the particle medium to pass from the inlet chamber (20a), through the inlet check valve assembly channel (20d), to a respective one of the upper and lower diaphragm pumping assemblies (12, 14), an outlet check valve assembly channel formed therein and being in fluidic communication with both of the upper and lower diaphragm pumping assemblies (12,14), an outlet duckbill check valve assembly having two output duckbill check valves (40, 42) arranged in the outlet check valve assembly channel (20e), each output duckbill check valve configured to allow the particle medium to pass from the respective one of the upper and lower diaphragm pumping assemblies (12, 14) and through the outlet check valve assembly channel, and an outlet having an outlet chamber (20b) and at least one outlet port (20b (1), 20b (2)), the outlet chamber (20b) being in fluidic communication with the outlet check valve assembly channel (20e), and configured to allow the particle medium to pass from the outlet check valve assembly channel (20e), through the outlet chamber (20b), to the at least one outlet port (20b (1), 20b (2)) for providing to at least one fluid outlet source.

20. A dual diaphragm pump (10) according to claim 19, wherein the at least one inlet port (20a (1), 20a (2)) comprises dual inlet ports (20a (1), 20a (2)) configured to receive inlet port fitting connections, and the at least one outlet port comprises dual outlet ports (20b (1), 20b (2)) configured to receive outlet port fitting connections.

21. A dual diaphragm pump (10) according to claim 20, wherein the dual inlet ports (20a (1), 20a (2)) are configured or oriented orthogonal to one another; and the dual outlet ports (20b (1), 20b (2)) are configured or oriented orthogonal to one another.

22. A dual diaphragm pump (10) according to claim 20, wherein the dual inlet ports (20a (1), 20a (2)) and the inlet chamber (20a) are configured to receive the particle medium from two fluid sources for mixing together in the inlet chamber (20a); and the dual outlet ports (20b (1), 20b (2)) and the outlet chamber (20b) are configured to provide a mixed fluid to the at least one fluid outlet source.

23. A dual diaphragm pump (10) according to claim 20, wherein either the dual inlet ports (20a (1), 20a (2)), or the dual outlet ports (20b (1), 20b (2)), or both the dual inlet ports (20a (I), 20a (2)) and the dual outlet ports (20b (I), 20b (2)) are configured to receive different port fitting connections.

24. A dual diaphragm pump (10) according to claim 19, wherein the manifold assembly (20) comprises two manifold assembly plates (12b, 14b) attached to upper and lower surfaces of the manifold body and configured with first and second manifold conduits.

25. A dual diaphragm pump (10) according to claim 19, wherein the two input duckbill check valves (30, 32) include an upper input duckbill check valve configured to provide the particle medium from the inlet check valve assembly channel (20d) to an upper diaphragm pumping assembly, and include a lower input duckbill check valve configured to provide the particle medium from the inlet check valve assembly channel (20d) to a lower diaphragm pumping assembly; and the two output duckbill check valves (40, 42) include an upper output duckbill check valve configured to provide the particle medium from an upper diaphragm pumping assembly via the outlet check valve assembly channel (20e) to the outlet chamber (20b), and include a lower output duckbill check valve configured to provide the particle medium from a lower diaphragm pumping assembly via the outlet check valve assembly channel (20e) to the outlet chamber (20b).

Description

BRIEF DESCRIPTION OF THE DRAWING

[0035] The drawing, which are not necessarily drawn to scale, includes the following Figures:

[0036] FIG. 1 shows a front-to-back cross-sectional view of a pump that is known in the art.

[0037] FIG. 2 shows a perspective view of a pump having a single inlet and outlet, according to some embodiments of the present invention.

[0038] FIG. 2A shows a cross-sectional view of a lower half of the pump in FIG. 2 along lines and arrows 2A-2A, according to some embodiments of the present invention.

[0039] FIG. 3 shows a top down plan view of the pump in FIG. 2, according to some embodiments of the present invention.

[0040] FIG. 4 shows a side view of the pump in FIG. 2, according to some embodiments of the present invention.

[0041] FIG. 4A shows a cross-sectional view of a left side of the pump in FIG. 2 along lines and arrows 4A-4A, according to some embodiments of the present invention.

[0042] FIG. 5 shows a front-to-back cross-sectional view of the pump in FIG. 2 along lines and arrows 5-5, according to some embodiments of the present invention.

[0043] FIG. 6 shows a top perspective view of a pump housing with multi-ports, including inlet ports and outlet ports, according to some embodiments of the present invention.

[0044] FIG. 7 shows a top perspective view of a pump housing with multi-ports including inlet ports and outlet ports, according to other embodiments of the present invention.

[0045] FIG. 7(A) shows a top perspective view of part of a pump having a pump assembly with the pump housing in FIG. 7 configured with inlet/outlet port fitting connections extending in left/right directions transverse to the longitudinal axis of the pump, according to other embodiments of the present invention.

[0046] FIG. 7(B) shows a top perspective view of part of a pump having a pump assembly with the pump housing in FIG. 7 configured with inlet/outlet port fitting connections extending in a front direction along the longitudinal axis of the pump, according to other embodiments of the present invention.

[0047] FIG. 7(C) shows a top perspective view of part of a pump having a pump assembly with the pump housing in FIG. 7 configured with inlet/outlet port fitting connections extending in the left/right directions and a dual outlet port fitting connection extending in a left/right direction and a front direction, according to other embodiments of the present invention.

[0048] FIG. 8 shows a back-to-front cross-sectional view of the pump in FIG. 2 along lines and arrows 8-8, according to some embodiments of the present invention.

[0049] FIG. 9A shows a flowchart having steps for implementing control functionality for operating a pump arrangement or configuration like that shown in FIG. 9B, according to some embodiments of the present invention.

[0050] FIG. 9B shows part of a pump arrangement or configuration having a motor coupled via a printed circuit board assembly (PCBA) to a pressure switch, an on/off switch and a connector for receiving an input, for operating a pump, according to some embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 2-8: The Dual Diaphragm and Manifold Assembly

[0051] FIGS. 2-8 show a dual diaphragm pump generally indicated as 10, according to some embodiments of the present invention. FIGS. 1-5 show the dual diaphragm pump generally indicated as 10 having a single inlet/outlet configuration. In contrast, FIGS. 6-8 show configurations for a dual diaphragm pump having a multiple inlet/outlet configuration. In either case, the dual diaphragm pump may be configured with a multipart pump housing, e.g., having a motor housing 11a and a removable front cover 11b, and may also include a pump stand or mount 11c. FIG. 2A shows a motor 13 and a motor shaft/diaphragm actuator assembly 15 arranged in the multipart pump housing, which couples to upper and lower diaphragm pumping assemblies generally indicated as 12, 14 (see FIGS. 7A, 7B and 7C), e.g., that cooperate consistent with that described below. FIGS. 7A, 7B, 7C also shows the dual diaphragm pump configured with a pressure sensor or switch module 50 (see also FIG. 9B) that senses the pressure of the fluid being pumped, and provides a suitable pressure sensing signal containing information about the pressure sensed. Pressure sensors and/or switches are known in the art, and the scope of the invention is not intended to be limited to any particular type or kind thereof either now known or later developed in the future. In FIGS. 7A, 7B and 7C, the front pump housing for covering the configuration of the multiport manifold assembly is not shown, e.g., which is analogous to element 11b in FIGS. 1-5. The scope of the invention is not intended to be limited to how the multipart pump housing may be configured, combined or assembled together, etc., e.g., including the number of discrete parts in the configuration, combination or assembly.

[0052] Moreover, FIGS. 2 through 4A and 8 show that the dual diaphragm pump may also be configured with a quick connector 60 (see also FIG. 9B) for coupling to a corresponding connector for providing electrical power to the pump, e.g., including from a wall mounted transformer (not shown). The quick connector 60 configured on the pump wiring allows a user to specify the connector they require, and the wiring from their system would be configured with a suitable mating connector and plug for coupling directly into the pump. This quick connector configuration 60 allows for a quick and safe removal of a pump for a power source for the purpose of servicing. Flexible wiring options may also be configured that also allow for remote mounting of signal input/output devices and a power input.

The Manifold Assembly 20, 20

[0053] The diaphragm pump may include a manifold assembly like elements 20 and 20, e.g., as shown in FIGS. 6 and 7.

[0054] By way of example, FIG. 7 shows the manifold assembly 20 equipped with internal input and output duckbill valves 30, 32, 40, 42 that allow for the passing of solids and particulate in the liquid being pumped without fouling or clogging the internal duckbill valves 30, 32, 40, 42. The integration of the internal duckbill valves 30, 32, 40, 42 allows the diaphragm pump 10 to handle higher viscosity fluids with less restriction and is capable of passing a larger particle medium of sizes up to 4 millimeters (mm) in diameter, especially when compared to the prior art pump shown in FIG. 1. The internal input and output duckbill valves 30, 32, 40, 42 can be reinforced with an internal support to prevent the respective valve from collapsing in applications that will generate higher back pressures during operation or when the pump is not running, e.g., consistent with that disclosed in U.S. Pat. No. 8,276,616 (Atty docket no. M-FLJ-0902//911-5.49-2) and U.S. Pat. No. 8,690,554 (Atty docket no. M-FLJ-1002//911-5.52-1), which are assigned to the assignee of the present application and hereby incorporated by reference in their entirety.

[0055] The diaphragm pump may include the upper and lower diaphragm pumping assemblies generally indicated as 12, 14 in combination with the manifold assembly 20, e.g., as shown in FIG. 4A and 5. By way of example, the upper and lower diaphragm pumping assemblies 12, 14 may be configured with upper and lower diaphragm 12a, 14a, and upper and lower diaphragm assembly covers or plates 12b, 14b that are respectively fastened to the manifold assembly 20, as shown. See the five (5) fasteners/screws like element f1 in FIGS. 7A, 7B and 7C, and the corresponding five (5) fastener openings like element o1 configured or formed in the manifold assembly 20 in FIG. 7. See also FIGS. 7A, 7B and 7C, which show the upper diaphragm pumping assembly 12.

[0056] In operation, the upper and lower diaphragm pumping assemblies 12, 14 may be configured for pumping fluid through the dual diaphragm pump 10. By way of example, the upper diaphragm pumping assembly 12 may be configured to draw the fluid from the inlet chamber 20a into the manifold assembly 20, through the upper input duckbill valve 30, through the upper output duckbill valve 40, to the outlet chamber 20b and from the manifold assembly 20; and the lower diaphragm pumping assembly 14 may be configured to draw the fluid from the inlet chamber 20a into the manifold assembly 20, through the lower input duckbill valve 32, through the lower output duckbill valve 42, to the outlet chamber 20b and from the manifold assembly 20, e.g., consistent with that shown in FIG. 5.

[0057] The manifold assembly 20 may be configured or arranged between the upper and lower diaphragm pumping assemblies 12, 14 and have components configured to operate as follows:

[0058] As best shown in FIGS. 5 and 7, in addition to the inlet chamber 20a, and the outlet chamber 20b, the manifold assembly 20 may also include or be configured with a combination of a one-piece integral manifold body 20c, an inlet check valve assembly channel 20d having upper diaphragm pumping assembly orifices, one such inlet orifice which is labeled 20d (1), and an outlet check valve assembly channel 20e having upper and lower diaphragm pumping assembly orifices, one such outlet orifice which is labeled 20e (1).

[0059] The inlet 20a may be configured with dual inlet ports generally indicated as 20a (1), 20a (2) to receive the fluid from at least one fluid source (not shown). The dual inlet ports 20a (1), 20a (2) may be configured with inlet port channels 20a (3), 20a (4) to slidably receive inlet fitting couplers 20a (5), 20a (6) that couple inlet fittings 20a (7), 20a (8) to the dual inlet ports 20a (1), 20a (2) of the manifold assembly 20.

[0060] The inlet check valve assembly channel 20d may include an inlet duckbill check valve assembly arranged therein that may include the inlet duckbill check valve 30, 32, as well as one or more other inlet duckbill check valve assembly components like valve receiving members 30(1), 32(1), and internal supports (not shown) to prevent the valve from collapsing in applications that will generate higher back pressures during operation or when the pump is not running, e.g., consistent with that disclosed in U.S. Pat. No. 8,276,616 (Atty docket no. M-FLJ-0902//911-5.49-2) and U.S. Pat. No. 8,690,554 (Atty docket no. M-FLJ-1002//911-5.52-1).

[0061] By way of example, the manifold body 20c may include, or take the form of, a plastic injection molded integral structure, although embodiments are envisioned using other structures or configuration both now known and later developed in the future within the spirit on the underlying invention.

[0062] FIG. 5 shows a flowpath of fluid through the dual diaphragm pump, including an input partway of a fluid flow path FP.sub.in for fluid flowing into the inlet 20a, an internal part for fluid flowing through the inlet check valve assembly channel 20d, through the upper and lower diaphragm pumping assemblies 12, 14, and through the outlet check valve assembly channel 20e, and an output flowpath FP.sub.out for fluid flowing from the outlet 20b, e.g., consistent with that set forth herein.

[0063] The upper diaphragm pumping assembly inlet orifice 20d (1) may be configured to be in fluidic communication with the upper diaphragm pumping assembly like element 12 arranged therein to receive the fluid from the inlet duckbill check valve 30, as well as one or more other inlet duckbill check valve assembly components like valve receiving members 30(1), provide (i.e. pump) the fluid via upper manifold conduits indicated by reference label 12b , 12b , 12, to the upper diaphragm pumping assembly orifice 20e (1). In operation, and as a person skilled in the art would appreciate, the motor shaft/diaphragm actuator assembly 15 together with the diaphragm 12a may be configured in order to provide the liquid from the upper manifold conduit 12b , through the upper manifold conduits 12b , and to the upper manifold conduit 12. The upper diaphragm pumping assembly outlet orifice 20e (1) may be configured to be in fluidic communication with the outlet check valve assembly channel 20e, for providing fluid to the outlet duckbill check valve 40, as well as one or more other outlet duckbill check valve assembly components like valve receiving members 40(1), and provide (i.e. pump) the fluid to the outlet 20b.

[0064] As a person skilled in the art would appreciate, the lower diaphragm pumping assembly 14 is configured to operate in a similar manner to the upper diaphragm pumping assembly 12.

[0065] The outlet 20b may be configured with dual outlet ports generally indicated as 20b (1), 20b (2) to provide the fluid the pump 10 to at least one fluid outlet source (not shown). The dual outlet ports 20b (1), 20b (2) may be configured with outlet port channels 20b (3), 20b (4) to slidably receive outlet fitting couplers 20b (5), 20b (6) that couple outlet fittings 20b (7), 20b (8) to the dual outlet ports 20b (1), 20b (2) of the manifold assembly 20.

FIGS. 7, 7A, 7B and 7C

[0066] FIGS. 7, 7A, 7B and 7C show multi-directional port configurations. In effect, the present invention allows for many different inlet/outlet port connections which provide for flexibility in certain tight, fixed spaces. By way of example, with the dual inlet ports, mixing of two (2) different fluids may be made possible as well; and the dual discharge ports allow for two (2) dispensing valves/faucets.

[0067] As shown, the dual inlet ports 20a (1), 20a (2) may be configured or oriented orthogonal to one another; and the dual outlet ports 20b (1), 20b (2) are configured or oriented orthogonal to one another, although embodiments are envisioned using other types or kinds of geometric relationship between the dual inlet ports, the dual output ports, or both.

[0068] The dual inlet ports 20a (1), 20a (2) and the inlet chamber 20a may be configured to receive the fluid from two fluid sources (not shown) for mixing together in the inlet chamber 20a; and the dual outlet ports 20b (1), 20b (2) and the outlet chamber 20b are configured to provide a mixed fluid to at least one fluid outlet source (not shown).

[0069] The inlet duckbill check valve assembly 20d and the outlet duckbill check valve assembly 20e may be configured to process a particle medium having up to 4 millimeters (mm) in diameter.

[0070] Either the dual inlet ports 20a (1), 20a (2), or the dual outlet ports 20b (1), 20b (2), or both the dual inlet ports 20a (1), 20a (2) and the dual outlet ports 20b (1), 20b (2), may be configured to receive different port fitting connections.

[0071] It is noted that in FIGS. 7A, 7B and 7C the part of the pump shown does not include, by way of example, the front pump housing analogous to element 11b in FIG. 2. A person skilled in the art would appreciate how to configured such a front pump housing without undue experimentation, e.g., based on that disclosed herein.

[0072] FIG. 6 shows an alternative embodiment of the manifold assembly 20, having parts and components thereof labeled similar to the parts and components of the manifold assembly 20 in FIG. 7 with the additional of a single quote . The manifold assembly 20 is configured to operate in a manner substantially similar to the manifold assembly 20 (FIG. 7).

FIGS. 9A and 9B: The Controller

[0073] FIG. 9A shows a flowchart generally indicated as 100 having steps 100a through 100k for implementing control functionality according to the present invention for operating a pump, e.g., having at least some combination of the components shown in FIG. 9B, consistent with that set forth herein.

[0074] Controller 52The electronics controller may include, or take the form of, an electronic PCBA 52, e.g., that may be internal to the pump, as shown in FIG. 9B. [0075] i. Steps 100a and 100b: Power may be applied to the pump via a power supply jack or an integral connector 60, which allows for direct power to the pump via the end user's source or from a wall mount transformer (not shown), so the On/Off switch 54 can be turned On. [0076] ii. Steps 100c and 100d: The control circuit 52 then applies power to the motor 13 and allows a pre-designated time for priming. If the pump exceeds that time and there is a low/no current draw condition, then the control circuit 52 shuts the power off. The control circuit 52 then sends a signal indicating that the pump has shut down due to a run dry/no power condition. By way of example, the signal may take the form of an audio or visual alarm, as well as a wireless signal provided to a remote location, including a wifi signal transferred via the Internet to a remote (e.g., off site) access point. [0077] iii. Steps 100d, 100e, 100f: If the pump primes and is running, then the control circuit 52 monitors the current draw on the pump, and if the pump unit's current draw drops beneath a designated current range, whether by the fluid being pumped being exhausted or by some other issue, then the control circuit 52 will remove power to the motor 13. The control circuit 52 then sends a signal indicating that the pump has shut down due to a run dry/no power condition or an out-of-product being dispensed condition. [0078] iv. Steps 100h, 100i, 100j: If the pump experience a high current draw, e.g., exceeding a pre-designated range, then the control circuit 52 will remove power to the motor 13 and then sends a signal indicating that the pump has shut down due to an over-current condition. [0079] v. By way of further example, if the power to the circuit board 52 should be removed by the pressure switch 50, e.g., due to an outlet (not shown) being shut off, then the control circuit 52 may be configured to remove power form the pump until the pressure is relieved at which time the control circuit 52 may be configured to automatically turn the pump back on and supply fluid. [0080] vi. By way of further example, if the pump runs continuously for a specified period of time, then the circuit board 52 may be configured to remove the power from the motor and sends a signal indicating the pump has shut down due to a continuous running or time-out condition. [0081] vii. By way of further example, the control circuit 52 may also be configured to precisely control the dispense amount and flow rate, e.g., by controlling the time and/or varying the voltage to the motor 13 using a pulse wave modulation (PWM) technique, or other method of motor speed control, including techniques both known in the art or later developed in the future. [0082] viii. By way of further example, the control circuit 52 may also be used for storing, communicating, and/or remotely adjusting the pump operating parameters/settings, pump performance profiles with various fluids and media, error codes, flow rate, and dispensed quantity information, power consumption, etc.

Possible Applications

[0083] Food and Beverage dispensing/processing, Fluid and chemical transfer and mixing, any application that may require moving liquid with high viscosity, particulates and/or solids.

The Scope of the Invention

[0084] Further still, the embodiments shown and described in detail herein are provided by way of example only; and the scope of the invention is not intended to be limited to the particular configurations, dimensionalities, and/or design details of these parts or elements included herein. In other words, a person skilled in the art would appreciate that design changes to these embodiments may be made and such that the resulting embodiments would be different than the embodiments disclosed herein, but would still be within the overall spirit of the present invention.

[0085] It should be understood that, unless stated otherwise herein, any of the features, characteristics, alternatives or modifications described regarding a particular embodiment herein may also be applied, used, or incorporated with any other embodiment described herein. Also, the drawings herein are not drawn to scale.

[0086] Although the invention has been described and illustrated with respect to exemplary embodiments thereof, the foregoing and various other additions and omissions may be made therein and thereto without departing from the spirit and scope of the present invention.