Dual-head, pulseless peristaltic-type metering pump

Abstract

A dual-head, pulseless peristaltic-type pump comprises a pump housing, cover, two compressible tube chambers and two sets of rotatable occluding members. An off-center drive axis driven by motor or other rotational mechanism rotate inner large diameter disk. Balls or rollers between inner disk rotate in one direction from center drive axis where the outer ring is stationary and occludes the tube by linear motion without friction between tube and outer ring. The linear roller occluding motion transfers liquid or slurry from inlet to outlet of tube. In one embodiment, two separate sets of occluding members are installed 180 degree opposite to each other such that pulsations are compensated for and canceled out.

Claims

1. A dual-head, pulseless peristaltic-type metering pump comprising: a main body portion; a drive shaft assembly extending longitudinally through the main body portion and having two drive shaft portions and a central common axis, two distal ends and at least one non-round portion; a first pump head comprising: an L-shaped cover portion; a tube input, the tube input in conjunction with the L-shaped cover portion defining an input buffering space within which the tube is free to move, before being occluded by a roller element, and accumulated tension in the tube is relieved; a tube output, the tube output in conjunction with the L-shaped cover portion defining an output buffering space unique from the input buffering space within which the tube is free to move and accumulated tension in the tube is relieved following occlusion by a roller element; and a roller element assembly comprising: a round inner roller element having a non-round shaped, keyed opening that matches the at least one non-round portion of the drive shaft assembly, the round inner roller element mounted off-axis onto the at least one non-round portion of the drive shaft assembly, the inner roller element having an external surface; a set of ball bearings disposed around the inner roller element in contact with the external surface thereof; and a round outer race roller element having an inner surface and an external surface, the outer race roller element encircling and containing the set of ball bearings such that as the drive shaft assembly is rotated, the inner roller element rotates off axis, the round, outer race element is stationary relative to a tube and radial rotation of the drive shaft assembly transfers a single linear occluding force to the tube adjacent the roller element assembly; a second pump head comprising: an L-shaped cover portion; a tube input, the tube input in conjunction with the L-shaped cover portion defining an input buffering space within which the tube is free to move, before being occluded by a roller element, and accumulated tension in the tube is relieved; a tube output, the tube output in conjunction with the L-shaped cover portion defining an output buffering space unique from the input buffering space within which the tube is free to move and accumulated tension in the tube is relieved following occlusion by a roller element; and a roller element assembly comprising: a round inner roller element having a non-round shaped, keyed opening that matches the at least one non-round portion of the drive shaft assembly, the round inner roller element mounted off-axis onto the at least one non-round portion of the drive shaft assembly, the inner roller element having an external surface; a set of ball bearings disposed around the inner roller element in contact with the external surface thereof; and a round outer race roller element having an inner surface and an external surface, the outer race roller element encircling and containing the set of ball bearings such that as the drive shaft assembly is rotated, the inner roller element rotates off axis, the round, outer race element is stationary relative to a tube and radial rotation of the drive shaft assembly transfers a single linear occluding force to the tube adjacent the roller element assembly; a first full loop 360 degree tube path defined by the main body portion and L-shaped cover portion of the first pump head, the first tube path extending from the tube input of the first pump head, encircling the round outer race element of the first pump head and leading to the tube output of the first pump head within the output buffering space of the first pump head; a second full loop 360 degree tube path defined by the main body portion and L-shaped cover portion of the second pump head, the second tube path extending from the tube input of the second pump head, encircling the round outer race element of the second pump head and leading to the tube output of the second pump head within the output buffering space of the second pump head, wherein occlusion points for the first and second pump heads are out of phase by 180 degrees; a common input port tubing manifold coupling flow from a single fluid source to the separate tube inputs of each of the first and second pump heads; and a common output port tubing manifold coupling flow from the tube outputs of each of the first and second pump heads to a single fluid output; wherein when the at least one non-round portion of the drive shaft assembly is placed within both the non-round shaped, keyed opening of the inner roller element of the first pump head and the non-round shaped, keyed opening of the inner roller element of the second pump head, the inner roller element of the first pump head and the inner roller element of the second pump head are both mounted off-axis onto the drive shaft assembly out of phase by 180 degrees with respect to each other such that the combined output of the first pump head and the second pump head is pulse-less with minimal variation.

2. The dual-head, pulseless peristaltic-type metering pump of claim 1, further comprising a set of shaft fastener bearings distributed circumferentially around the drive shaft assembly at each of the first pump head assembly and the second pump head assembly.

3. The dual-head, pulseless peristaltic-type metering pump of claim 2, further comprising a bearing holding element holding in place the shaft fastener bearings distributed circumferentially around the drive shaft assembly at each of the first pump head assembly and the second pump head assembly.

4. The dual-head, pulseless peristaltic-type metering pump of claim 1, in which a minimal occlusion pulse width is less than 1% of an entire revolution.

5. The dual-head pulseless peristaltic-type metering pump of claim 1, wherein the shape of the at least one non-round portion of the drive shaft assembly matches the shapes of the non-round, keyed openings of the inner roller element of each of the first and second pump heads, wherein the at least one non-round portion of the drive shaft assembly and the non-round keyed openings are rectangular.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a front view of the dual-head, pulseless peristaltic-type metering pump 100 of the present invention.

(2) FIG. 2 is a top view of the dual-head, pulseless peristaltic-type metering pump 100 of the present invention.

(3) FIG. 3 is a detail view of the dual-head, pulseless peristaltic-type metering pump 100 of the present invention.

(4) FIG. 3-1 is a representative view of the friction and drag forces imparted to the flexible tube in the metering pumps of the prior art.

(5) FIG. 4 is a representative view showing the elimination pulsation from the dual-head, pulseless peristaltic-type metering pump 100 of the present invention.

(6) FIG. 4-1 is a graphical illustration showing the elimination pulsation from the dual-head, pulseless peristaltic-type metering pump 100 of the present invention.

(7) FIG. 4-2 is a graphical illustration showing pulsation from the metering pumps of the prior art.

(8) FIG. 4-3 are the graphed results of experimental data collected from the dual-head, pulseless peristaltic-type metering pump 100 of the present invention.

(9) FIG. 5 is a front view of the single-head, pulseless peristaltic-type metering pump 500 of the present invention.

(10) FIG. 6 is a side view of the single-head, pulseless peristaltic-type metering pump 500 of the present invention.

(11) FIG. 7 is a perspective view of the single-head, pulseless peristaltic-type metering pump 500 of the present invention.

(12) FIG. 8 is a perspective view of a different embodiment of the pulseless peristaltic-type metering pump 800 of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

(13) The description that follows is presented to enable one skilled in the art to make and use the present invention, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be apparent to those skilled in the art, and the general principals discussed below may be applied to other embodiments and applications without departing from the scope and spirit of the invention. Therefore, the invention is not intended to be limited to the embodiments disclosed, but the invention is to be given the largest possible scope which is consistent with the principals and features described herein.

(14) The following is a list of reference numerals and associated elements of the dual-head, pulseless peristaltic-type metering pump of the present invention. 1a, 1b Cover 2 Main body 3a, 3b Tube input 4a, 4b Tube output 5a, 5b Outer race roller element 6a, 6b Ball bearings or other roller elements 7a, 7b Inner roller element 8a, 8b Shaft 9a, 9b Input buffering space 10a, 10b Output buffering space 11a, 11b Dual occluding frame 12a, 12b Bearing holding element 13a, 13b Shaft fastener bearing 14 Common input port manifold 15 Input 16 Common output port manifold 17 Output 18 Flexible Tube R1 Roller element Assembly 1 R2 Roller element Assembly 2 300a, 300b Straight load force P1 First pump housing P2 Second pump housing 201a 201b, 202, 203, 204, and 205 Rotation angle W Pulsation width C Off-center axis A Center of drive axis radial E Arm B Large radius S Small radius D Drag force W Pulsation angle F Rollers or occluding shoes

(15) FIG. 1 is a front view of the dual-head, pulseless peristaltic-type metering pump 100 of the present invention. FIG. 2 is a top view of the dual-head, pulseless peristaltic-type metering pump 100 of the present invention. FIG. 3 is a detail view of the dual-head, pulseless peristaltic-type metering pump 100 of the present invention. Roller element assemblies R1, R2 that uses ball bearings or other roller elements 6a, 6b to maintain separation between the inner roller elements 7a, 7b and outer race roller elements 5a, 5b. Opposing cover portions 1a and 1b are designed with an L-shape and have half-round surfaces to guide the flexible tube 18. This L-shape design makes it easy to replace tube 18. Main body portion 2 has two identical pumping chambers. Inputs 3a, 3b and outputs 4a, 4b from each chamber are combined by common input port manifold 14 and common output port manifold 16. These common port manifolds 14 and 16 compensate for the pulsation of each side individually by the 180 degree difference in the phase of the pumps. Finally input 15 and output 17 are stable, volumetric flow rate controlled without pulsation.

(16) Inner roller elements 7a, 7b, ball bearings or other roller elements 6a, 6b and outer race roller elements 5a, 5b are made of ceramic, polyether ether ketone (PEEK) thermoplastic polymer or other comparable material having low thermal conductivity and amenable to application of a fine surface finish. These features of the inner roller elements 7a, 7b, ball bearings or other roller elements 6a, 6b and outer race roller elements 5a, 5b improve the flexible tube 18 lifetime that by reducing damage caused by heat and friction between hose 18 and outer race roller elements 5a, 5b. Ceramic bearings require no lubrication which reduces maintenance time and cost. This wide single bearing mechanism reduces drive and motor loading. Therefore, smaller motors that use less energy can be used to drive the dual-head, pulseless peristaltic-type metering pump 100 of the present invention.

(17) Center shafts 8a, 8b are designed with a combination of round and square shaped portions. This makes them easy to couple two roller element assemblies R1 and R2 together. The center shafts 8a, 8b are driven by a single motor or other drive mechanism to rotate center shafts 8a, 8b in a clockwise (CW) or counterclockwise (CCW) direction. Flexible tube input ports 3a, 3b and tube output ports 4a, 4b are used as inlet or outlet, depending upon the rotation of shaft 8a, 8b in a CW or a CCW direction. Shaft fastener bearings 13a, 13b are mounted in the bearing holding elements 12a, 12b. Most loop-type prior art peristaltic pumps are designed such that one of the shaft fastener bearing are mounted into cover or use only single side. If only a single bearing is used, the bearing has heavy loading during shaft rotation, and even if mounted onto the pump cover it has the potential to change from a center position. However, the shaft bearing holding elements 12a, 12b secure the shaft fastener bearings 13a, 13b that prevent centering problems and provide more robust operation.

(18) The purpose of using ball bearings or other roller elements 6a, 6b is to reduce the forces of rotational friction and support radial and axial loads. When the inner roller elements 7a, 7b rotate with center shaft 8a, 8b, they cause the ball bearings or other roller elements 6a, 6b to rotate as well. Because the ball bearings or other roller elements 6a, 6b are rolling they have a much lower coefficient of friction than if two flat surfaces were sliding against each other. Therefore, the ball bearings or other roller elements 6a, 6b do not need lubricant. The ball bearings or other roller elements 6a, 6b tend to have lower load capacity due to a smaller contact area between the inner roller elements 7a, 7b and the outer race roller elements 5a, 5b.

(19) The dual-head, pulseless peristaltic-type metering pump 100 of the present invention also transfers a straight load force 300a, 300b in a direction perpendicular to the central axis C of shaft portions 8a, 8b. Outer race roller elements 5a, 5b come into contact with flexible tube 18 and impart a linear occluding motion to the flexible tube 18 at tube inputs 3a, 3b and at tube outlets 4a, 4b. Thus, the peristaltic pump 100 of the present invention uses less energy to cause the occlusion of flexible tube 18. The off-center axis C of inner roller elements 7a, 7b results in a large radius of motion resulting in the occluding of the flexible tube 18 at the tubing inputs ports 3a, 3b and tubing output ports 4a, 4b. Also, roller element assemblies R1, R2 are made by nonmetallic components which are washable and protect against corrosion. Minimizing the number of moving parts all formed using robust materials saves maintenance cost and increase the mean time between failure (MTBF). When shaft portions 8a, 8b rotate in one direction, either CW or CCW, ball bearings or other roller elements 6a, 6b rotate in the opposite direction. The opposing rotation makes outer race roller element 5a, 5b essentially stationary. This motion transfers a straight load force 300a, 300b by small contact as above described. When off-center axis 8a, 8b rotates, then outer race roller elements 5a, 5b transfer straight force 300a, 300b to the tube 18 by linear occlusion motion.

(20) FIG. 3-1 is a representative view of the friction and drag forces imparted to the flexible tube in the metering pumps of the prior art. Most peristaltic pumps of the prior art use occluding members to reduce friction between occluded surface of tube and rolling elements. However, use of smaller size rollers or occluding shoes F still produce a large amount of rotational friction that drags the flexible tube from one side to another. This results in reduced lifetime of the tube due to tube shape change, stretch motion and friction. In the prior art pumps, the center of radial drive axis A drives drive arm E which make large radius B. This requires more force by the motor or other drive mechanism. Also drive arm E needs to be strong in order to transfer small radius to large radius rotational movement. Furthermore, a different rolling speed between large radius B and small radius S generates friction at the roller or shoe that produces a drag force D that drags the tube from one side to another. The pulsation angle W of the prior art peristaltic pump is larger than that of the present invention. This causes a large pulsation along with negative pressure, as shown in FIG. 4-2. It will be understood that in the metering pumps of the prior art, a small radius S need more force to drive large radius B as described, and also has roller or occluding shoes F which has small radial make heavy drive force D that caused by radial speed difference between two rolling mechanism.

(21) FIG. 4 is a representative view showing the elimination pulsation from the dual-head, pulseless peristaltic-type metering pump 100 of the present invention. When shaft 8a is rotated by the motor or other rotational device, the inner roller element 7a in roller element assembly R1 and inner roller element 7b in roller element assembly R2 are rotated in the same direction as that of shaft 8a. 8b. This action causes transfer of a radial load from the center of shaft 8a, 8b to the outer race roller elements 5a, 5b through the ball bearings or other roller elements 6a, 6b. These actions create straight load forces 300a, 300b by linear occluding of the flexible tube 18 between the outer race roller elements 5a, 5b and the outer surface of flexible tube 18. The straight load force 300a at pump housing P1 and the straight load force 300b from center of shaft 8a, 8b are aligned at a 180 degree different phase between each other in pump housing P1 and pump housing P2.

(22) As show best in FIG. 4, when the straight load force 300a is located within rotation angle 201a, the outer race roller element 5a occludes dual layer flexible tube 18 against dual occluding frame 11a in the first pump P1. At the moment of rotation angle 201a, flow from tube input 3a and from tube output 4a are stopped in pump P1, but rotation angle 201b in the pump housing P1 compensates for the volume of flow in pump housing P2. The peristaltic pump 100 of the present invention has a minimized width of dual occluding frame 11a below 1% out of one revolution where pulsation occurs. This results in a narrow pulse width due to the design of the input buffering spaces 9a, 9b and the output buffering spaces 10a, 10b. It will thus be understood that when shaft portions 8a, 8b rotate to CW, the straight load force 300a moves in rotation-angle 202, the outer race roller element 5a starts to occlude the single layer of flexible tube 18 due to design of outer buffering space 10b. This action generates a vacuum at tube input 3a to suck fluid in and push fluid to the tube output 4a by uniform flow volume output until the straight load force 300b reaches rotation angle 201a.

(23) The straight load force 300b in the second pump P2 is at the 180 degree opposite position from the straight load force 300a in the first pump P1. This maintains uniform fluid flow by push and full operation at tube inputs 3a, 3b and tube outputs 4a, 4b until the straight load force 300b reaches the rotation angle 201a.

(24) The improved peristaltic pump 100 of the present invention significantly reduced pulsation as follows: The narrow occluded position at dual layer tube 18 is located at rotation angle 201a where pulsation is generated. The input buffering spaces 9a, 9b and output buffering spaces 10a and 10b are in the main body 2. Non frictional design of the roller elements assemblies R1, R2 keep a uniform shape of the flexible tube 18 without changes in the volume of the tube 18. In the present invention, one main body 2 is comprised of two separate pumps P1, P2 assembled having 180 degree different phase where the residual pulsations caused by the 2 pumps P1 and P2 individually compensate and cancel each other. Another benefit provided by the buffering spaces 9a, 9b, 10a and 10b is relief of any accumulated tension in the flexible tube 18 when shafts 8a, 8b rotate one direction continuously, like most peristaltic pumps do.

(25) Thus, the present invention reduces flexible tube 18 stretching and slipping, and allows longer tube 18 life. For example, as best shown in FIG. 4, when the straight load force 300a is moved to about the 3 o'clock position, the tube output 4a is free to move back to it's original shape and position. When the straight load force 300a moved to the 9 o'clock position, then the tube input 3a is free to move back to it's original shape.

(26) FIG. 4-1 is a graphical illustration showing the elimination pulsation from the dual-head, pulseless peristaltic-type metering pump 100 of the present invention. FIG. 4-2 is a graphical illustration showing pulsation from the pumps of the prior art. As shown in FIG. 3-1, a prior invention used single loop type peristaltic pump but the pulsation width W is about 70 degrees out of one entire revolution of 360 degrees. This makes the pulsation period over 10% of one complete revolution of 360 degrees. The present invention makes a small rotation-angle 201a such that the pulsation width is below 1% of the complete 360 degrees as shown in FIG. 4.

(27) In FIG. 4-1, the first pump P1 generates one pulse at the rotation angle 201a shown in FIG. 4, but the second pump P2 maintains the same volume of fluid output by occluding the single layer tube 18. As shown in the P1+P2 graph, the pulses generated at the rotation angle 201a compensate each other and reduce overall pulse. There is no pulse, but it has a small variation in output due to mechanical error.

(28) As shown below, actual flow data proves the pump 100 of the present invention keeps positive flow without pulsation which does not stop flow or cause suck-back by negative pressure. It appear some draft by mechanical tolerance error.

(29) As shown in FIG. 2, tube outputs 4a, 4b from the 2 pumps P1, P2 connected at the common output port manifold 16.

(30) As shown in FIG. 4-2, the pulsation width W that is described with regard to FIG. 3-1, the prior art peristaltic pumps have about 70 degree pulsation angle. However, simple use of two pump housing without other mechanical design considerations will not generate a 180 degree different in phase of pulsation angle.

(31) FIG. 5 is a front view of the single-head, pulseless peristaltic-type metering pump 500 of the present invention. FIG. 6 is a side view of the single-head, pulseless peristaltic-type metering pump 500 of the present invention. FIG. 7 is a perspective view of the single-head, pulseless peristaltic-type metering pump 500 of the present invention. Opposing cover portions 1a and 1b are designed with an L-shape and have half-round surfaces to guide the flexible tube 18. This L-shape design makes it easy to replace tube 18. Main body portion 2 has a single pumping chamber with input 3 and output 4. Input 3 and output 4 are stable, pulseless volumetric flow rate controlled.

(32) Inner roller element 7, roller element ball bearings 6 and outer race roller elements 5 are made of ceramic, polyether ether ketone (PEEK) thermoplastic polymer or other comparable material having low thermal conductivity and amenable to application of a fine surface finish. These features of the inner roller element 7, ball bearings or other roller elements 6 and outer race roller element 5 improve the flexible tube 18 lifetime that by reducing damage caused by heat and friction between hose 18 and outer race roller elements 5a, 5b.

(33) Center shaft 8 is designed with a combination of round and square shaped portions. This makes it easy to couple the assembly of inner rolling element 7, ball bearings or other roller elements 6 and outer rolling element 5. The center shaft 8 is driven by a single motor or other drive mechanism to rotate center shaft 8 in a clockwise (CW) or counterclockwise (CCW) direction. Flexible tube input port 3 and tube output port 4 are used as inlet or outlet, depending upon the rotation of shaft 8 in a CW or a CCW direction. Other elements and aspects of the dual-head, pulseless peristaltic-type metering pump 100 described above such as but not limited to shaft fastener bearings and bearing holding elements would also be used in the single-head pump 500.

(34) The new design addresses the issues raised above that exist with prior art pumps by:

(35) 1. This invention minimizes the stress applied to the tube by eliminating rolling and drag motion across the tube with less stretching force applied to the tube. This is achieved by use of an outer ring setup and by using elongated tube channels that holds the tubing less rigidly than prior designs. The tube does not need to be held by rigid anchoring systems. The tube is routed through the pump with a flexible tension absorption section that allows the tube to move under roller contact and then return after the roller releases the tube section.

(36) 2. The roller design does not need lubrication.

(37) 3. The new head design incorporates a tube overlap areas 11a, 11b to allow constant tube 18 to roller 5a, 5b contact. Prior arts that use single loop design had issues at overlap area that stop flow caused pinched inputs 3a, 3b and outputs 4a, 4b at the same time. In the present design, overlap areas 11a, 11b are narrow pinched areas. Prior art pumps use of single loop design gives rise to issues caused by the overlap area that effectively stop flow caused as the tubing is pinched both in the input and output tube at essentially the same time. The present invention utilizes a narrow pinched area. This maintains constant tube pressure and minimizes pulsation time and magnitude of pulsation.

(38) 4. The new design minimizes the change in tube diameter. Pump volumes are maintained for longer periods and pump calibration requirements are minimized

(39) FIG. 8 is a perspective view of a different embodiment of the pulseless peristaltic-type metering pump 800 of the present invention.

(40) Experimental Results

(41) FIG. 4-3 are the graphed results of experimental data collected from the dual-head, pulseless peristaltic-type metering pump 100 of the present invention. Plot A shows the raw data DC Voltage output signal collected for flow out. Data was collected every 50 msec by flow measurement test equipment. A total of around 3000 data points are shown in plot A. Plot B is a zoom into a portion of the graph of Plot A that shows 100 data points plotted on the graph, related to the residual pulsation area caused by mechanical tolerance/margin of error. Pulsation occurs where there is a switching of flow and no flow in a short period of time. As can be seen, there is no pulsation in the output of plot B and variation is minimal

(42) Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present invention belongs. Although any methods and materials similar or equivalent to those described can be used in the practice or testing of the present invention, the preferred methods and materials are now described. All publications and patent documents referenced in the present invention are incorporated herein by reference.

(43) While the principles of the invention have been made clear in illustrative embodiments, there will be immediately obvious to those skilled in the art many modifications of structure, arrangement, proportions, the elements, materials, and components used in the practice of the invention, and otherwise, which are particularly adapted to specific environments and operative requirements without departing from those principles. The appended claims are intended to cover and embrace any and all such modifications, with the limits only of the true purview, spirit and scope of the invention.