Apparatus and method for dispensing a fluid formulation into a polymeric material

Abstract

Device 2 for dispensing liquid color components into a polymer includes: a weighing platform 4 supported on a pair of load cells 6, which in turn are supported on a base 8. A reservoir 12 contains liquid color component 14. A pump 16 is arranged to pump the liquid component through a pipe 20 to an extruder or injection molding machine. Above the inlet 24 is a transfer module 26, which includes a bag-in-a-box structure 28. The transfer module 26 includes: a transfer pump 36 associated with the outlet of container 32. A transfer pump motor 38 is arranged to engage with the transfer pump 36 and operates such that the liquid component can be pumped from container 32 into reservoir 12 through an air gap 13 defined between the transfer pump 36 and the inlet 24 of reservoir 12. There are no pipes, tubes, or other conduits between the transfer module 26 and reservoir 12 for the liquid component to travel through.

Description

Technical Field

[0001] This invention relates to polymer materials, and in particular (but not exclusively) to apparatus and methods for dispensing fluid formulations into polymer materials. Injection-molded products (e.g., container preforms) or continuously extruded products (e.g., fibers) can be produced. Background Technology

[0002] It is known that fluid formulations (e.g., liquid components) including colorants and / or functional additives (e.g., UV blockers) are dispensed into thermoplastic polymer materials to produce injection-molded or extruded products. However, it is difficult to confirm that the dispensing system is functioning with appropriate accuracy and / or ensuring that the correct amount (neither too little nor too much) of the liquid component is dispensed into the polymer material. For example, beverage bottle manufacturers would like to have certainty about the levels of additives (e.g., colorants) included in their bottled products. When bottles or other containers are intended to include specific levels of functional additives (e.g., UV light blockers to prevent spoilage of the product contained in the container), it is important from a quality assurance perspective to be certain that the container contains the appropriate amount of functional additive.

[0003] Various reservoirs are manufactured by injection molding preforms in an injection molding machine. The preforms are then left to condition for a period of time before being blow-blown in a stretch blow molding machine. The resulting reservoirs can then be periodically sampled and evaluated. For example, the color of the selected reservoir can be evaluated whenever possible, and the level of any functional additives can be assessed. In some cases, it may not be feasible or convenient to assess the level of a particular functional additive in the blown reservoir, making it difficult for the reservoir manufacturer to provide reliable quality assurance (QA) processes for such reservoirs, at least regarding that functional additive.

[0004] When the color or level of functional additives in a reservoir is assessed as part of the QA process, it should be recognized that such an assessment occurs far downstream of the node where the color or functional additives are introduced into the preform (which is subsequently stretch blow-formed to define the reservoir). If the QA assessment reveals defects in the reservoir in some respect, all reservoirs produced during the period between the production of the defective reservoir preform and the discovery of the defect must also be considered defective (or will require rigorous inspection) and may need to be discarded. Assuming that the time between preform production and the assessment of the reservoirs produced from it can easily exceed one hour, and assuming that reservoirs are typically produced at high speeds (e.g., 15,000 per hour), it is possible to produce tens of thousands of defective reservoirs that need to be discarded.

[0005] The production of defective containers (e.g., those containing too few additives) can be even more serious when it is not feasible or convenient to assess the levels of specific functional additives included in preforms or containers. This is because containers may be filled with products and sold to customers without assessing the additive levels. Defective products (e.g., those with too few functional additives, such as UV blockers) may not adequately protect the products they contain, thus shortening their shelf life. The presence of such shortened-shelf-life products may necessitate the recall of thousands of containers, resulting in significant losses for retailers, manufacturers of the products contained within the containers, and / or container manufacturers. Summary of the Invention

[0006] The object of the present invention in a preferred embodiment is to solve the above-mentioned problems and provide an accurate quality assurance (QA) system that can provide alerts relatively quickly in the event that defective preforms and / or accumulators may be produced.

[0007] More typically, there are situations where it is desirable to be able to accurately dispense fluid formulations into polymer materials associated with melt processing equipment and / or monitor the dispensing rate of the fluid formulations.

[0008] The purpose of the preferred embodiments of the present invention is to solve the above-mentioned problems.

[0009] The object of the preferred embodiments of the present invention is to provide an apparatus and / or method for substantially continuous verification that the apparatus for dispensing liquid color components into polymer materials is functioning with appropriate accuracy.

[0010] According to a first aspect of the present invention, an apparatus is provided for dispensing a fluid formulation into a polymer material, the apparatus comprising:

[0011] (i) A container (A) for containing the fluid formulation, wherein the container (A) includes an outlet for the fluid formulation;

[0012] (ii) A storage assembly for containing a fluid formulation delivered from a container (A), wherein the storage assembly includes an inlet for receiving the fluid formulation delivered from the container (A);

[0013] The outlet of the container (A) is arranged to transfer the fluid formulation through an air gap into the storage assembly.

[0014] Thus, a space is suitably defined between the outlet of container (A) and the storage assembly (e.g., between the outlet and the portion of the storage assembly closest to the outlet). Consequently, there is preferably no physical connection or link between the outlet of container (A) and the wall and / or any physical portion of the storage assembly. That is, preferably, there is no physical connection or link between the outlet of container (A) and the wall and / or any physical portion of the storage assembly, for example, for transferring liquid components from container (A) to the storage assembly. Thus, in use, suitably, the fluid formulation falls through the free space between container (A) and storage assembly (B) before contacting a physical entity (e.g., the wall of the storage assembly and / or the fluid formulation already present within the storage assembly). This arrangement facilitates accurate monitoring of the weight of the storage assembly in use without the measured weight being affected by container (A) and / or portions thereof. Thus, the device preferably does not include any conduits and / or tubes extending from container (A) to the storage assembly and simultaneously contacting both container (A) and the storage assembly.

[0015] The outlet of container (A) is suitably the area in which container (A) comes into contact with the fluid formulation just before it enters the air gap during use. Container (A) suitably includes a pump as described below (hereinafter referred to as "the first pump"). The outlet of container (A) may be the outlet of the first pump. The first pump is preferably a positive displacement pump. The first pump is preferably arranged to releasably engage the shaft of a motor arranged to drive the rotor of the pump.

[0016] The container (A) may include a closure mechanism, which is an integrated part of the container (A). The first pump may be arranged to operate as a closure mechanism for the container (A) when fluid is not pumped from the container (A) and / or when the container (A) is not effectively connected to a motor arranged to drive the rotor of the pump, suitably as described below.

[0017] The container (A) suitably comprises: a first pump and a container portion, the container portion being suitably located upstream of the first pump and suitably arranged to contain a fluid formulation. The container portion is suitably directly connected to the first pump. The first pump is preferably fastened (preferably substantially permanently and / or irremovably fastened) to the outlet of the container portion. The first pump is preferably directly connected to and / or adjacent to the outlet of the container portion. Preferably, there is no extending tubing, e.g., no flexible tubing, between the container portion (e.g., the outlet of the container portion) and the first pump.

[0018] The outlet of container (A) is preferably vertically aligned with the inlet of the storage assembly. This position the outlet of container (A) such that the fluid formulation can fall under gravity through the air gap to be received into the storage assembly. The outlet of container (A) is preferably separate from each wall of the storage assembly.

[0019] The outlet of container (A) may extend into free space within the storage assembly, or the outlet of container (A) may be separated from the inlet of the storage assembly, for example, vertically (e.g., at least 1 mm, or a vertical distance of 1 to 20 mm). The outlet of container (A) is preferably separated from the nearest horizontally extending inner wall of the storage assembly (directly below the outlet) by a distance of at least 10 mm or at least 50 mm.

[0020] The inlet of the reservoir assembly may be defined in the top wall of the reservoir assembly, the inlet suitably defining an upward-facing opening. The opening may be defined by a collar, wherein preferably the column wall of the collar extends upward, preferably substantially vertically upward. The opening may have a maximum width ranging from 2 to 10 cm. It is preferably circular, thus the preferred diameter of the opening is in the range of 2 to 10 cm. The opening may have a minimum 4 cm clearance for the passage of the fluid formulation during use. 2 And preferably less than 70cm 2 The area of ​​the opening can be 4 to 40 cm. 2 The area within the specified range. The opening is preferably arranged to be closed by a detachably fastened closure. The collar may have screw threads and be arranged to engage a corresponding screw-threaded closure to close and / or seal the entrance of the storage assembly when the storage assembly is not in use and / or is not part of the device (e.g., during transport or storage of the storage assembly).

[0021] The storage assembly (preferably its storage unit, as described below) has an internal total volume (i.e., when full) of at least 2 liters or at least 3 liters to contain the fluid formulation. The internal total volume may be less than 50 liters, less than 20 liters, or less than 6 liters.

[0022] The storage assembly (preferably its storage unit, as described below) may have a substantially constant internal cross-sectional area along a length L, wherein L is at least 25 mm, preferably at least 50 mm. The length L may be less than 400 mm or less than 100 mm. The volume of fluid capable of being contained within the substantially constant cross-sectional area may be at least 500 cm³. 3 Preferably at least 1000cm 3 It can be less than 20,000 cm. 3 Less than 10000cm3 or less than 7000cm 3 .

[0023] The approximately constant internal cross-sectional area can be at least 100 cm². 2 Preferably at least 200cm 2 It can be less than 2000cm. 2 Less than 1000cm 2 or less than 600cm 2 .

[0024] The generally constant internal cross-sectional area is preferably curved along its entire extension, and preferably circular or elliptical.

[0025] The ratio of a substantially constant internal cross-sectional area to the total internal volume of the storage component (preferably its storage, as described below) can be in the range of 0.01-0.20, preferably in the range of 0.02-0.14, and more preferably in the range of 0.03-0.10.

[0026] The storage assembly is preferably associated with a generally horizontally positioned platform. The generally constant internal cross-sectional area preferably extends generally parallel to the platform. The length L is preferably measured generally perpendicular to the platform.

[0027] The reservoir assembly (preferably its reservoir, as described below) is preferably rigid. It is preferably self-supporting. It is preferably not arranged to be compressed to thereby transfer the fluid formulation. Its internal volume is preferably not arranged to change (e.g., decrease) during the removal of the fluid formulation from it (e.g., during the removal of fluid from the reservoir of the assembly, as described below).

[0028] The storage assembly suitably includes an inlet for introducing the fluid formulation into the storage container. The inlet is preferably located in the upper part of the storage assembly (preferably the upper part of its storage container, as described below). It is preferably positioned above the maximum fill level of the storage assembly (preferably above the maximum fill level of its storage container, as described below), wherein data of the maximum fill level (e.g., its location) is stored in a central processing unit (CPU) suitable as a component of the device.

[0029] The device preferably includes: a level sensor for assessing the level of the fluid formulation in the storage assembly (preferably the level in its storage container, as described below).

[0030] The level sensor is preferably non-invasive. It is preferably arranged so that it does not contact the fluid formulation in the storage assembly during measurement (e.g., when sensing the level of the fluid formulation in the storage assembly). The level sensor preferably includes a transmitter for transmitting a signal, such as a wave. The signal is suitably arranged to be transmitted toward the fluid in the storage assembly (preferably toward the fluid-air interface), that is, the wave is suitably arranged to be transmitted so as to impact the top of the fluid formulation contained in the storage assembly, suitably facilitating the determination of the level of the fluid formulation in the storage assembly. The level sensor preferably includes a receiver for receiving the signal, such as a wave, reflected from the fluid formulation in the storage assembly. The level sensor and / or its associated CPU are suitably arranged to evaluate the level of the fluid formulation in the storage assembly using the transmitted and received signals (e.g., waves).

[0031] The transmitter and receiver of the liquid level sensor are preferably fixed in place relative to each other and / or fixed to the same housing.

[0032] The level sensor (e.g., the housing) is preferably mounted such that it occupies a position higher than the fluid formulation in the reservoir assembly during use. The level sensor is preferably vertically aligned with the inlet of the reservoir assembly. The level sensor is preferably an ultrasonic sensor. It suitably includes a housing accommodating an ultrasonic transmitter and an ultrasonic receiver.

[0033] The CPU of the device is suitably programmed such that the storage assembly is filled with a fluid formulation to a level at least 30 mm away from the transmitting surface of the level sensor.

[0034] The liquid level sensor is preferably arranged to communicate liquid level information to the CPU, which is suitable as part of the device, for example, through time-varying communication.

[0035] The device preferably includes: a first weighing mechanism for monitoring the weight of the storage component and its contents. The first weighing mechanism may include: a platform supporting the storage component. The first weighing mechanism is preferably arranged to communicate information related to the weight of the storage component over time to the CPU.

[0036] The storage assembly is preferably associated with a rack suitably arranged to support it. The rack is preferably arranged to be releasably fastened to the weighing mechanism (e.g., the platform). Sensors may be associated with the rack and / or the weighing mechanism for sensing when the rack is correctly positioned relative to the weighing mechanism (e.g., the platform), preferably arranged to communicate information to the CPU. The rack may include a plurality of convex or concave elements (preferably concave elements) arranged to releasably engage another convex or concave element fixed relative to the weighing mechanism (e.g., the platform).

[0037] The reservoir assembly preferably includes a pump (hereinafter referred to as the "second pump") for pumping liquid components from the reservoir assembly. The second pump is preferably an integrated part of the reservoir assembly. The reservoir assembly may include a reservoir and the second pump. The second pump is preferably associated with, for example, fastened to (preferably substantially permanently and / or irremovably fastened) the outlet of the reservoir. The second pump is preferably directly connected to and / or adjacent to the outlet of the reservoir. Preferably, there is no extending tubing, such as flexible tubing, between the outlet of the reservoir and the pump.

[0038] The second pump is preferably a positive displacement pump. The second pump is preferably arranged to be releasably engaged with the shaft of a motor (suitably arranged to drive the rotor of the pump). The reservoir of the reservoir assembly may include a closure mechanism as an integrated part of the reservoir assembly. The second pump is arranged to operate as a closure mechanism for the reservoir assembly when fluid is not pumped from the reservoir assembly, and / or when the reservoir assembly is not effectively connected to the motor (suitably arranged to drive the rotor of the pump), as suitably as described below.

[0039] The first pump and the second pump may be the same or different. Preferably, the first pump and / or the second pump includes a positive displacement pump (hereinafter referred to as a "PD pump"), as described below.

[0040] The PD pump suitably includes a housing having an inlet for connection to a fluid source. The inlet is suitably arranged to be filled with fluid from the fluid source. Preferably, the inlet is filled by the passage of fluid from the fluid source under gravity (suitably without any other force), that is, the fluid does not require (preferably does not) be pressurized into the inlet.

[0041] The PD pump suitably includes an outlet for the fluid pumped by the PD pump.

[0042] The PD pump preferably includes a rotor capable of rotating within the housing, and the inlet and the outlet are preferably separated along the path of the rotor within the housing.

[0043] The rotor preferably has a rotation axis, wherein the inlet is arranged to introduce fluid into the housing in a direction transverse to (e.g., perpendicular to) the rotation axis; preferably, the outlet is arranged to exit the housing in a direction transverse to (e.g., perpendicular to) the rotation axis. The inlet and the outlet are preferably circumferentially separated about the rotation axis.

[0044] Preferably, the rotor includes rotor surfaces that form a plurality of enclosed chambers with the interior region of the housing. As the rotor rotates, the enclosed chambers travel along the housing to transport fluid from the inlet to the outlet. More particularly, preferably, the chambers travel about the axis, but preferably not along the axis. The housing preferably includes a seal that cooperates with the rotor surfaces as the rotor surfaces move between the outlet and the inlet to prevent fluid from flowing across the rotor from the inlet to the outlet and / or vice versa; and / or to prevent any fluid backflow. Thus, the chambers are effectively sealed. Preferably, fluid cannot flow between the inlet and the outlet when the rotor is not rotating. Thus, in this case, the PD pump acts as a sealing mechanism, effectively preventing fluid flow, as described above for the first and second pumps.

[0045] The rotation axis of the PD pump may have a length of less than 100 mm, and preferably less than 60 mm. The rotation axis of the PD pump may be in the range of 10 to 60 mm, and preferably 18 to 50 mm.

[0046] The reservoir of the reservoir assembly is preferably arranged to deliver the fluid formulation to the inlet of the second pump at a pressure of less than 1.5 bar. The reservoir assembly is preferably open to the atmosphere. Advantageously, it is preferred that it be unpressurized. Suitably, the device is arranged such that the pressure at the inlet of the second pump is limited by the static head of the fluid in the reservoir and atmospheric pressure, without providing an additional mechanism to pressurize the reservoir. Preferably, the reservoir and the second pump are arranged to allow for the infusion and aspiration of the second pump via fluid from the reservoir.

[0047] The container portion of the container (A) is preferably arranged to deliver the fluid formulation to the inlet of the first pump at a pressure of less than 1.5 bar. The container (A) is preferably subjected to only atmospheric pressure. It is preferably not pressurized. Preferably, the container portion and the first pump are arranged to allow for the infusion and aspiration of the first pump via fluid from the container portion.

[0048] In a first embodiment, the second pump may be arranged to pump the fluid formulation to the device outlet. Preferably, the second pump is the only pump positioned between the outlet of the reservoir and the outlet of the device. Such an arrangement can be used to introduce the fluid formulation into the polymer material (e.g., unmelted and / or polymer material under peripheral pressure) at relatively low pressure. In this case, the outlet of the device may be arranged to transfer the fluid formulation onto solid pellets of polymer material. The solid pellets may be upstream of the melting zone of a melt processing device (which may be associated with and / or effectively connected to the device).

[0049] In a second embodiment, the device may be arranged to introduce a fluid formulation into a polymer material (e.g., molten polymer material), for example, at a relatively high pressure (e.g., greater than 50 bar). In this case, the outlet of the device may be arranged to transfer the fluid formulation into molten polymer in a melt processing device (e.g., an injection molding machine or an extruder). The device may be associated with and / or effectively connected to the melt processing device.

[0050] Preferably, the tube is connected to the outlet of the second pump, wherein the tube is arranged to transfer a fluid formulation to a polymer material, such as that associated with melt processing equipment, such as an injection molding machine or an extruder. A portion of the tube is preferably secured (e.g., clamped) to a portion of the equipment in a first position. The first position is suitably such that its position does not change when the weighing mechanism (e.g., the platform) moves with changes in the weight of the reservoir assembly. The first position is suitably not fixed in place relative to the weighing mechanism (e.g., the platform). The securing of the tube in the first position is suitably arranged to minimize (preferably eliminate) movement of the tube between the first position and the position where the tube is connected to the outlet of the second pump. Thus, the portion of the tube downstream of the first position is maneuverable (e.g., positioned to transfer the fluid formulation to the polymer material) without transmitting any such movement to the weighing mechanism (which could otherwise affect weight measurement).

[0051] The tube may have an inner diameter ranging from 0.2 to 1.5 cm, preferably from 0.3 to 0.9 cm, and / or a length ranging from 50 cm to 5 m or from 60 cm to 3 m.

[0052] The container (A) is suitably in fluid communication with the storage assembly and is suitably arranged to contain the same fluid formulation as contained in the storage assembly. The device is suitably arranged to deliver fluid from the container (A) to the storage assembly to replenish the fluid in the storage assembly.

[0053] The container (A) preferably has a larger total internal volume than the storage assembly (e.g., the storage therein). The ratio of the total internal volume of the container (A) to the total internal volume of the storage assembly can be at least 1.5, for example, in the range of 1 to 100, or preferably 1.5 to 10.

[0054] The container (A) suitably includes the first pump and the container portion as described. The container portion may be retractable. It preferably includes a plastic reservoir. The container (A) may include a pallet box in which the container portion is arranged. The container (A) may include a bag-in-box structure, suitably wherein the first pump is directly connected to and / or adjacent to the outlet of the container portion.

[0055] The container (A) is suitably positioned above (preferably completely above) the storage assembly. Suitably, the coverage area of ​​the container (A) completely overlaps the coverage area defined by the storage container and / or the storage assembly. Thus, the container (A) is suitably stacked on the storage container and / or the storage assembly. The area of ​​the coverage area of ​​the container (A) can be between 200 and 2000 cm². 2 (e.g., 200 to 1400 cm) 2 Or 500 to 1200cm 2 The coverage area of ​​the storage device and / or the storage assembly can be between 2000 and 32000 mm. 2 (e.g., 5000 to 25000 mm) 2 Within the range of ).

[0056] The device preferably includes a second weighing mechanism for monitoring the weight of the container (A) and its contents. The second weighing mechanism may include a second platform supporting the container (A). The weighing mechanism is preferably arranged to communicate information related to the weight of the container (A) over time to the CPU.

[0057] When the second weighing mechanism includes a second platform, the second platform is suitably arranged to releasably engage the container (A). Preferably, the second platform, if present, overlaps the first platform. The first and second platforms are suitably vertically separated, wherein at least 50%, 90%, or 100% of the coverage area of ​​the second platform overlaps the coverage area of ​​the first platform.

[0058] The CPU associated with the dispensing device is suitably arranged to receive input related to the rate at which the fluid formulation is injected into a polymer material, which may be present in a melt processing device associated with the dispensing device.

[0059] The CPU is preferably configured to control the operation of the second pump, such as its speed. The second pump may serve as the primary controller for the rate at which the polymer material is introduced into the fluid formulation. Other information monitored by the CPU can verify that the second pump is functioning correctly. For example, information related to the level of the fluid formulation in the reservoir assembly and / or information related to the weight change of the reservoir assembly over time can be used to check the operation of the second pump.

[0060] The CPU is suitably configured to receive inputs related to the discharge ratio (LDR).

[0061] The invention extends to a dispensing apparatus combined with a melt processing device, wherein the outlet of the apparatus is suitably arranged to transfer the fluid formulation from the apparatus to a polymer material disposed in the melt processing device for melt processing. The melt processing device may include an injection molding machine or an extruder.

[0062] The device can be mounted on a transport vehicle. Preferably, the transport vehicle supports both the container (A) and the storage assembly, both of which contain the fluid formulation. The transport vehicle can be arranged to roll to its place of use, such as adjacent to the melt processing equipment. The transport vehicle may include wheels or rollers. The area covered by the transport vehicle may be less than 10,000 cm². 2 or less than 7000cm 2 It can be at least 3000cm. 2 .

[0063] Unless otherwise stated, the viscosities described herein can be measured using a Brookfield viscometer at 20 rpm and 23°C.

[0064] The fluid formulation may have a viscosity of at least 1000 cP, suitably at least 10000 cP, and preferably at least 15000 cP. The viscosity may be less than 75000 cP, preferably less than 40000 cP, and more preferably less than 35000 cP.

[0065] The fluid formulation may comprise a single fluid. However, preferably, the fluid formulation comprises at least two different components. The fluid formulation may comprise multiple components that are liquid at standard temperature and pressure (STP). In one embodiment, the fluid formulation may comprise only the component that is liquid at STP. In another embodiment, the fluid formulation may comprise at least one component that is liquid at STP and at least one component that is solid at STP.

[0066] The fluid formulation may comprise at least 20 wt%, suitably at least 30 wt%, preferably at least 40 wt%, more preferably at least 50 wt%, and particularly at least 60 wt% of solids. The solids may comprise particulate materials, such as solid pigments and / or dyes. The fluid formulation may comprise 85 wt% or less of solids of the aforementioned type. The fluid formulation suitably comprises 15-70 wt%, preferably 15-50 wt% of a fluid, such as a liquid. The solids are suitably configured as a dispersion in the fluid (suitably a carrier). Thus, the solids may be substantially insoluble in the carrier. The ability to use a high loading component (and therefore a relatively low carrier level) may be advantageous in minimizing any adverse effects associated with the incorporation of the carrier into the polymeric material.

[0067] The solid may be arranged to modulate the properties of the polymer material (the solid may be transferred thereto by the device). The solid may include any material desired to be introduced into the plastic material, and may be selected from colorants, ultraviolet (UV) filters, oxygen absorbers, antibacterial agents, acetaldehyde scavengers, reheat additives, antioxidants, light stabilizers, optical brighteners, processing stabilizers, and flame retardants. Colorants may include pigments or dyes.

[0068] The solid preferably comprises an insoluble colorant (i.e., insoluble in the carrier), such as an insoluble pigment or dye. In some embodiments, a partially soluble colorant or other additive may be used.

[0069] The carrier is suitably liquid in the STP. The fluid formulation is preferably liquid in the STP. The carrier preferably has a boiling point greater than 300°C, more preferably greater than 350°C, and more preferably greater than 500°C (at atmospheric pressure of 760 mmHg). The boiling point may be less than 1150°C or less than 1000°C.

[0070] The storage assembly preferably contains the fluid formulation. Container (A) suitably includes the fluid formulation, wherein container (A) and the fluid formulation in the storage assembly are the same. The device is suitably arranged to transfer the fluid formulation from the storage assembly into contact with a polymer material, wherein the fluid formulation in contact with the polymer material is the same as the fluid formulation in the storage assembly.

[0071] According to a second aspect of the present invention, a method is provided for dispensing a fluid formulation into a polymer material, the method comprising:

[0072] (a) Select a device, the device comprising:

[0073] Container (A) containing a fluid formulation and an outlet for said fluid formulation;

[0074] A storage assembly comprising a fluid formulation delivered from the container (A), wherein the storage assembly includes an inlet for receiving the fluid formulation delivered from the container (A);

[0075] (b) Transferring the fluid formulation from container (A) to the storage assembly;

[0076] (c) Transferring the fluid formulation to the polymer material downstream of the reservoir assembly.

[0077] The method preferably uses the equipment as described in the first aspect.

[0078] The method preferably includes transferring the fluid formulation via an air gap as it is transferred from container (A) to the storage assembly. In this method, the fluid formulation preferably falls through the air gap over a distance of at least 1 mm, at least 5 mm, or at least 10 mm. The air gap may extend from the outlet of container (A) to the wall of the storage assembly or to the surface of the fluid formulation already contained in the storage assembly.

[0079] The container (A) may have any of the features of the container (A) of the first aspect. The storage assembly may have any of the features of the storage assembly of the first aspect. The fluid formulation may have any of the features of the first aspect.

[0080] The method preferably includes: the CPU of the device controlling the operation of a first pump that is part of the container (A).

[0081] The method preferably includes: the CPU receiving information related to the weight of the container (A). The method preferably includes: the CPU receiving information related to the weight of the storage component.

[0082] The method preferably includes: the CPU controlling the operation of a second pump arranged to pump a fluid formulation from the storage assembly to transfer the fluid formulation into the polymer material.

[0083] The method may include: an operator inputting information into the CPU based on the desired dosing rate (e.g., release ratio (LDR)) of the fluid formulation into the polymer material.

[0084] The method preferably includes: the CPU receiving information related to the level of a fluid formulation in the storage assembly. The level of the fluid formulation may be assessed by the level sensor, as described in the first aspect.

[0085] In this method, the fluid formulation delivery rate of the second pump is a primary parameter, set to determine the rate at which the fluid formulation is dispensed into the polymer material. The CPU may be configured to compare the fluid formulation delivery rate of the second pump with information related to the fluid formulation level in the reservoir assembly and / or information related to the weight change of the reservoir assembly over time, appropriately confirming that the equipment (particularly the rate of fluid formulation delivery into the polymer material) is functioning correctly. If a discrepancy exists, the CPU may initiate an alert or signal the operator.

[0086] The method may include: an operator inputting information about the amount of polymer material fed into the CPU for each batch and / or information about the production volume of the polymer material in the melt processing equipment.

[0087] In step (c) of the method, the tube is suitably extended between the storage assembly and the melting processing apparatus.

[0088] The method may include replacing the container (A) when the amount of the fluid formulation therein drops below a predetermined level (e.g., as assessed by its weight).

[0089] The method may include replacing the reservoir assembly, including its second pump, after a predetermined time, for example, after a predetermined amount of fluid formulation has been transferred through the second pump (suitably evaluated by the CPU).

[0090] The method may include: adjusting the device to deliver an alternative fluid formulation, wherein the method includes: replacing the container (A) and the reservoir assembly including the second pump with an alternative container (A) and an alternative reservoir assembly including a second pump, wherein the container (A) contains the alternative fluid formulation.

[0091] According to a third aspect of the present invention, a container (A) is provided for dispensing a fluid formulation into a polymer material, said container (A) comprising:

[0092] i) Container section for containing fluid formulations;

[0093] ii) A first pump, which is connected to the container portion and is a component of the container (A), the first pump being used to pump a fluid formulation from the container portion to dispense the ingredients into the polymer material, wherein the container (A) contains the fluid formulation as described herein.

[0094] The container (A) may be as described in the first aspect.

[0095] According to a fourth aspect of the invention, a storage assembly is provided for containing a fluid formulation delivered from a container (A), wherein the storage assembly includes an inlet for receiving the fluid formulation delivered from the container (A), wherein a second pump is provided for pumping the fluid formulation from the storage assembly, wherein the second pump is an integrated part of the storage assembly, wherein the container (A) contains the fluid formulation as described herein.

[0096] The storage component may be as described in the first aspect.

[0097] The invention extends to a combined structure comprising: a container (A) according to a third aspect and a reservoir assembly according to a fourth aspect, wherein, suitably, the container (A) and the reservoir assembly comprise at least a residue of the same fluid formulation.

[0098] In another aspect, an apparatus is provided for dispensing a fluid formulation into a polymer material, the apparatus comprising:

[0099] (i) A container (A) for containing the fluid formulation, wherein the container (A) includes an outlet for the fluid formulation;

[0100] (ii) A storage assembly for containing a fluid formulation delivered from a container (A), wherein the storage assembly includes an inlet for receiving the fluid formulation delivered from the container (A);

[0101] The device includes any feature of the device according to the first aspect.

[0102] With the necessary minor modifications made, any feature of any aspect of any inventive solution or embodiment described herein may be combined with any feature of any aspect of any other inventive solution or embodiment described herein. Attached Figure Description

[0103] Specific embodiments of the invention will now be described by way of example with reference to the accompanying drawings, in which:

[0104] Figure 1 It is a schematic front view showing partial cutaways of the various parts of the dispensing equipment;

[0105] Figure 2 This is a front view of the frame of the device;

[0106] Figure 3 This is a front view of the device, in which the transmission module is attached to the frame;

[0107] Figure 4 yes Figure 3 A bottom view along the direction of arrow III;

[0108] Figure 5 It is a front-view perspective view of the components, including the rack and storage.

[0109] Figure 6 yes Figure 5 The components are viewed from the opposite side;

[0110] Figure 7 This is a front view of the device, wherein Figure 5 The components are in place (but part of the transmission module has been omitted);

[0111] Figure 8 yes Figure 7 A magnified view of a portion of the image.

[0112] Figure 9 This is a front view of the device in its operational configuration;

[0113] Figure 10 yes Figure 9 The side view of the device in the operating configuration;

[0114] Figure 11 It is similar to Figure 9 The view also shows the transmission tube;

[0115] Figure 12 This is a three-dimensional view of the pump assembly from top to one side;

[0116] Figure 13 yes Figure 12 A three-dimensional view of the pump assembly from top to one side;

[0117] Figure 14 It is similar to Figure 12 The view is shown, but the inlet of the pump assembly is shown in the cross-section;

[0118] Figure 15 It is through the cross-section of the pump assembly;

[0119] Figure 16 It is through the cross-section of the pump assembly, perpendicular to Figure 15 The cross section.

[0120] In the figure, the same or similar parts are labeled with the same reference numerals. Detailed Implementation

[0121] See Figure 1The device 2 for dispensing a liquid color component (optionally including other additives) into a polymer includes: a weighing platform 4 supported on a pair of load cells 6, which in turn are supported on a substrate 8. A storage assembly 10 includes: a storage tank 12 containing the liquid color component 14. The assembly 10 includes an integrated metering pump 16 at its outlet, the pump 16 being driven by an associated motor 18.

[0122] Pump 16 is arranged to pump the liquid component through pipe 20 to a polymer processing machine (not shown), such as an extruder or injection molding / molding machine, wherein the liquid component is mixed with the polymer. An extruded or molded product comprising the polymer and one or more additives delivered via the liquid component is produced.

[0123] An ultrasonic level sensor 22 is located above the inlet 24 of the reservoir 12 and is arranged to continuously monitor the level (e.g., level 25) of the liquid components within the reservoir 12.

[0124] The transfer module 26, also located above the inlet 24, includes a bag-in-a-box structure 28. Structure 28 includes a pallet box 30 in which a container 32 is disposed. The container 32 contains the liquid component 34. The transfer module 26 also includes a transfer pump 36 associated with the outlet of the container 32. A transfer pump motor 38 is disposed and engaged with the transfer pump 36 and operates such that the liquid component can be pumped from the container 32 into the storage tank 12 through an air gap 13 defined between the transfer pump 36 and the inlet 24 of the storage tank 12. There are no pipes, tubes, or other conduits between the transfer module 26 and the storage tank 12 for the liquid component to travel through.

[0125] Device 2 and its components are described in more detail below.

[0126] See Figure 2 Platform 4 (and associated load cells, not shown) is supported on base 8. Platform 4 has an L-shaped cross-section, wherein the shorter, upright branch 39 of the L-shape includes separate support tubes 40, 42. Support tubes 40, 42 are arranged to releasably engage (and support) a rack including storage unit 12 (shown on the back of the rack). Figures 5 to 7 (Middle). The support tube 40 includes a drive shaft 44, which is operatively connected to a motor 18 (not shown). Figure 2 In the middle, but displayed Figure 1 (In the middle), motor 18 is mounted after the upright branch 39 of platform 4. The motor is operable to drive shaft 44, which is in turn arranged to operate metering pump 16.

[0127] The device includes a frame that includes an upright portion 46. Opposite flanges 48, 50 are fixed adjacent to the upper end of the upright portion 46 and support a horizontal platform 52. Platform 52 includes a load cell 54, which supports an upper platform 58. Platforms 52, 58 are stacked and include aligned semi-circular openings through which the neck of container 32 is arranged to extend.

[0128] The upper platform 58 is arranged to be detachably engaged with the transfer module 26, which is supported on the upper platform 58 during use. The load sensor 54 is arranged to monitor the weight of the transfer module 26 as liquid is transferred from the container 32.

[0129] Furthermore, opposite flanges 48 and 50 support horizontally extending guide rails 60 and 62 extending between them. The guide rail supports include a transfer pump motor 38. Figure 2 The carrier assembly 64 (not shown) is arranged to move toward the transfer pump 36, allowing the transfer pump motor 38 to be operatively connected to the transfer pump 36. The assembly 64 can move away from the transfer pump 36 when not in use and / or allow the transfer module 26 to be disengaged from the device 2.

[0130] The liquid level sensor 22 is fixed to a plate 64 that hangs down from the lower side of the platform 52.

[0131] See Figure 3 and 4 The transfer module 26 is positioned and engaged and supported by the upper platform 58. When thus positioned, the outlet 66 of the container 32, the associated transfer pump 36, and its outlet 74 are located below the plane of the lower surface of the upper platform 58.

[0132] It should be noted that the transfer module 26 includes the bag-in-box structure 28 and an integrated transfer pump 36, details of which will be provided below.

[0133] Pump 36 includes: in the opening 70 ( Figure 4 and 8 A bonding mechanism (not shown) is located within the pump, extending transversely to the direction of fluid flow through the pump. The bonding mechanism is arranged by a drive shaft 72 ( Figure 1 and 4 In this configuration, drive shaft 72 is operatively connected to and arranged to be driven by motor 38. More specifically, during movement of the transport assembly 64 (including the transfer pump motor 38), drive shaft 72 can move toward the keying mechanism to engage pump 36. When thus arranged, motor 38 can rotate the rotor within pump 36 and thereby pump fluid from container 32 and via outlet 74 (located above inlet 24 of reservoir 12, as shown in the image). Figure 8 (As clearly shown in the image) to the outside of the pump.

[0134] See Figure 5 and6 The component 80 includes a storage unit 12 supported within a rack 82. The component 80 is arranged such that the storage unit can be releasably engaged with the rack 82, and when engaged with the rack, the storage unit is substantially immobile relative to the rack.

[0135] The frame 82 is made of metal. It includes a handle 84 and a manual engagement opening 85, thereby allowing the assembly to be easily manipulated by an operator, for example, to engage or disengage it from the platform 4. The frame 82 defines a support region 86 that engages with the collar of the pump 16 to seat the pump 16 in the frame, with the pump outlet 88 facing away from the frame.

[0136] Pump 16 includes a bonding mechanism (not shown) arranged to engage with a drive shaft 44 extending within a support tube 40. Figure 2 It is arranged to be driven by a motor 18 located after branch 39. Pump 16 may be as described below for pump 36.

[0137] The frame 82 includes circular openings 85 and 87, which are slidably engaged with corresponding support tubes 40 and 42. Furthermore, the frame 82 includes a retaining member 90. Figure 6 The retaining member 90 is arranged to engage with the cooperating retaining member 92 associated with the branch 39. Figure 2 and 3 This allows the frame 82 to be loosely and securely fastened into place.

[0138] The reservoir 12 is made of a plastic material. It includes a handle 94 for easy operation. The inlet 24 is defined by a collar 96 with external threads. The outlet of the reservoir 12 is effectively defined by the outlet 88 of the pump 16, which extends transversely to the direction in which liquid is introduced into the reservoir 12 via the inlet 24.

[0139] Pipe 20 is connected to outlet 88 and fastened to platform 4 at position 100 and clamped to flange 50 at position 102. This arrangement is configured such that any movement of pipe 20 downstream of position 102 (e.g., at position 104) has minimal impact on the weight of platform 4 as measured by load cell 6.

[0140] In a preferred embodiment, the components of device 2 may have the following features:

[0141] (a) Weighing platform 4 – 300mm wide, 200mm deep.

[0142] (b) Storage container 12 – 3.7 liters (nominally holds about 3 kg of liquid color component, depending on component density).

[0143] (c) Pipe 20 – 0.95 cm (3 / 8 inch outer diameter), 0.64 cm (1 / 4 inch inner diameter).

[0144] (d) Metering pump 16 - The pump is arranged to have a displacement of up to 2cc / rev and to be able to operate at a rotational speed of up to 500rpm.

[0145] (e) Transfer pump 36 – The pump is arranged to have a displacement of up to 2 cc / rev and is capable of operating at a rotational speed of up to 500 rpm. It can transfer up to 1000 cc per minute.

[0146] (f) Container 32 – Volume 27 liters.

[0147] (g) The distance between pump 36 and inlet 24 of reservoir 12 is 5 mm.

[0148] The device and its associated central processing unit (CPU) are arranged to be securely (i.e., with appropriate protection) encapsulated in a square box with the following dimensions: 410 mm wide, 460 mm deep, and 450 mm high (in the disassembled state). If removed from the box, the partially pre-assembled device can be fully assembled and ready for use, as described below.

[0149] Figure 2 The arrangement shown (suitably in a pre-assembled form) can be engaged by slidably engaging the support tubes 40, 42 within the openings 85, 87 and engaging the retaining member 90 with the retaining member 92. Figure 5 The frame 80. During this engagement, the drive shaft 44 engages with the keying mechanism of the pump 16, allowing the pump to be driven by the motor 18. The transfer module 26 can then be placed on the platform 58. When thus positioned, the device can be used as follows: Figure 7 and 8 The arrangement is shown. Subsequently, the carrier assembly 64 is operated to move it toward the transfer pump 36, such that the drive shaft 72 passes through the opening 70 and engages the pump's keying mechanism, thereby defining... Figure 9 and 10 The arrangement is shown. Pipe 100 can then be fastened into place to define... Figure 11 The arrangement.

[0150] A central processing unit (CPU) (not shown) is associated with device 2 and is arranged to operate the device and receive data and / or feedback before and / or during device operation, including the following information:

[0151] (a) The weight of the storage component 10 as measured by the load sensor 6 and the weight determination time;

[0152] (b) Pumping rate of pump 16 and operation of motor 18 used therein;

[0153] (c) The weight of the transmission module 26 measured by the load sensor 54 and the weight determination time;

[0154] (d) Pumping rate of pump 36 and operation of motor 38 used therein;

[0155] (e) Liquid level and sensing time sensed by liquid level sensor 22;

[0156] (f) Production of polymer materials in the melt processing equipment;

[0157] (g) The release ratio of the amount of liquid component to be introduced into the polymer;

[0158] (h) Lifespan of container 12 (via associated RFID tag / marker);

[0159] (i) The lifespan of pump 16 (via associated RFID tag / marker).

[0160] Advantageously, device 2 includes only a single tube 20 to transfer the liquid color component into the polymer in the polymer processor. Thus, it should be appreciated that there is no tube or connector connecting the transfer module 26 to the reservoir assembly 10. As previously described, the liquid component is transferred through an air gap between the transfer pump 36 of the transfer module 26 and the inlet 24 of the reservoir assembly. While the absence of a tube or conduit reduces the number of components constituting device 2, it advantageously reduces the risk of leakage that may be associated with couplings and / or pipes used in the prior art to connect liquid flow paths.

[0161] When the transfer module 26 is not transferring liquid components (i.e., when the transfer pump 36 is not operating), the pump is automatically shut off. Thus, the pump 36 functions as a valve that is only opened when the pump motor 38 is operating.

[0162] Once the transfer module 26 has transferred its contents into the storage assembly 12 and emptied, it is readily recyclable—the transfer pump 36 can be detached from the plastic bag of the bag-in-box structure 28 and suitably detached from each recycling section. The transfer module 26 can be replaced with another transfer module 26 containing the same liquid composition (or a different liquid composition if needed). The new module 26 can be securely mounted and connected to the transfer pump motor 38.

[0163] The storage assembly 10 includes a storage tank 12 and a metering pump 16, as well as any liquid components contained therein. Furthermore, the assembly 10 includes a radio frequency identification (RFID) tag arranged to record information related to the use of the storage assembly 10. Specifically, the RFID tag can record how long the assembly 10 has been used, allowing it to be replaced before the pump 16 exceeds its service life.

[0164] If pump 16 has not exceeded its service life, reservoir assembly 10 can be used to transfer liquid components to the plastics processing machine for extended periods, with its reservoir 12 replenished from transfer module 26. However, assembly 10 can be removed and replaced from the equipment before reaching the end of its service life. The removed assembly 10 can be disposed of, removing pump 16 from reservoir 12, RFID tags, and recycled or otherwise disposed components. A new assembly 10 can be secured in place and coupled to motor 18.

[0165] Preferred pump designs for use as transfer pump 38 or metering pump 16 are shown in the figure. Figures 12 to 16 Pump 107 includes: an inlet 110 of a guide housing 111, the housing 111 being connected to an outlet 112. Pump 107 is formed entirely of a plastic material.

[0166] Inlet 110 has a circular cross-section and guides to chamber 169, which is seated above housing 111. Chamber 169 has an open upper end and is provided with separate annular ribs 113 to fasten the pump to a container outlet, such as the outlet of reservoir 12 or bag-in-box structure 28, by push-fit. To allow this connection to be achieved mechanically, an annular flange 114 is disposed around the outside of inlet 110 at the base of inlet 110 to cooperate with a machine arranged to insert chamber 169 into the container outlet. Chamber 169 houses cap 115. Cap 115 has an annular body 116 that fits tightly within chamber 169 and terminates in an outward flange 117, which is seated on the open end of chamber 169 and secured to chamber 169 (e.g., by ultrasonic welding) to connect the parts together. Cap 115 has a disc-shaped closure 118 at its lower end (see...). Figure 15 The enclosure 118 is provided with multiple passages to allow liquid to pass from chamber 169 to inlet 110. For example... Figure 14 and 16 As seen, rib 120 extends upward from closure 118 and diagonally across cap 115. Tube 121 extends upward from closure 118 to hold an emptying strip of a known type (not shown), which, when in use, extends through the outlet of an associated container, which is retractable to prevent a telescopic container from blocking the container outlet when the container is emptied.

[0167] The lower surface of the closed body 118 has a shaped channel 122 for receiving the spring 123.

[0168] The housing 111 is generally cylindrical, closed at one end 39 and open at the other. The axis of the housing 111 is perpendicular to the plane including the centerline of the inlet 110 and the centerline of the outlet 112. The housing 111 is integrated with a flexible diaphragm seal 124, which extends along the axial length of the housing 111 and extends circumferentially about 40° around the perimeter of the housing. The diaphragm seal 124 is supported by a spring 123, which is an elongated member with an inverted U-shaped cross-section, formed of a conformable, flexible, and elastic elastomeric material (e.g., silicone rubber). The spring 123 has separate arms 125a, 125b connected by a base portion 126, on the outer surface of which a rib 127 is supported. The rib 127 extends parallel to the longitudinal axis of the member. The free ends of the separate arms 125a, 125b are thickened. Spring 123 is inverted in channel 122, with the outer surfaces of arms 125a, 125b pressing against sidewalls 28a, 28b, such that the ends 29a, 29b of base portion 26 are fixed relative to sidewalls 28a, 28b. Rib 27 supports the lower surface of diaphragm seal 124. Channel 122 includes parallel, separated channels 130a, 130b that receive the respective free ends of arms 125a, 125b, positioning spring 123 relative to cap 115 and thus relative to housing 111. Cap 115 compresses spring 123, forcing rib 127 against diaphragm seal 124. Spring 123 and seal 124 are thus positioned at the lower end of chamber 169.

[0169] The housing 111 has an inlet hole 131 that leads from the inlet 110 into the interior of the housing 111 and an outlet hole 132 that leads from the interior into the outlet 112. The outlet 112 is a tube with a generally circular cross-section, having an axis parallel to but separate from the centerline of the inlet 10 and terminating in an open end.

[0170] The inlet hole 131 has its largest dimension in a plane perpendicular to the axis of the housing 111, between the first portion 133a (adjacent to the first side edge 134a of the seal 124) and the second portion 133b (on the same side as the diameter of the seal 124 of the housing 111, perpendicular to the diameter of the housing 111 passing through the center of the rib 127). Figure 16 As seen in the diagram. The outlet orifice 132 has its maximum dimension in a plane perpendicular to the axis of the housing 111, between the first portion 135a (adjacent to the second side edge 134b of the seal 124) and the second portion 135b (on the same side as the diameter of the seal 124 of the housing 111, perpendicular to the diameter of the housing 111 passing through the center of the rib 127). Figure 16 As seen in the text.

[0171] The housing 111 houses the rotor 137, which is inserted into the housing 111 through its open end and can be shaped in any convenient manner to form two channels 138a, 138b together with the housing 111. The rotor 137 includes a trunnion 143, thereby positioning the rotor 137 axially at the closed end 139 of the housing 111. The open end of the housing 111 is closed by a cap 140, which carries a rubber lip seal 144 (see...). Figure 15 The lip seal 144 prevents fluid leakage from the housing 111 through the open end along the cap 140. A spindle 141 is formed at the end of the rotor 137 and has a shaped inner bore to receive a complementary shaped drive shaft of the drive motor. The drive shaft reaches the bottom at the blind end of the bore, and the rotor 137 is positioned between the drive shaft and the cap 140 (positioned via trunnion 143). The drive shaft can be spring-loaded in a known manner to accommodate manufacturing tolerances.

[0172] It is necessary to position the second portions 133b and 135b of the inlet hole 131 and the outlet hole 132 to the diameter side of the housing 111 that is almost identical to or the same as that of the sealing body 124, as previously stated. This is because the rotor 137 has two vertices that are 180° apart, and it is necessary to ensure that one vertex always contacts the portion of the housing 111 between the inlet hole 131 and the outlet hole 132 along the rotation direction of the rotor 137, in order to prevent direct communication between the inlet 110 and the outlet 111.

[0173] Inlet 110 is connected to a liquid supply (e.g., from reservoir 12 or bag-in-box structure 28), allowing liquid to enter the open end of inlet 110. Figure 16 At the bottom dead center position shown, fluid enters chamber 138a through inlet port 131 and exits chamber 138b through outlet port 132. Spring 123 causes diaphragm seal 124 to engage rotor 111 to prevent fluid from flowing from outlet 112 to inlet 110. When rotor 137... Figure 16 As the rotor 137 continues to rotate counterclockwise, the rotation forces fluid from the second chamber 138b through the outlet hole 132 to the outlet 112. This causes the volume of the second forming chamber 138b to decrease, while the volume of the first chamber 138a increases to draw fluid from the inlet 110 through the inlet hole 131. Under the action of the spring 123, the diaphragm seal 124 remains in contact with the rotor 111 along the sealing line.

[0174] Rotor 111 faces the center of the bottom dead corner (where rotor 37 is from) Figure 16(Rotating 90° from the position shown) Further rotation causes the first chamber 138a to be closed by the housing 111 and contain a predetermined amount of fluid. The second chamber 138b communicates partially with the outlet 112 via the outlet port 132 and partially with the inlet port 131 to receive fluid from the inlet 110. The diaphragm seal 124 is kept in contact with the rotor 137 by the action of the spring 123 to prevent fluid from flowing between the outlet 112 and the inlet 110.

[0175] Rotor 111 continues to rotate (from Figure 16 The position shown (above 90°) opens the first chamber 138a to the outlet port 132, allowing almost all fluid in the first chamber 138a to exit the outlet 112. The second chamber 138b communicates with the inlet 110 to draw more fluid into the second chamber 138b. The diaphragm seal 112 is kept in contact with the rotor 111 along the sealing line by the action of the spring 123.

[0176] Rotor 11 continues to rotate, continuing the pumping action from inlet 110 to outlet 112.

[0177] The inlet 10, housing 11, inlet hole 31, outlet 12, outlet hole 32, chamber 69 and diaphragm seal 24 are formed as a single piece, forming a single molded component in a single molding operation.

[0178] In summary, the device is operable as follows:

[0179] (i) The liquid components are transferred from the transfer module 26 to the storage assembly 10. The weight change of the transfer module 26 can be monitored by the load sensor 54, and the information can be transmitted to the CPU.

[0180] (ii) The liquid level is monitored over time by sensor 22, and the information is communicated to the CPU. The CPU appropriately controls the transfer from component 10 to the storage component 10, keeping the liquid level between the upper and lower limits, in which case the storage 12 has a constant cross-section. By utilizing such control, the change in the liquid level of the liquid component in the storage 12 is proportional to the amount of liquid component. Therefore, this can be used to provide a volumetric measurement of the amount of liquid component transferred via pipe 20 over time.

[0181] (iii) The weight of the storage assembly 10 is monitored over time by the load sensor 6 to provide a gravimetric method to determine the amount of liquid component transmitted via the tube 20, which can be compared with a volume measurement.

[0182] (iv) The rate at which liquid components are injected via pipe 20 into polymer material, for example, a melt processing device, is determined by the rate of operation of the metering pump 16 controlled by the CPU.

[0183] (v) Under the control of the CPU, the liquid components in the storage 12 are periodically and automatically replenished from the transmission module 26.

[0184] While the transfer rate of the liquid component can be assessed by the weight change of the storage assembly 10 and / or the rate of change of the liquid component level as measured by sensor 22, it is preferable that the primary determination of the liquid component transfer rate is achieved by calibrating the metering pump 16. Other methods may be used to verify the transfer rate of the metering pump 16.

[0185] Further details regarding the assembly and operation of device 2 are as follows:

[0186] 1. Remove device 2 from its container and assemble it. The device can be positioned at ergonomic height on a frame or trolley to ensure safe operation.

[0187] 2. The frame 80 (including the metering pump 16) is located on the weighing platform 4. More specifically, the following steps can be performed:

[0188] a. The frame 80 slides onto the support tubes 40, 42, ensuring that the components are aligned with the metering pump drive shaft 44 sensor and the clamping part 92 (which holds the frame 80 in place).

[0189] b. When the frame 80 slides toward the rear of the weighing platform 4, but before the pump 16 encounters the shaft 44, at the shoulder of the reflective proximity sensor sensing storage 12, the CPU starts the metering pump motor to oscillate to facilitate shaft engagement.

[0190] c. When rack 80 is detected by reflective proximity sensor, radio frequency identification (RFID) reader also detects the presence of tag / adhesive mark on shoulder of storage 12 (which enables writing of RFID tags / marks).

[0191] d. When the rack 80 is fully engaged and pulled "back into place" by the cooperation of the holding members 90 and 92, the rack 80 stops within the range (without contact) of the inductive sensor communicating with the CPU. The CPU confirms that the rack 80 is fully engaged, thus stopping the metering pump oscillation.

[0192] e. Pipe 20 then runs from pump 16 through clamp 102, which is positioned on flange 50 to prevent bending, vibration, or tension of the pipe from being transmitted to the weighing platform that monitors the contents of storage tank 12.

[0193] 3. The filled bag-in-the-box structure 28 is placed on platform 4. More specifically, the following steps can be used:

[0194] a. The transfer pump 36 is pre-installed in the neck of the container 32, which serves as a cap / closure during transport from the production workshop to the customer.

[0195] b. Open part of structure 28 by tearing off the perforated cardboard box panel to expose the transfer pump 36.

[0196] c. Structure 28 is placed on platform 4, and transfer pump 36 is pulled down onto the extendable flexible neck incorporated into container 32.

[0197] d. The transfer pump motor 38 is engaged with the transfer pump 36 by sliding the motor toward the pump shaft. Engagement is facilitated by the oscillation of the drive shaft 2.

[0198] e. By sensing that the pump is located before the motor, the CPU confirms that the bag structure 28 in the box is assembled onto the platform 4. This can be achieved using a reflective proximity sensor.

[0199] 4. The CPU monitors the liquid level in the reservoir 12 via the rack 80 (which includes the metering pump 16 in place and the bag-in-tank structure 28) and attempts to fill the reservoir from the bag-in-tank structure 28. Further details are as follows:

[0200] a. The liquid level in the reservoir 12 is determined by an ultrasonic sensor 22 arranged above the inlet 24.

[0201] b. Sensor 22 may be a digital device with two predetermined switching / turning points.

[0202] i. Transfer pump 36 fills to the upper liquid level.

[0203] ii. At the lower liquid level (where the liquid level is sufficiently reduced), transfer pump 36 will begin to replenish the storage tank 12. If the liquid level reaches this low point and is not quickly restored by turning on transfer pump 36, an alarm will be triggered to call the operator.

[0204] c. As an alternative, the level sensor 22 can be an analog device that provides continuous level readings to the CPU.

[0205] i. The upper and lower liquid levels can be adjusted within the CPU, but this also applies to the pre-programmed digital switching / on / off points mentioned above.

[0206] d. An alarm can be issued to the operator: insufficient liquid transfer from structure 28 to storage tank 12. This could indicate a problem, but more likely it would indicate that container 32 is empty and needs to be replaced.

[0207] 5. The device can be calibrated manually or automatically, for example, to determine the effective number of grams per revolution for a particular metering pump 16 and additive combination.

[0208] 6. Through the input screen associated with the CPU, the operator can directly input the necessary parameters of the liquid composition of the polymer to be contacted (which will be processed in the melt treatment equipment), as follows:

[0209] i. For injection molding applications:

[0210] • SHOT WEIGHT g – Polymer weight per machine cycle

[0211] • (Excretion Ratio) LDR% – Percentage by weight of additives (0–10%)

[0212] ii. For extrusion or other continuous forming applications:

[0213] • WEIGHT / HR Kg – Weight of polymer processed per hour

[0214] • LDR% – Percentage by weight of additives (0–10%)

[0215] 7. Once set up, the operator can start the unit, which will respond to external signals from the processing equipment and transmit an amount determined based on production volume or for each subsequent cycle of the processing.

[0216] 8. During operation, the reservoir 12 should be periodically replenished with liquid components without intervention:

[0217] a. An alarm is triggered when transmission module 26 is empty and needs to be replaced.

[0218] b. The transfer module 26 can be replaced while the metering pump 16 continues to transfer residual material from the storage tank 12.

[0219] c. The unit periodically records the number of rotations performed by the metering pump 16 (returned to the RFID tag / marker on the attached storage).

[0220] i. This provides a continuous record of the remaining pump life.

[0221] ii. The unit will indicate to the operator when the metering pump should be replaced.

[0222] iii. Record pump dwell times and load them onto RFID tags / markers when the rack (including the pump) moves between units, or store them between periods of use.

[0223] In some cases, it may be desirable to alter the properties of the liquid color component in the polymer to be introduced into the melt treatment machine. For this purpose, the transfer module 26 can be decoupled from the transfer pump motor 38 and then stored for later use. As previously described, the pump 36 (remaining attached to the bag structure 28 in the tank) acts as a shut-off valve, thereby preventing any leakage of the color component from the transfer module 26. Furthermore, the reservoir assembly 10 is decoupled from the motor 18. At the outlet of the reservoir assembly 10, the pump 16 remains attached to the reservoir 12 and acts as a shut-off valve, thereby preventing any leakage of the color component from the reservoir assembly 10 at the outlet. The inlet 24 of the assembly 10 can be closed using a screw thread cap (not shown). The removed liquid-tight assembly 10 can be stored for reuse. Finally, the tube 20 can be replaced. Thus, it should be appreciated that the properties of the color component transferred by the proposed device 2 can be easily and quickly changed, as previously described.

[0224] The company operating device 2 may have an inventory / list including device 2 and a series of pairs of storage components 10 and transfer modules 28, each pair containing the same liquid composition (and which may be used as part of device 2). Different pairs may include different liquid color compositions.

[0225] After a period of time, components of the metering pump 16 may wear down, rendering it unable to meter components with sufficient accuracy. In this case, the reservoir assembly 10 can be replaced with a new reservoir assembly, which includes a new pump 16. The old reservoir assembly can be disassembled, and its components can be recycled in a suitable manner.

[0226] This invention is not limited to the details of the foregoing embodiments. The invention extends to any novel feature or any novel combination thereof disclosed in this patent document (including any appended claims, abstract, and drawings), or to any novel step or any novel combination thereof of any steps of any method or process thus disclosed.

Claims

1. An apparatus for dispensing a fluid formulation into a polymer material, the apparatus comprising: (i) Container A for containing the fluid formulation, wherein container A includes an outlet for the fluid formulation; (ii) A storage assembly for containing a fluid formulation delivered from container A, wherein the storage assembly includes an inlet for receiving the fluid formulation delivered from container A; The outlet of container A is vertically aligned with the inlet of the storage assembly; The outlet of container A is arranged to transfer the fluid formulation through an air gap into the storage assembly; The fluid formulation in container A is the same as that in the storage assembly; Container A has a larger total internal volume than the storage assembly; The reservoir assembly includes a second pump for pumping the fluid formulation from the reservoir assembly; The device includes: a level sensor for assessing the level of a fluid formulation in the storage assembly, wherein the level sensor is arranged to communicate level information to a central processing unit (CPU) that is a component of the device; and the device includes: a first weighing mechanism for monitoring the weight of the storage assembly and its contents; and There is no physical connection between the outlet of container A and the wall of the storage assembly to allow the liquid formulation to be transferred from container A to the storage assembly; The inlet of the storage assembly is defined in the top wall of the storage assembly, and the inlet defines an upward-facing opening, wherein the opening is arranged to be closed by a releasably fastened closure. The reservoir assembly includes a reservoir and a second pump, wherein there is no extension pipe between the outlet of the reservoir and the second pump; The tubing is connected to the outlet of the second pump, and is arranged to deliver the fluid formulation to a polymer material associated with a melt processing device; and A portion of the tube is clamped to a portion of the device in a first position, and a portion of the tube downstream of the first position is operable to position it to transfer the fluid formulation onto the polymer material without transmitting any such movement to the weighing mechanism.

2. The device according to claim 1, wherein, Container A includes a first pump, wherein the first pump is a positive displacement pump.

3. The device according to claim 2, wherein, The first pump is arranged to operate as a closure mechanism for container A when fluid is not pumped from container A, and / or when container A is not effectively connected to a motor arranged to drive the rotor of the pump.

4. The device according to claim 2, wherein, The container A includes: a first pump and a container portion arranged to contain a fluid formulation, the first pump being directly connected to and / or adjacent to the outlet of the container portion, wherein there is no extension tube between the container portion and the first pump.

5. The device according to claim 1, wherein, The inlet of the reservoir assembly defines an opening having a maximum width ranging from 2 to 10 cm and / or at least 4 cm for the fluid formulation to pass through during use. 2 and less than 70cm 2 The area.

6. The device according to claim 1, wherein, The storage assembly has a total internal volume of at least 2 liters and less than 50 liters.

7. The device according to claim 1, wherein, The storage assembly has a constant internal cross-sectional area along a length L, wherein L is at least 25 mm and less than 400 mm; and / or, the volume of fluid capable of being contained within the constant cross-sectional area is at least 500 cm³. 3 And less than 20000cm 3 .

8. The device according to claim 1, wherein, The storage assembly includes an inlet for inputting the fluid formulation into the storage assembly, wherein the inlet is located in the upper part of the storage assembly above a defined maximum fill level of the storage assembly, wherein data of the maximum fill level is stored in a central processing unit (CPU) that is a component of the device.

9. The device according to claim 1, wherein, The first weighing mechanism includes a platform supporting the storage component, and the first weighing mechanism is arranged to communicate information related to the weight of the storage component over time to the CPU.

10. The device according to claim 9, wherein, The storage assembly is associated with a rack arranged to support the storage assembly, wherein the rack is arranged to be releasably fastened to the weighing mechanism.

11. The device according to claim 1, wherein, The first position is such that its position does not change when the platform of the first weighing mechanism moves with the weight of the storage component; wherein the platform supports the storage component.

12. The device according to claim 1, wherein, The second pump is a positive displacement pump.

13. The device according to claim 2, wherein, The device includes a first pump and a second pump, wherein each of the pumps is a positive displacement pump, wherein the positive displacement pump includes a housing and a rotor rotatable within the housing, the housing having an inlet connected to a fluid source and an outlet for fluid pumped by the positive displacement pump, the inlet and the outlet being separated along a path of the rotor within the housing, wherein the rotor has an axis of rotation, wherein the inlet is arranged to introduce fluid into the housing in a direction transverse to the axis of rotation; The outlet is arranged in a direction transverse to the axis of rotation to discharge fluid out of the housing, and the inlet and the outlet are circumferentially separated about the axis of rotation.

14. The device according to claim 13, wherein, The rotor includes rotor surfaces that form multiple enclosed chambers with the interior region of the housing. As the rotor rotates, the enclosed chambers travel along the housing to transport fluid from the inlet to the outlet.

15. The device according to claim 1, wherein, The ratio of the total internal volume of container A to the total internal volume of the storage assembly is 1.5 to 10.

16. The device according to claim 1, wherein, The container A includes a first pump and a container section, and the container section is retractable.

17. The device according to claim 1, wherein, The container A is located above the storage assembly, and the container has a coverage area that completely overlaps the coverage area defined by one or the storage unit and / or the storage assembly.

18. The device according to claim 1, wherein, The device includes a second weighing mechanism for monitoring the weight of container A and its contents, wherein the second weighing mechanism is arranged to communicate information related to the weight of container A over time to one or the CPU.

19. The device according to claim 1, wherein, One of the devices associated with the dispensing equipment or the CPU is arranged to receive input related to the rate at which the fluid formulation is injected into a polymer material, which may be present in a melt processing device associated with the device.

20. The device according to claim 1, wherein, One of the devices or the CPU associated with the dispensing equipment is arranged to control the operation of one or the second pump, and / or to receive inputs related to the discharge ratio (LDR).

21. The device according to claim 1, wherein, The device is combined with a melt processing device, and thus the outlet of the device is arranged to transfer the fluid formulation from the device to the polymer material that is melt-processed in the melt processing device.

22. The device according to claim 1, wherein, The equipment is installed on the transport vehicle.

23. The device according to claim 1, wherein, The storage assembly contains a fluid formulation, and container A comprises the same fluid formulation, wherein the fluid formulation has a viscosity of at least 1000 cP and less than 75000 cP.

24. A method for dispensing a fluid formulation into a polymeric material, the method comprising: (a) Select the device as described in any one of claims 1 to 23, (b) Transferring the fluid formulation from container A to the storage assembly; (c) Transferring the fluid formulation to the polymer material downstream of the reservoir assembly.

25. The method according to claim 24, wherein, The method includes: The fluid formulation is transferred via an air gap as it is transferred from container A to the storage assembly, wherein the fluid formulation falls through the air gap over a distance of at least 1 mm.

26. The method according to claim 25, wherein, The method includes: the CPU of the device controlling the operation of a first pump that is part of the container A; and / or The method includes: the CPU receiving information related to the weight of the container A; and / or The method includes: the CPU receiving information related to the weight of the storage component; and / or The method includes: the CPU controlling the operation of a second pump arranged to pump a fluid formulation from the storage assembly to transfer the fluid formulation into the polymer material; and / or The method includes: an operator inputting information into the CPU according to the desired dosing rate of the fluid formulation into the polymer material; and / or The method includes: the CPU receiving information related to the level of a fluid formulation in the storage assembly.

27. The method according to claim 24, wherein, In the method, the fluid formulation delivery rate of a second pump, which is arranged to pump the fluid formulation from the reservoir assembly to deliver the fluid formulation into the polymer material, is a key parameter and is set to determine the rate at which the fluid formulation is dispensed into the polymer material.

28. The method according to claim 24, wherein, The method includes: replacing container A when the amount of fluid formulation in container A drops below a predetermined level; and / or The method includes replacing the reservoir assembly, which includes one of the second pumps, after a predetermined amount of fluid formulation has been delivered via the second pump.

29. The method according to claim 24, The method includes: Adjust the device to deliver alternative fluid formulations; The method includes replacing container A and the reservoir assembly including the second pump with an alternative container A and an alternative reservoir assembly including a second pump, wherein container A includes the alternative fluid formulation.

Images