Small fill volume pump

Abstract

A pump system for small fill volumes having a pump unit with a disposable pump head assembly, a controller, a drive motor, and a transmission between the drive motor and the pump unit. A user may enter pump operational data through a controller on the system housing. Operational data may be monitored remotely and through the controller. Access to the pump system is protected through required usernames, passwords, and electronic signatures of system operators.

Description

CROSS REFERENCE TO RELATED APPLICATION

This application is based upon and claims benefit of copending and co-owned U.S. Provisional Patent Application Ser. No. 60/789,792 entitled “Small Fill Volume Pump,” filed with the U.S. Patent and Trademark Office on Apr. 6, 2006 by the inventors herein, the specification of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to pumping apparatus, and more particularly to a small fill volume pump having disposable components and configured for accurate monitoring and data collection.

2. Background

Certain pumping operations lend themselves to use of disposable pump apparatus, or at least pump systems having disposable components that come in contact with the fluid that is to be pumped. Such pumping operations may include, for instance, dispensing chemicals, reagents, or other fluids in the medical, pharmaceutical, cosmetics, and like industries. In these cases, as the damage that might result from cross-contamination of one pumped fluid with another may be catastrophic, simply cleaning the pump components after pumping operations may not be sufficient; rather, to fully protect against such cross-contamination, system components that come in contact with the pumped fluids would desirably be disposed of after a pumping operation on a single fluid.

Unfortunately, as making a pump assembly disposable typically requires (for purposes of commercial acceptance) that the pump assembly be priced to allow easy replacement, the lower cost requirement has often resulted in pump systems and components of limited utility. For example, peristaltic pumps having disposable tubing for carrying the pumped fluid have been used in pumping operations. However, as many pumping operations in the pharmaceutical, medical, cosmetics, and like industries can require pumping very small volumes, and since peristaltic pumps lack the accuracy and repeatability of positive displacement pumps, they have not been suitable for pumping of such small volumes often required in these industries. Likewise, hand operated syringes have been used for pumping and/or dispensing extremely small volumes of fluid, but the repeatability and accuracy of such operations depends upon the human operator manipulating the syringe, and furthermore takes significantly more time than would an automated pumping operation.

Still further, such industries as the pharmaceutical, cosmetics, and medical industries are highly regulated, and require manufacturers to maintain data relating to their manufacturing operations in such a way as to allow for data validation, a clear audit trail, and record retention. Thus, those performing operations such as pumping fluids used in the manufacture of new products in those industries may be required to maintain data relating to, among other things, what is being pumped and dispensed, and when. However, while pump systems have previously been available having electronic control systems for operating pump components, to the knowledge of the inventors, there have been no small fill volume pumps of simplistic construction having disposable components that allow for the automated control of the pumping operation and pump data collection and storage capability on board the pump unit, or the capability to remotely monitor the operation of such a pump system.

It would therefore be advantageous to provide a pump system for small fill volumes have a simplistic construction that is capable of very fine pumping and dispensing operations while maintaining a simple and relatively low cost construction, and that provides for the automated control and data collection and storage on the pump system, and for the remote operational monitoring of such pump system.

SUMMARY OF THE INVENTION

Disclosed is a pump system for dispensing small volumes of fluid. The pump system is configured for quick, easy replacement of disposable components of the system so as to prevent cross-contamination of various fluids processed by the system. The pump system includes a controller that, when accessed by an authorized user, allows the user to set operational parameters, monitor operational data through the controller and remotely across a network, recall operational profiles for specific fluids being dispensed, provide diagnostic tools, and provide security features for operator intervention and logging.

The various features of novelty that characterize the invention will be pointed out with particularity in the claims of this application.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other features, aspects, and advantages of the present invention are considered in more detail, in relation to the following description of embodiments thereof shown in the accompanying drawings, in which:

FIG. 1 is an elevational side view of a pump system according to a first embodiment of the present invention.

FIG. 2 is a front elevational view of a pump assembly according to a first embodiment of the present invention.

FIG. 3 is a cross-section view of the pump assembly of FIG. 2 taken along line 3-3.

FIG. 4 is a front elevational view of a pump assembly according to an alternate embodiment of the present invention.

FIG. 5 is a cross-section view of the pump assembly of FIG. 4 taken along line 5-5.

FIG. 6 is a top plan view of a pump system according to the present invention.

FIG. 7 a front elevational view of a pump system according to the present invention.

DETAILED DESCRIPTION

The invention summarized above and defined by the enumerated claims may be better understood by referring to the following description, which should be read in conjunction with the accompanying drawings in which like reference numbers are used for like parts. This description of an embodiment, set out below to enable one to build and use an implementation of the invention, is not intended to limit the invention, but to serve as a particular example thereof. Those skilled in the art should appreciate that they may readily use the conception and specific embodiments disclosed as a basis for modifying or designing other methods and systems for carrying out the same purposes of the present invention. Those skilled in the art should also realize that such equivalent assemblies do not depart from the spirit and scope of the invention in its broadest form.

In a particularly preferred embodiment of the invention, and as shown in the side view of FIG. 1, a small volume pump system, indicated generally as 10, is provided comprising a housing 100 having a controller 30, with an operator interface 47, mounted on the side of housing 100, a mounting flange 4 on a front of housing 100, and a pump assembly (shown generally at 200) attached to mounting flange 4. Pump assembly 200 comprises a pump mounting base 1, a disposable pump head 2 removably attached to pump mounting base 1, an inlet 101, and an outlet 102. External valves (not shown) are preferably provided in tubing that is attached to inlet 101 and outlet 102 to control the direction of flow in such tubes, allowing the pump assembly 200 to pull product in from a supply and push product out to a dispensing nozzle. Housing 100 is preferably provided a handle 14 allowing the easy transport of the pump system 10, and a plurality of feet 11 supporting housing 100 above a surface on which it is intended to be used.

As shown more particularly in the front and cross-sectional views of pump assembly 200 of FIGS. 2 and 3, pump mounting base 1 comprises a generally cylindrical block having a flange 17 at its base. The flange 17 is provided a plurality of openings 205 configured to receive a fastener, such as a thumb screw 207 configured for connection with mounting flange 4 on pump housing 100, thus allowing the entire pump assembly 200 to be quickly connected to and removed from pump housing 100. Other fasteners may likewise be used without departing from the spirit and scope of the invention. Pump mounting base 1 has a generally cylindrical bore extending therethrough forming a hollow cylinder 210, which cylinder 210 is configured to receive a piston 3 and to allow for reciprocal motion of the piston 3 (and the piston rod 18 to which it is attached) through cylinder 210. A resilient sealing member, such as an o-ring 6, is preferably positioned in the bottom face of pump mounting base 1 so as to provide an air-tight seal between pump mounting base 1 and mounting flange 4 on housing 100, such that a vacuum may be applied to the interior of the cylinder 210 (as discussed in greater detail below).

A disposable pump head 2 is removably mounted to the top face of pump mounting base 1. Pump head 2 is preferably formed of a polymer so as to allow for easy reproduction and, thus, easy replacement at relatively low cost. Pump head 2 is provided a plurality of openings 215 configured to receive thumb screws 7 (or like configured connectors), which thumb screws 7 are configured to be received in threaded openings in the top face of pump mounting base 1, thus allowing the removable attachment of disposable pump head 2 to pump mounting base 1. Another o-ring 26 (or other resilient sealing member) is preferably positioned in the top face of pump mounting base 1 so as to provide a fluid-tight seal between disposable pump head 2 and pump mounting base 1.

Disposable pump head 2 is preferably provided a hollow fluid chamber 220, having an inlet port 222 operationally connected to inlet 101 receiving fluid from a fluid source (not shown) and an outlet port 224 operationally connected to outlet 102 for dispensing fluid from the pump assembly 200. Fluid chamber 220 is closed at its bottom end by a diaphragm 14, which diaphragm 14 is configured for reciprocating motion in fluid chamber 220 so as to draw fluid into the chamber 220 and push fluid out of the chamber 220 upon movement of the piston 3 away from and towards the chamber 220, respectively. Diaphragm 14 is preferably formed of a flexible elastomer. Diaphragm 14 is preferably held in place around the bottom of fluid chamber 220 by way of a retaining clip 5. Because the diaphragm 14 is permanently secured to the pump head 2, and thus creates a seal, the fluid being pumped never comes in contact with the piston 3. This allows a user to remove the pump head 2 from the pump mounting base 1 without contaminating the drive or any other components, and likewise allows the user to dispose of the pump head 2 without having to dispose of the rest of the pump system 10.

Using a system in accordance with the instant invention, during intake, fluid is pulled into chamber 220 until the stroke of piston rod 18 stops. The rearward movement of piston rod 18, and resulting rearward movement of piston 3 causes rearward movement of the diaphragm 14 within chamber 220, creates a vacuum in the fluid tubing causing the fluid to begin moving through inlet port 222 in the direction of the vacuum source. As the pump head 2 reaches the end of its intake cycle, the piston rod 18 reverses direction and moves the piston 3 against the diaphragm 14 back into the chamber 220 increasing the pressure in chamber 220. The increased pressure causes the fluid in the chamber to begin moving through outlet port 224 to be discharged from the pump head 2.

An alternate embodiment of a pump head 2′ is shown in FIGS. 4 and 5. The inlet port 222a and outlet port 224a have been moved to the side of the pump head 2′. This allows any air in the chamber 220′ to be evacuated automatically from the pump head 2′ during priming of the pump.

As shown in the top-down, sectional view of FIG. 6, piston 3 is mounted to piston rod 18, which in turn is configured for reciprocal movement out of and into housing 100. A slide mount 12, generally in the form of a spacer block, is mounted to the interior sidewall of housing 100. A slide 15 is mounted to a free side of slide mount 12, and is configured to receive a moveable transition mount 16. More particularly, slide mount 12 includes a transmission that converts the rotary motion of a drive motor 36 (FIG. 7), which rotary motion is transferred into linear displacement of the transition mount 16 along slide 15 through use of a ball screw and nut of standard configuration. A piston rod mount 19 is attached to transition mount 16 and clamps a portion of piston rod 18, such that movement of transition mount 16 along slide 15 likewise causes movement of piston rod 18, and thus piston 3, forward and backward causing fluid in the pump head 2 to be dispensed and drawn in, respectively. A vacuum exhaust port 22 is provided extending through housing 100 so as to allow air to enter and exit the interior of housing 100 upon extending and retracting the piston 3, respectively. Further, a vacuum fitting 23 is preferably provided at a free end of piston rod 18, and is configured (when attached to a vacuum source) to pull a vacuum through the center of piston rod 18 using a vacuum pump 325 (FIG. 1). As shown more particularly in the cross sectional view of FIG. 3, piston 3 is provided one or more vacuum ports 301 at its tip to aid in drawing diaphragm 14 against piston 3 as it retracts.

As shown in the front, sectional view of FIG. 7, controller 30 is preferably mounted within a cover 31 that is attached to housing 100 via a hinge 33. A lanyard 43 is preferably attached to cover 31 and to housing 100 to limit the extent to which cover 31 may be opened, thus reducing the risk of damage to controller 30 when opening the housing 100 to service components of the pump system 10. As shown in FIG. 7, a motor 36 is provided inside of housing 100 and, as mentioned above, rotary motion of the motor 36 is transferred into linear motion of the piston rod 18 and piston 3. Such transfer of motion may use, for example, a pulley 38 such as by way of a drive belt in which rotary motion of the pulley 38 is ultimately transferred to the piston 3 as linear motion. The controller 30 is in communication with the drive motor 36, the drive motor 36 being mechanically connected to the piston rod 18. To ensure control of the linear displacement of piston rod 18, and thus of the operation of the pump system 10, motor 36 preferably comprises a high precision servomotor. By way of example only, and not by way of limitation, motor 36 may comprise an Allen Bradley type Y series motor.

Controller 30 preferably includes at least a processor, a data storage device, a user interface 47, and a communication device allowing remote monitoring of the operational data of the pump system 10. The user interface 47 preferably includes a display screen, such as a touch sensitive display allowing a user to enter data and control system operation directly through the screen. In an alternate embodiment, the user interface 47 may comprise a separate keyboard or other input device. In some embodiments, the controller 30 may comprise a remote personal computer having data storage capability to record information concerning operation of the drive unit and attached pump components. Controller 30 preferably allows the user to monitor operational data through the display and from a remote location (such as across a wide area network), store predefined dispensing operation parameters for specific fluids, provide diagnostic tools, and provide security features for operator intervention and logging (such as username and password login requirements for engaging the system, accessing data, printing data, etc.). Controller 30 may be connected to a network for data storage, record keeping, and monitoring. In use, a user may use the user interface 47 to enter information identifying the substance to be pumped, such that the controller 30 may recall preset pumping parameters for such substance. Preferably, before the user may have such access to the pump system 10, they are required to input a username and password, and preferably an electronic signature confirming their operation of the system. During operation, operational data (including identification of the user, identification of the product being pumped, date of the operation, time of the operation, and the volume of the product being pumped) is recorded in a log file. Product dispense data can be sent to secure database units and can be viewed on a company's intranet or over a wide area network by authorized users. The controller 30 preferably logs all activities for auditing purposes. After the pumping operation is completed, the user may dispose of the pump head 2 or remove and replace the pump head 2 to begin another pumping operation. By disposing of and replacing the pump head 2, cross-contamination of the fluid products being dispensed is avoided.

The invention has been described with references to a preferred embodiment. While specific values, relationships, materials and steps have been set forth for purposes of describing concepts of the invention, it will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the specific embodiments without departing from the spirit or scope of the basic concepts and operating principles of the invention. It should be recognized that, in the light of the above teachings, those skilled in the art can modify those specifics without departing from the invention taught herein. Having now fully set forth the preferred embodiments and certain modifications of the concept underlying the present invention, various other embodiments as well as certain variations and modifications of the embodiments herein shown and described will obviously occur to those skilled in the art upon becoming familiar with such underlying concept. It is intended to include all such modifications, alternatives and other embodiments insofar as they come within the scope of the appended claims or equivalents thereof. It should be understood, therefore, that the invention may be practiced otherwise than as specifically set forth herein. Consequently, the present embodiments are to be considered in all respects as illustrative and not restrictive.

Claims

1. A pump system, comprising:

a housing;

a motor;

a piston rod operationally attached to said motor; and

a pump assembly comprising: a pump mounting base removably attached to said housing and operationally attached to said piston rod; and a pump head removably attached to said pump mounting base.

2. The pump system according to claim 1, wherein said pump mounting base comprises a generally cylindrical block having a flange at its base.

3. The pump system according to claim 2, said flange further comprising:

a plurality of openings configured to receive a fastener, wherein said fastener is configured for removably attaching said flange to said housing.

4. The pump system according to claim 1, said pump mounting base further comprising:

a generally cylindrical bore extending therethrough forming a hollow cylinder.

5. The pump system according to claim 4, wherein said hollow cylinder is sized and configured to receive a piston attached to one end of said piston rod.

6. The pump system according to claim 5, wherein said hollow cylinder is sized and configured to allow for reciprocal motion of said piston through said cylinder.

7. The pump system according to claim 1, said pump head further comprising:

a plurality of openings configured to receive a fastener, wherein said fastener is configured for removably attaching said disposable pump head to said pump mounting base.

8. The pump system according to claim 1, said pump head further comprising:

a hollow fluid chamber having an inlet port and an outlet port.

9. The pump system according to claim 8, wherein said hollow fluid chamber is closed at its bottom end by a diaphragm.

10. The pump system according to claim 9, wherein said diaphragm is sized and configured for reciprocating motion in said hollow fluid chamber.

11. The pump system according to claim 9, further comprising a retaining clip to hold said diaphragm onto said pump head.

12. The pump system according to claim 11, wherein said diaphragm is permanently attached to said pump head.

13. The pump system according to claim 1, wherein said pump head is constructed of materials selected to enable said pump head to be disposable.

14. The pump system according to claim 1, further comprising a vacuum pump.

15. The pump system according to claim 14, wherein said piston rod is hollow, said pump system further comprising a vacuum fitting attached to a second end of said piston rod, said vacuum fitting being configured to draw a vacuum through said piston rod.

16. The pump system according to claim 15, further comprising a piston having at least one vacuum port attached to a first end of said piston rod.

17. The pump system according to claim 1, wherein said piston rod is operationally connected to said motor by a pulley system.

18. The pump system according to claim 1, wherein said motor comprises a high precision servomotor.

19. The pump system according to claim 1, further comprising a controller.

20. The pump system according to claim 19, said controller further comprising a user interface having a display screen.

21. The pump system according to claim 20, wherein said display screen comprises a touch sensitive key pad.

22. The pump system according to claim 20, wherein said user interface further comprises a keyboard.

23. The pump system according to claim 19, wherein said controller comprises a remote personal computer attached to said pump system.

24. The pump system according to claim 19, wherein said controller further comprises data storage capability to record information concerning operation of said pump system.

25. The pump system according to claim 19, wherein said controller further comprises a processor to control operation of said motor.

26. The pump system according to claim 19, wherein said controller further comprises a communication device to enable remote monitoring of said pump system.

27. The pump system according to claim 1, in which said pump assembly is fitted in an exchangeable manner, so that said system is modular.

28. The pump system according to claim 1, said pump assembly further comprising a modular construction of said pump mounting base enabling quick-connect assembly to said piston rod.

29. The pump system according to claim 1, said pump assembly further comprising a modular construction of said pump mounting base enabling quick-connect assembly to said housing.

30. The pump system according to claim 1, said pump assembly further comprising a modular construction of said pump head enabling quick-connect assembly to said pump mounting base.