DOCKING VALVE
TECHNICAL FIELD
The invention relates to a docking valve for dispensing liquid or pasty material to a container provided with a filler valve, and to a method for dispensing said material.
PRIOR ART
Dispensing liquid and pasty materials from one container to another, for example from a storage container to a dosing container, often entails problems of leakage and waste.
The containers are each provided with a valve, and the valves have to be connected or held in contact with each other while the material is being dispensed. Leakage points in a valve can result in material leaking out from a storage container or dripping onto products on which the material is to be applied. This can entail extra costs for cleaning or for discarding products. Leakage at the point of contact between the valves mean that small amounts of material may be left behind and collect on or near the valves. In the long term this affects the function of the valves and can cause unnecessary production stoppages. In addition, if the dispensing is carried out at a high pressure and/or high temperature, a sudden leakage can have serious consequences.
Material that has collected around a docking valve, for example, attracts dirt and particles from the environment. Such particles can cause the docking valve to leak and can be transferred, for example, to a dosing container as the latter is being filled. This may in turn cause the valve of the dosing
container to leak. In addition, dirt and particles may become mixed up with the dispensed material and contaminate it, which can lead to blockages in the application nozzle and also to inferior quality of the product onto which the material is applied.
Even if such leakage from a valve may be considered insignificant, it can in the long term entail costs if the dispensed material itself is an expensive one.
An example of a system in which the above-mentioned problems can occur is equipment for applying glue or sealing compound. Such equipment is described for example in SE-C2-508434, which discloses a storage container with a docking valve, a robot arm with a dosing container, and a programmable control unit. The above-mentioned problems can occur when the robot arm moves the dosing container to the storage container for filling.
DISCLOSURE OF INVENTION
The object of the invention is to make available a system for dispensing material in which the above-mentioned problems of leakage and leaky valves are avoided. According to the invention this is achieved by means of a docking valve and a filler valve cooperating with the latter.
The invention relates to a docking valve for dispensing liquid or pasty material to a container, which valve comprises a valve body with at least one connection for pressure medium, a pressure-medium-controlled means for acting on the valve, a connection for material which is to be dispensed, and a nozzle for dispensing material, where the nozzle is provided with a needle valve, where the nozzle and the needle valve near their outer ends cooperate along a circular contact line, and where the distance between an inner surface of the nozzle and an outer surface of the needle valve diverges on either side of the contact line.
The nozzle and needle valve of the docking valve can be designed in a number of ways. According to a first embodiment, the outer end of the needle valve has a substantially conical section with a first cone angle and the nozzle has two conical sections, including an outer section with a second cone angle and an inner section with a third cone angle, where the first cone angle is slightly smaller than the second cone angle and slightly greater than the third cone angle.
According to a second embodiment, the nozzle has a substantially conical section with a first cone angle and the needle valve has two conical sections, including an outer section with a second cone angle and an inner section with a third cone angle, where the first cone angle is slightly greater than the second cone angle and slightly smaller than the third cone angle.
According to a third embodiment, the outer end of the needle valve has a substantially conical section with a first cone angle and the nozzle has one or two spherical sections, including an outer section with a first radius and an inner section with a second radius which is the same as or smaller than the first radius.
According to a fourth embodiment, the nozzle has a substantially conical section with a first cone angle and the needle valve has one or two spherical sections, including an outer section with a first radius and an inner section with a second radius which is the same as or smaller than the first radius.
These embodiments mean that only a very small volume of material is left in the space from the contact line between nozzle and needle valve to their outer ends. This remaining volume functions as a sealing gasket until the next filling. However, the volume is so small that no appreciable expansion takes place when the contact between the valves ceases. Since the contact
surface between nozzle and needle valve is formed as a line, a higher contact pressure is obtained and thus a tighter valve.
The nozzle is intended to cooperate with a filler valve, the nozzle and the filler valve cooperating near their outer ends along a circular contact line, and the distance between the outer surface of the nozzle and the inner surface of the filler valve diverging on each side of the contact point.
According to one embodiment, the outer end of the nozzle has an outer surface which is intended to cooperate with a filler valve having an inner conical surface with a first cone angle, said outer surface having two conical sections, an outer section with a second cone angle and an inner section with a third cone angle, and the first cone angle is slightly smaller than the second cone angle and slightly greater than the third cone angle.
According to a further embodiment, the outer end of the nozzle has an outer surface which is intended to cooperate with a filler valve having an inner conical surface, said outer surface having one or two spherical sections, including an outer section with a first radius and an inner section with a second radius which is the same as or greater than the first radius.
Said inner section, viewed in the axial direction, constitutes a centering arrangement upon cooperation with a filler valve on the container. Having a centering section means there is reduced wear on the outer section of the nozzle, which is intended to seal against the filler valve.
The needle valve has a plane end surface for cooperating with a corresponding surface on the filler valve on the container. To open and close the docking valve, a piston is preferably used which is controlled by pressure medium. The piston can be controlled by pressure medium both for opening
and for closing the valve, or can open counter to a spring which loads the valve towards the closed position.
Certain materials may require to be heated before they can be dispensed, and in these cases the docking valve is provided with means for heating the material which is to be dispensed.
The invention additionally relates to a filler valve for a container for liquid or pasty material, which valve is intended to cooperate with the above- mentioned docking valve. The side facing towards the docking valve is provided with an opening of conical cross section, intended to cooperate with the centering and sealing surfaces of the nozzle of the docking valve, and a valve sealing the opening and intended to cooperate with the needle valve included in the nozzle.
The sealing valve is moved from the closed position to the open position by the direct action of said needle valve and is provided with a return spring which biases the valve towards the closed position.
In order to avoid wasting dispensed material, the smallest diameter of the opening is very slightly greater than the greatest diameter of the needle valve included in the docking valve. In addition, a contact surface facing towards the sealing valve is provided with a groove whose outer diameter is greater than the diameter of the valve and whose inner diameter is greater than the diameter of the opening, for the purpose of increasing the valve contact pressure.
According to a preferred embodiment of the invention, the container and its filler valve are mounted on a robot arm. The invention can of course be applied to a similar programmable multi-axle apparatus.
The invention finally relates to a method for dispensing liquid or pasty material from a docking valve, provided with a nozzle with an axially displaceable needle valve, to a container, provided with a filler valve. The method according to the invention comprises the following steps:
a) the docking valve and the filler valve are positioned relative to each other, with the aid of centering surfaces on the nozzle, and the needle valve, which has a plane end surface, is placed in contact with or almost touching a plane end surface, directed towards it, of the container valve; b) the docking valve is opened by means of the needle valve being acted on and being displaced axially through an opening in the filler valve, which opening has a slightly greater diameter than the needle valve, and the container valve is opened against the force of a return spring with the aid of the needle valve; c) the desired volume of material is dispensed; d) the needle valve of the docking valve is moved to the closed position, while simultaneous closing of the container valve is caused by the return spring.
The means of positioning the filler valve of the container relative to the docking valve can preferably consist of a robot arm.
Said valves and method will be described in detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 shows a docking valve according to the invention; Figure 2A shows a first embodiment of the outer surface of the nozzle;
Figure 2B shows a second embodiment of the outer surface of the nozzle; Figs 3A-3E show different embodiments of the inner surface of the nozzle and its cooperating needle valve; Figure 4 shows a filler valve according to the invention;
Figure 5 shows an enlarged view of the cooperating surfaces of the valves; Figure 6 shows a partial enlargement of the cooperating surfaces from
Figure 5.
PREFERRED EMBODIMENTS
Figure 1 shows an embodiment of the invention intended for dispensing glue or sealing compound. A docking valve 1 comprises a nozzle 2 with an inner chamber 3 and a needle valve 4 for opening and closing the valve 1. The nozzle 2 is mounted on the docking valve via a holder 5 in such a way that it can be exchanged, and it is sealed by an O-ring seal 6.
At one end the needle valve 4 is provided with a section 7 which has a substantially conical shape which is directed towards the nozzle 2 and is in contact with a surface 8 of substantially conical shape in the latter. The cooperating parts of the nozzle 2 and needle valve 4 will be described in detail below, with reference to Figures 3A-3E.
So that it can be opened and closed, the needle valve 4 is provided at its other end 9 with a pressure-medium-controlled piston 10 which is secured to
the end of the valve via a screw connection 11. The piston 10 is displaceable in a chamber 12 in the docking valve 1 and is provided with a seal 11 about its periphery. Connections 13, 14 for providing the chamber 12 with compressed air are arranged on each side of the piston 10. A first connection 13 provides the chamber 12 with compressed air to act on that side of the piston 10 remote from the nozzle 2, so as to open the needle valve 4. A second connection 14 provides the chamber 12 with compressed air in order to act on that side of the piston 10 directed towards the nozzle 2, so as to close the needle valve 4. The piston 10 is additionally spring-loaded towards the closed position by means of a helical spring 15 so that the valve is automatically closed if the compressed air should suddenly be cut off during the dispensing operation.
The docking valve 1 is also provided with a connection 16 for supplying the material which is to be dispensed. The material is forced under pressure from a storage container (not shown), through the connection 16 and into the chamber 3 in the nozzle 2. Depending on the material, the pressure can be up to 400 bar. To ensure that the pressurized material does not affect the function of the needle valve 4, the diameter of the latter has been increased in the area where it runs out from the chamber 3. In this way, the pressure on the conical section 7 of the needle valve can largely be balanced against the pressure acting on a surface 17 facing towards said section 7.
Some types of material have to be heated to be able to be pumped to the docking valve for dispensing. To ensure that the material does not become too viscous to be dispensed, the docking valve 1 is provided with a heating cartridge 18. To be able to regulate the power to the heating cartridge 18, a temperature sensor 19 has been arranged at the nozzle. Some materials can be dispensed at room temperature, while others may need to be heated to 150-200° to become sufficiently viscous.
Figure 2A shows a partially sectioned and enlarged part of the nozzle 2 and part of the needle valve 4. The outer end of the nozzle has an outer surface 21a, 21 b, 22a, 22b intended to cooperate with a substantially opposite surface 25 of a filler nozzle (dotted line). The outer surface is divided into two sections, where an outer section 21 a with a spherical surface, consisting of a circular segment with a predetermined radius, cooperates with a conical surface of the filler valve. The outer section 21a is in sealing contact with said conical surface along a circular contact line in order to prevent material from leaking out between the docking valve and the filler valve during dispensing. The distance between the cooperating surfaces of the two valves thus diverges on each side of the contact line. The inner section 21 b consists of a conical surface which is used for centering when the two valves are to be coupled together. The inner section 21b cooperates with a corresponding conical or cylindrical surface of the filler valve. The cone angle α of the inner section 21 b is also slightly smaller than the cone angle of the sealing conical surface of the filler valve.
As is evident from Figure 2B, it is also possible to form both the outer and inner sections 22a, 22b of the nozzle as spherical surfaces. The radius Ri of the outer section 22a in this case corresponds to the radius of the outer section 21a in Figure 2a. The radius R2 of the inner section is adapted for even transition between the inner section 22b and the cylindrical head part 23 of the nozzle.
In the same way, it is possible to form the outer section 21 a, 22a of the nozzle as a conical surface, in which case the receiving inner surface of the filler valve is spherical and cooperates with the conical surface along a circular contact line.
Figures 3A-3E show a number of diagrammatic partial enlargements of the section A1 of the nozzle 2 cooperating with the needle valve 4, indicated in
Figure 2A. All angles and radii in these figures have been shown slightly exaggerated for the sake of clarity.
According to a first embodiment, shown in Figure 3A, the needle valve 4 has a conical surface 30 with a predetermined cone angle βi. As will be seen from Figures 3A and 3B, the nozzle 2 has been divided into two sections along its inner periphery. The outer section has a second conical surface 31 a with a second predetermined cone angle β2, the inner section having a third conical surface 31 b with a third predetermined cone angle β3. To establish contact along a circular line between the needle valve and the nozzle, at a point 32 the ratio between the angles β2 > βi > β3 is such that the distance between the cooperating surfaces diverges on each side of the contact line. In this way, the contact pressure between the needle valve and the nozzle is increased, which means that the valve is made tighter and can withstand higher pressures from the material in the chamber 3.
According to the embodiment shown, suitable angles are 45° for β-i, 47° for β2 and 30° for β3. However, the invention is not limited to these angles and instead can preferably be used within the angle ranges (βi + 1 °) > β2 > (βi + 5°) and (βH 0°) < β3 < (β 20°).
According to a second embodiment, shown in Figure 3C, the inner and outer sections of the nozzle can be spherical surfaces. In this case the outer section 35 of the nozzle has a first predetermined radius n and the inner section 36 has a second radius r2. The second radius r2 is preferably smaller than or equal to the first radius r-i. At the ratio ri > r2 the transition between the two radii takes place at the contact point 32 for the circular contact line. The size of the radii is chosen such that the valve has the desired properties and dimensions. The above-mentioned first radius n is for example chosen
in such a way that the outer end of the nozzle has the desired diameter in relation to the filler valve.
A third embodiment is shown in Figure 3D where the inner section 34 of the nozzle 2 consists of a conical surface with a cone angle δi. To establish diverging surfaces on each side of the contact point 32 for the circular contact surface, the needle valve 4 has been divided into two sections along its outer periphery.
The outer section has a second conical surface 35a with a second predetermined cone angle δ2, and the inner section has a third conical surface 35b with a third predetermined cone angle δ3. To establish contact at a point 32 along a circular line between the needle valve and the nozzle, the ratio between the angles is δ2 < δi < δ3.
According to the illustrated embodiment, suitable angles are 45° for βi, 43° for β2 and 20° for β3. However, the invention is not limited to these angles and instead can preferably be used within the angle ranges (βi - 1 °) < β2 < (β1-5°) and (β1-10o) > β3 > (βι-20o).
According to a fourth embodiment, shown in Figure 3E, the inner and outer sections of the needle valve can be spherical surfaces. In this case the outer section 36a of the needle valve has a first predetermined radius r3 and the inner section 36b has a second radius r . The second radius r4 is preferably smaller than or equal to the first radius r3. At the ratio r3 > r the transition between the two radii suitably occurs at the contact point 32 for the circular contact line. In this case the radius r3 is for example chosen in such a way that the outer diameter of the needle valve has the desired dimension in relation to the nozzle and the filler valve.
Because of the diagrammatic nature of Figures 3A-3E, they do not show how close the contact point 32 for the circular contact line should lie to the outermost tip 38 of the nozzle. This will be described in more detail below in connection with the filler valve.
In all the above embodiments, the needle valve 4 has a plane upper surface 37 which is level with the outer tip 38 of the nozzle 2 (see Figures 2A and 3A). This upper surface 37 is intended to cooperate with a corresponding plane surface 40 on a valve body 47 in the above-mentioned filler valve 41 , as is shown in Figure 4. The valve 41 is provided with a centering guide 42 for cooperating with corresponding guide surfaces 21 b, 22b on the nozzle 2. Situated inside the centering guide 42 there is a valve seat 43 with an opening delimited by a substantially conical surface 44, intended to cooperate sealingly with corresponding surfaces 21a, 22a along the outer periphery of the nozzle. Both the centering guide 42 and the valve seat 43 are secured in an exchangeable manner on the valve 41 by way of a holder 45. On that side of the valve seat 43 facing away from the nozzle, a circular groove 46 is formed around the opening in the seat. The valve body 47 is in sealing contact with the valve seat 43, the outer diameter of the valve body being greater than the opening in the valve seat 43 but smaller than the outer diameter of the groove 46. The valve body 47 is spring-loaded towards the closed position by a helical spring 48.
The filler valve 41 is opened by means of the needle valve of the docking valve being pressed against the valve body 47 and lifting the latter counter to the force of the spring 48 towards a stop 50. Pressurized material can then flow from the docking valve, past the valve body 47 and out through a connection 49 to a container for dosing the material (not shown).
Figure 5 shows how the docking valve 1 cooperates with the filler valve 41 as material is being dispensed. The nozzle 2 is in contact with the centred
guide 42 and against the valve seat 43. The needle valve 4 of the nozzle is positioned close to the valve body 47, which is lifted when the needle valve 4 is actuated. The distance between the upper surface of the needle valve 4 and the lower surface of the valve body 47 depends on the design of the nozzle 2. However, the surfaces are not in direct contact with each other, as can be seen from Figure 6.
Figure 6 shows a diagrammatic partial enlargement of the area A2 indicated in Figure 5. It will be seen here that the diameter D-i of the nozzle, measured at its outer tip, is slightly greater than the diameter D2 of the opening of the valve seat. Since the upper surface of the needle valve is to lie in the same plane as the outer tip of the nozzle, this means that the needle valve must be actuated to come into contact with the valve body. However, it is desirable for the difference between D1 and D2 to be very small, preferably of the order of 0.01 - 0.1 mm, so that the surfaces lie very close to each other. Finally, the diameter D2 of the opening of the valve seat 43 must exceed the greatest diameter D3 of the needle valve so that the needle valve will be able to pass through the opening. In summary, this means that the contact point 48 for the circular contact line between the nozzle 2 and the valve seat 43 will lie very near the opening in the seat, and that the enclosed volume between the upper surface of the needle valve and the lower surface of the valve body is very small or insignificant. When the needle valve 4 closes after the desired amount of material has been dispensed, remaining material between the docking valve and filler valve collects in the space 60 between the needle valve and the nozzle. By this means there is no waste that could interfere with the function of the valves, and the remaining material functions as a sealing material or sealing ring at the next docking cycle.
According to one embodiment intended for dispensing glue, suitable diameters are 13.6 mm for D^ 13.5 mm for D2 and 13.2 mm for D3.
The measurements and angles which have been indicated above can of course be varied with respect to the actual area of application, the viscosity and/or the desired temperature of the sealing material/glue.
Although the preferred embodiment above relates to an alternative in which the upper surface of the needle valve is not placed in contact with the valve body of the filler valve during docking, it is of course possible to do this. The enclosed volume between the needle valve and the valve body is thereby eliminated.
Because of the high pressures and relatively high temperatures prevailing here, it is important to ensure that all the connections and seals are dimensioned for these. For materials requiring heating, the temperature can be up to 150-200°C and the pressure which is used during dispensing can be in excess of 400 bar.
A combination of hard and less hard materials in cooperating components of the valves gives a better sealing function. In addition, this eliminates unnecessary wear between the various parts of the valves since inexpensive wear parts can be made of a relatively soft material and more expensive components can be made of a hardened material. The needle valve and the seat of the filler valve can be made, for example, of a hardened steel, while the nozzle is made of bronze. Despite high contact pressures between the valves (ca. 750 kg in the present embodiment), the wear is thus limited to an easily exchangeable wear part. The contact pressure is important for the sealing between the valve parts and can vary from 300 kg and upwards, depending on the actual field of application, the dispensing pressure, the viscosity and/or the desired temperature of the sealing material/glue.