WO2021188908A1

WO2021188908A1 - Two component resin dispensing system with replaceable pump and mixing cartridge

Info

Publication number: WO2021188908A1
Application number: PCT/US2021/023175
Authority: WO
Inventors: Kyle Sanford SMITH; Murty Venkata BHAMIDIPATI; Robert S. Smith; Peter V. FERRIS; Daniel R. ALLEN; David Royston HUGHES; Charles R. Sperry
Original assignee: Dur-A-Flex, Inc.
Priority date: 2020-03-20
Filing date: 2021-03-19
Publication date: 2021-09-23

Abstract

An automatic dispensing system is configured to utilize a replaceable cartridge. The compact, modular, portable system can easily be brought to a work site and quickly prepared for operation. The cartridge integrates pumps, a mixer, and other functionality into a single, replaceable unit. In further aspects, the automatic dispensing system includes a supply reservoir adapter, co-mixer, improved gear pump and multiple supply reservoir transfer system.

Description

TWO COMPONENT RESIN DISPENSING SYSTEM WITH REPLACEABLE PUMP AND

MIXING CARTRIDGE

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of United States Provisional Patent Application No. 62/992,654 filed March 20, 2020, the entire contents of which are incorporated herein by reference.

BACKGROUND OF THE DISCLOSURE

[0002] High performance resin flooring systems are used in a variety of settings, including commercial, industrial and healthcare facilities, and the like. Various resins are used, some of the most common being epoxy, urethane and methyl methacrylate (MMA) resins. These are typically 2-component resin systems, using a resin and hardener that must be accurately measured and mixed immediately prior to application. Due to rapid cure time, these resins are typically mixed and used in multiple small batches. Conventionally, measuring, mixing and dispensing of flooring coating components are performed manually. Resin and hardener from separate supply containers are measured and combined in a mixing bucket, then mixed with a hand held power mixer before being poured onto the floor to be coated.

[0003] In certain aspects, an automated dispensing system is disclosed in Patent Cooperation Treaty (PCT) Application No. PCT/US2019/047907 filed August 23, 2019, which claims priority to, and the benefit of, United States Provisional Patent Application No. 62/722,916 filed August 26, 2018. Each of the applications listed above is commonly owned by Dur-A-Flex, Inc. and the entire contents are incorporated herein by reference in their entirety. The applications listed above are generally directed to an automated two-component resin mixing and dispensing system and respectively or together disclose, in certain aspects and among other things, an automated dispensing system that pumps two components, a resin and a hardener, individually and at a controlled, specific ratio. For example, epoxy resin used in flooring systems may have a ratio of two parts resin to one part hardener. The resin and hardener may be individually pumped into a mixer at a specified ratio. In certain aspects, the resin and hardener may mix together in the mixer to become a homogenous product. The homogenous product ready for use may exit an end of the mixer. Resin product (i.e., final homogenous product) may be produced in on-demand dispensing cycles that produce batches of a desired quantity, to be spread by a user before curing. BRIEF DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

[0004] This disclosure is directed generally to an automated floor coating dispensing apparatus and system, and corresponding methods for applying a floor coating including, without limitation, transporting, mixing, and dispensing the floor coating having a predetermined composition.

[0005] Disclosed are exemplary embodiments of an automatic two component resin dispenser cartridge with, among other things, integrated pump components and mixer elements, as well as other functional components. Also provided within the cartridge are components configured to prevent resin product from escaping from the cartridge between dispensing cycles. Exemplary embodiments of a resin dispenser cartridge according to this disclosure may confine all wetted dispenser components to a single, cartridge based system. This cartridge can be economically manufactured as a limited or single use device. At the end of its useful life, the cartridge can be replaced. The rest of the dispensing system, including, for example, motors, drives, sensors and other control components, remains ready for use with no further cleaning or maintenance necessary.

[0006] Exemplary embodiments of an automatic dispensing system according to this disclosure are configured to utilize the replaceable cartridge. This is a compact, modular, portable dispensing system that can easily be brought to a work site and quickly prepared for operation.

[0007] An exemplary supply reservoir adapter is disclosed to provide simple and secure attachment of the dispensing system to a supply reservoir. It provides an airtight seal allowing the supply reservoir to be pressurized with air to assist with pump priming and component flow. In an aspect of an exemplary supply reservoir adapter according to this disclosure, an arrangement of features incorporated on the supply reservoir adapter provides for the adapter’s use as a mixing device, helpful in incorporating pigment that has settled in the bottom of a supply reservoir into a consistently suspended, ready to use supply.

[0008] An exemplary gear pump arrangement for use with the dispensing system is disclosed. Conventional gear pumps have a known difficulty with pumping high viscosity fluids at high rates of flow. Exemplary embodiments of a gear pump arrangement according to this disclosure may include a gear tooth arrangement that eliminates the buildup of pressure that can occur as the gears attempt to mesh, which can slow or stall a conventional pump. Also disclosed is a test method to evaluate the condition of the pumps.

[0009] An exemplary co-blender is disclosed for the addition of aggregate in predetermined quantities at a predetermined rate into the resin and hardener product once it has been homogenously mixed, and prior to being dispensed.

[0010] An exemplary component transfer system is disclosed to allow multiple supply reservoirs to be connected to the dispensing system so that an entire project may be completed without the need to replace a supply reservoir. In an aspect of the exemplary embodiments of the component transfer system according to this disclosure, a component is transferred from a second supply reservoir into a first supply reservoir as the component is consumed, extending the amount of component that can be dispensed without stopping for a replacement.

[0011] In an aspect, the disclosure relates to a dispenser assembly for a floor coating. The dispenser assembly may include a cartridge and the cartridge may include a first passageway in fluid communication with each of a first fluid inlet and a first pump and a second passageway in fluid communication with each of a second fluid inlet and a second pump. A common passageway of the cartridge may be in fluid communication with each of the first passageway and the second passageway, and a mixing passageway of the cartridge may be in fluid communication with the common passageway. A mixer may be positioned within the mixing passageway. An outlet of the cartridge may be in fluid communication with the mixing passageway. The dispenser assembly may further include a first motor configured for driving the first pump and a second motor configured for driving the second pump.

[0012] In an aspect, the disclosure relates to a dispenser assembly for a floor coating, including a first fluid in a first reservoir and a second fluid in a second reservoir. The dispenser assembly may include a cartridge, and the cartridge may include a first passageway, a first pump, a second passageway, a second pump, a common passageway, and a mixing passageway. The first pump may be positioned in the first passageway and the second pump may be positioned in the second passageway. The common passageway may be in fluid communication with each of the first passageway and the second passageway, and the mixing passageway may be in fluid communication with the common passageway. A mixer may be positioned within the mixing passageway. The dispenser assembly may further include a first motor that may drive the first pump and a second motor that may drive the second pump. In an aspect, the cartridge may receive the first fluid in the first passageway and the second fluid in the second passageway, and form a mixture product comprising a specified ratio of the first fluid to the second fluid.

[0013] In an aspect, the disclosure relates to a method for dispensing a floor coating. The method may include receiving a first fluid in a first passageway of a cartridge which may include a first pump positioned within the first passageway. The method may further include receiving a second fluid in a second passageway of the cartridge which may include a second pump positioned within the second passageway. In an aspect, the method may include pumping the first fluid, via the first pump, and the second fluid, via the second pump, into a mixing passageway of the cartridge, via a common passageway of the cartridge. In an aspect, the common passageway may be in fluid communication with each of the first passageway, the second passageway, and the mixing passageway. The method may further include mixing the first fluid with the second fluid, with a mixer positioned within the mixing passageway, to form a mixture product, and collecting the mixture product through an outlet in fluid communication with each of the mixing passageway and an outside of the cartridge.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] A more particular description will be rendered by reference to exemplary embodiments that are illustrated in the accompanying figures. Understanding that these drawings depict exemplary embodiments and do not limit the scope of this disclosure, the exemplary embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

[0015] Figure 1 illustrates a front isometric view of an arrangement of an automatic dispensing system according to an exemplary embodiment;

[0016] Figure 2 illustrates a rear isometric view of an arrangement of an automatic dispensing system according to an exemplary embodiment;

[0017] Figure 3 illustrates a side cross sectional view of a supply reservoir and drum adapter arrangement according to an exemplary embodiment;

[0018] Figure 4 illustrates a top view of an arrangement of a drum adapter according to an exemplary embodiment; [0019] Figure 5 illustrates a cross sectional side view of an arrangement of a drum adapter according to an exemplary embodiment;

[0020] Figure 6 illustrates a cross sectional side view of detail of an arrangement of a drum adapter according to an exemplary embodiment;

[0021] Figure 7 illustrates a cross sectional side view of a detail of an arrangement of a drum adapter in use as a mixer according to an exemplary embodiment;

[0022] Figure 8 illustrates an isometric view of an arrangement of a drill adapter according to an exemplary embodiment;

[0023] Figure 9 illustrates a top isometric view of an arrangement of a dispenser assembly according to an exemplary embodiment;

[0024] Figure 10 illustrates a bottom isometric view of an arrangement of a dispenser assembly according to an exemplary embodiment;

[0025] Figure 11 illustrates a top view of an arrangement of a cartridge assembly according to an exemplary embodiment;

[0026] Figure 12 illustrates a side view of an arrangement of a cartridge assembly according to an exemplary embodiment;

[0027] Figure 13 illustrates a bottom view of an arrangement of a cartridge assembly according to an exemplary embodiment;

[0028] Figure 14 illustrates a top view of an arrangement of an exemplary cartridge assembly with the cartridge top removed;

[0029] Figure 15 illustrates an isometric view of an arrangement of an exemplary cartridge assembly with the cartridge top removed;

[0030] Figure 16 illustrates a cross sectional side view of a detail of an arrangement of cartridge assembly on a supply reservoir according to an exemplary embodiment;

[0031] Figure 17 illustrates an isometric view an arrangement of a gear pump according to an exemplary embodiment;

[0032] Figure 18 illustrates a top view of a prior art gear pump arrangement; [0033] Figure 19 illustrates a top view of a gear pump arrangement according to an exemplary embodiment;

[0034] Figure 20 illustrates an isometric view of an arrangement of a static mixer element according to an exemplary embodiment;

[0035] Figure 21 illustrates a side view of an arrangement of a cartridge outlet according to an exemplary embodiment;

[0036] Figure 22 illustrates a cross sectional side view of an arrangement of a cartridge outlet according to an exemplary embodiment;

[0037] Figure 23 illustrates an isometric front view of an arrangement of a co-blender according to an exemplary embodiment;

[0038] Figure 24 illustrates an isometric rear view of an arrangement of a co-blender according to an exemplary embodiment;

[0039] Figure 25 illustrates a top front view of an arrangement of a co-blender according to an exemplary embodiment;

[0040] Figure 26 illustrates an isometric view of an arrangement of an auger according to an exemplary embodiment;

[0041] Figure 27 illustrates an isometric view of an arrangement of a control box according to an exemplary embodiment;

[0042] Figure 28 illustrates a top view of an arrangement of a control box according to an exemplary embodiment;

[0043] Figure 29 illustrates a top view of an arrangement of an exemplary control box with the separator plate removed;

[0044] Figure 30 illustrates a side view of an arrangement of a component transfer system according to an exemplary embodiment;

[0045] Figure 31 illustrates a cross sectional side view of a detail of an arrangement of a component transfer system according to an exemplary embodiment; and,

[0046] Figure 32 illustrates a cross sectional side view of a detail of an arrangement of a component transfer system according to an exemplary embodiment. [0047] Various features, aspects, and advantages of the exemplary embodiments will become more apparent from the following detailed description, along with the accompanying drawings in which like numerals represent like components throughout the figures and detailed description. The various described features are not necessarily drawn to scale in the drawings but are drawn to aid in understanding the features of the exemplary embodiments.

[0048] The headings used herein are for organizational purposes only and are not meant to limit the scope of the disclosure or the claims. To facilitate understanding, reference numerals have been used, where possible, to designate like elements common to the figures.

DETAILED DESCRIPTION

[0049] Reference will now be made in detail to various exemplary embodiments. Each example is provided by way of explanation and is not meant as a limitation and does not constitute a definition of all possible embodiments. It is understood that reference to a particular “exemplary embodiment” of, e.g., a structure, assembly, component, configuration, method, etc. includes exemplary embodiments of, e.g., the associated features, subcomponents, method steps, etc. forming a part of the “exemplary embodiment”.

[0050] Figure 1 illustrates a front isometric view and Figure 2 illustrates a rear isometric view of an arrangement of an automatic dispensing system 100 according to an exemplary embodiment. Liquid resin and hardener are supplied individually in respective supply reservoirs 101, 102. Unmixed resin, hardener, or other mixture constituents may be generically referred to as “component(s)” in this disclosure. In the exemplary arrangement shown in Figure 1 and Figure 2, the supply reservoirs 101, 102 are in the form of 55-gallon drums. These drums are shown on drum dollies 107 that are used to roll the supply reservoirs 101, 102 to a desired location and to help in aligning the drums for operation. A drum alignment plate 204 aligns and positions the drums and is used as a mount for a dispenser assembly 103 and a co-blender 106.

[0051] For purposes of this disclosure, 55-gallon drums will be used to illustrate the supply reservoirs 101, 102, however other sizes and types of supply reservoirs consistent with this disclosure may be utilized by the automatic dispensing system 100. Other types of supply reservoirs may include, but are not limited to, drums of other sizes, 5-gallon pails, 275-gallon tote tanks, and the like. [0052] Pumps, mixing structures and components, and other operational components are contained in the dispenser assembly 103. A control box 104 contains a power supply, controls and other components for operating the automatic dispensing system 100. In the exemplary arrangement shown in Figures 1 and 2, the control box 104 has the capacity to hold and carry additional components during transport of the system 100 to and from a job site.

[0053] In an exemplary method for applying a floor coating according to this disclosure, resin and hardener are pumped from the supply reservoirs 101, 102 at a predetermined ratio, mixed into a homogenous mixture, and transferred into a bucket 105 or other receptacle in predetermined batch volumes. The bucket 105 containing the mixed product ready for use is then removed from the automatic dispensing system 100 for use. For the purposes of this disclosure, this ready to use mixed resin and hardener may be referred to as “product” or otherwise as the disclosure makes clear.

[0054] Some flooring products contain additives such as aggregate or other dry powdered or granular additives. With continuing reference to Figures 1 and 2, the exemplary automatic dispensing system 100 arrangement includes the co-blender 106 that supplies the additive in predetermined quantities at a predetermined rate into the combined resin and hardener product after they have been homogenously mixed, and prior to being dispensed into the bucket 105.

[0055] Figure 3 illustrates a side view of a supply reservoir 101 with a supply reservoir adapter, which in the exemplary embodiment of Figure 3 is generally and without limitation referred to as a drum adapter 108, installed. The front of the supply reservoir 101 has been cut away for clarity. It should be understood that each of the supply reservoirs 101, 102 in the exemplary automatic dispensing system 100 shown in Figures 1 and 2 will have the same configuration that is shown in Figure 3. In order for the pumps to draw the resin and hardener from the supply reservoirs 101, 102 the drum adapter 108 must be used. Figure 4 illustrates a top view of the exemplary drum adapter 108 shown in Figure 3, Figure 5 illustrates a cross sectional view of the drum adapter 108 taken through section 1-1 of Figure 4, and Figure 6 illustrates a cross sectional view of the top of the drum adapter 108 seen as detail A in Figure 5. The exemplary drum adapter 108 comprises an elongated tubular portion 109 that extends from a bung 110 to the bottom of the supply reservoir 101. The tubular portion 109 is hollow so that resin and/or hardener may be drawn into the bottom 111 of the tubular portion 109 and exit through the opening 112 at the top of the drum adapter 108.

[0056] During operation, it is desirable for an amount of air pressure to be maintained within the supply reservoir 101. The connection between the top of the drum adapter 108 and the bung 110 of the supply reservoir 101 may therefore be sealed. A connector portion 113 at the top of the drum adapter 108 includes an externally threaded portion 114 that screws into an internally threaded portion of the bung 110. An external O-ring 115 creates a seal between the connector portion 113 and the bung 110. An internal O-ring 116 and elastomeric square section seal 117 are used to seal between the drum adapter 108 and a connection such as, without limitation, lower cartridge adapters 129, 130 (Figure 10) to the dispenser assembly 103. A series of slots 118 allows air to enter the supply reservoir 101 to create the pressure.

[0057] Flooring product is often tinted to a desired color. Tinting is accomplished by adding pigment to the resin prior to mixing the resin to the hardener. This is generally performed when the supply reservoir 101 is being filled with component. When a new supply reservoir is opened, or has been sitting unused for an extended period of time, the pigment can settle to the bottom of the supply reservoir. The pigment must be remixed back into the resin prior to use. This remixing can be accomplished using the drum adapter 108 shown in this arrangement. The drum adapter 108 may contain features, such as helical spines 119 that can be used to promote a mixing action. Figure 7 illustrates a side view of an arrangement that can be used to operate the drum adapter 108 as a mixer. Prior to screwing the connector portion 113 of the drum adapter 108 into the threaded bung 110 of the supply reservoir 101, a bracket 120 is placed onto the supply reservoir 101 as shown. A standard power drill 121 or other device capable of rotating the drum adapter 108 is mounted onto the bracket 120. Attached to the end of the drill is a drill adapter 122 (shown in Figure 8) that is configured to couple with the connector portion 113 of the drum adapter 108 in order to make a solid connection between the drill 121 and drum adapter 108. The bracket 120 is configured to hold the drum adapter 108 above the bung 110 so that the threads do not engage during use. When a supply reservoir 101 containing a new supply of resin or hardener is opened, this arrangement is put into place. The drill 121 is now powered so that it rotates the drum adapter 108. The helical spines 119 operate as an auger and mix the resin and pigment until they are fully mixed. Other shapes and structures, such as paddles and the like, may be used in place of the helical spines 119 to perform the mixing function. In one arrangement, the drum adapter 108 is rotated at about 1000 revolutions per minute for about 30 seconds to completely mix the resin and pigment.

[0058] Figure 8 illustrates an exemplary embodiment of a drill adapter 122 that may be used with the exemplary drum adapter 108 and the drill 121. In the exemplary embodiment shown in Figure 8, the drill adapter 122 has a surface feature 123 configured to connect to the power drill 121 or other device used to rotate the drum adapter 108. For example, the surface feature 123 may be, without limitation, a square aperture 123 dimensioned complimentarily to a square drive feature 222 on a tool held by a chuck 223 of the drill 121. The surface feature 123 may receive the drive feature 222 in mechanical or frictional engagement. Alternatively, the connection between the drill adapter 122 and the drill 121 (or other device for rotating the drum adapter 108) including any features, components, and/or structures of the drill adapter 122 or the connection itself may be configured in any manner consistent with this disclosure for connecting the drill adapter 122 to the drill 121. Known techniques for such a connection may include, without limitation, clips, magnets, tongue-in-groove engagements, and the like. The drill adapter 122 itself may have a surface feature such as, without limitation, a projection that may be clamped by the drill chuck without requiring a separate tool for the drill 121.

[0059] At an end of the drill adapter 122 opposite the surface feature 123 are a series of tabs 124 that are configured to fit within the slots 118 of the connector portion 113 of the drum adapter 108. As the drill adapter 122 is rotated clockwise, cut-outs 125 in the tabs 124 engage with the slots 118 to prevent the drum adapter 108 from disengaging with the drill adapter 122 during the mixing process. Once mixing is complete, the drill 121 is reversed, and the tabs 124 disengage from the drum adapter 108. The drill 121, the drill adapter 122 and the bracket 120 are removed from the supply reservoir 101. The drum adapter 108 can now be screwed into the bung 110 of the supply reservoir 101 and is ready for use.

[0060] While the exemplary drill adapter 122 shown in Figure 8 is one solution for connecting the power drill 121 to the drum adapter 108, other arrangements for connecting the power drill 121 to the drum adapter 108 consistent with this disclosure may be possible and remain within the scope of this disclosure. For example, the drill 121 and/or a drill attachment or tool may connect directly to the drum adapter 108 by, without limitation, known techniques such as clamps, mechanical or frictional engagements between complimentary structures, complimentary threaded connections, and the like. While the above arrangement including, e.g., the drum adapter 108 and associated configurations, seals, and connections for, among other things, mixing the supply reservoir contents, sealing the supply reservoir, and providing a fluid feed path is illustrated for use on a 55 gallon drum, one skilled in the art would understand that the exemplary arrangement may be configured and/or dimensioned for use with, among other things, supply reservoirs that are larger, smaller or differently configured and still be within the scope of this disclosure.

[0061] Figure 9 illustrates a top isometric view and Figure 10 illustrates a bottom isometric view of an arrangement of an exemplary embodiment of the dispenser assembly 103. The cartridge assembly 126 contains pumping and mixing components as explained further below. Attached to the cartridge assembly 126 are the pump drive motors 127, 128. The pump drive motors 127, 128 drive the gears 155 (Figures 14-15) that comprise gear pumps that are inside of the cartridge assembly 126. The pump drive motors 127, 128 may be of any suitable type having a torque and speed output compatible with a desired output. A motor with an encoder allows a controller to run the motor at a precise speed to control the output of the pumps, as explained further below. Many useful motors are known that have advanced capabilities such as torque monitoring and control and the ability to provide feedback regarding usage and operational data to the controller. One such commercial motor is stepper motor model 42Y112D-LW8 from Anaheim Automation of Anaheim, CA.

[0062] Lower cartridge adapters 129, 130 connect the dispenser assembly 103 to the connector portion 113 of the drum adapter 108 in each supply reservoir 101, 102. Upper cartridge adapters 145, 146 are connected to sensor adapters 131, 132 to which liquid sensors 133, 134 are attached. The liquid sensors 133, 134 are used to determine whether there is air entrapped within the cartridge assembly 126, which may cause an incorrect resin/hardener mix ratio and produce a poor quality product. Generally, air can be introduced into the cartridge assembly 126 under two conditions. One is when a supply reservoir 101, 102 is replaced, and the drum adapter 108 is removed. The component in the drum adapter 108 drains and is replaced by air. Bleed screws 135, 136 allow the user to bleed off, through the upper cartridge adapters 145, 146 the air in the drum adapter 108 and cartridge assembly 126 prior to beginning a dispensing cycle. The other condition occurs when a supply reservoir 101, 102 becomes empty. The sensors 133, 134 are used to detect air when the component has run out and air enters the cartridge 126 via the drum adapter(s) 108 and the lower cartridge adapter(s) 129, 130. When air is sensed, the automated dispensing system 100 is prevented from dispensing product before any off-ratio product can be produced. The liquid sensors 133, 134 may be any suitable device for distinguishing between air and liquid. An exemplary arrangement uses a capacitive proximity sensor, such as model CK1-00-2H sold by Automation Direct of Cumming, GA.

[0063] A bracket 137 supports a device such as, without limitation, a load cell 136 or other known device that is capable of determining a weight or force. An exemplary arrangement uses a Pull Pressure Force S-type Load Cell Sensor with Cable available from Amazon. The load cell 136 (or the like) is used to measure the weight of the dispensed product during operation. An additional bracket 139 is operatively connected to the load cell 136, such that a weight or force applied to the additional bracket 139 will be measured by the load cell 136, and positioned for allowing the bucket 105 to hang from the load cell 136, via the additional bracket 139, and collect the dispensed product. Product exits the dispenser assembly 103 from the outlet 140, and is collected in the bucket 105.

[0064] Figure 11 illustrates a top view, Figure 12 illustrates a side view, and Figure 13 illustrates a bottom view of an arrangement of an exemplary cartridge assembly 126, where the resin and hardener are combined, mixed and dispensed. The cartridge assembly 126 comprises a cartridge top 141 and cartridge bottom 142. This two piece construction allows the internal components to be assembled into the cartridge bottom 142, after which the cartridge top 141 is attached.

[0065] Figure 14 illustrates a top view and Figure 15 illustrates an isometric view of the cartridge bottom 142 of the exemplary cartridge assembly 126 shown in Figures 11-13, with the cartridge top 141 removed and the cartridge assembly 126 interior components and configurations, described further below, visible. In the illustrated exemplary arrangement, the cartridge top 141 and cartridge bottom 142 are held together using screws (not shown) in multiple locations 143 to ensure a tight fit and seal. An elastomeric seal 144 is inserted into a perimeter groove (not shown) to ensure that no component can leak externally. The cartridge top 141 and bottom 142 may be manufactured from any suitable material, such as plastics, metals, etc. [0066] The internal parts of the cartridge assembly 126 are the only components of the dispenser assembly 103 that come into contact with combined resin and hardener. Once resin and hardener are combined, the chemical reaction begins immediately. If the cartridge assembly 126 is left unused for a period of time, for example, overnight or between projects, the curing product can plug and bind the internal components and render the cartridge assembly 126 unusable. To allow for continued use of the cartridge assembly 126 it must be flushed with a cleaning solvent between uses and, left long enough, may require disassembly to clean the internal components. Alternatively, the cartridge assembly 126 may be made as a disposable unit. In this case, construction and assembly techniques may be used that include, for example and without limitation, an injection molded cartridge top 141 and bottom 142 that are ultrasonically welded, adhesive or solvent bonded, etc. A permanent bonding method may be used, since disassembly will no longer be needed. Internal components can be made inexpensively as single use parts.

[0067] Figure 16 illustrates a section view taken through section 2-2 of Figure 12. This figure contains the cartridge assembly 126, and also contains the sensor adapter 132, the liquid sensor 133, a portion of the drum adapter 108 and a portion of the supply reservoir 101. These components are included in order to illustrate the connection between the cartridge assembly 126 and the drum adapter 108. Refer also to Figure 6. In the exemplary embodiment shown in Figure 16, the lower cartridge adapter 129 comprises a wedge shaped annular portion 147 that contacts the elastomeric square section seal 117 to create an outer seal between the lower cartridge adapter 129 and the connector portion 113 at the top of the drum adapter 108. The O-ring seal 116 creates an inner seal between the lower cartridge adapter 129 and the upper portion 113 of the drum adapter 108. Pressurized air from an air compressor (not shown) travels through a tube (not shown) and enters the cartridge assembly 126 through a port 148. It then flows through the lower cartridge adapter 129, passes through the slots 118 and into the supply reservoir 101 through a space 149 in the upper portion 113 of the drum adapter 108. The flow path is illustrated by the dashed line 150. The supply reservoir 101 is pressurized to, for example, approximately 3 psi. This pressure may vary and be chosen depending upon the size and type of supply reservoir 101 and other factors. When a supply reservoir 101 is started or replaced, it is pressurized with air from the air compressor (not shown). The pressure within the now pressurized supply reservoir 101 is used to prime the pumps. The pressure forces the component in the supply reservoir 101 up through the tubular portion 109 of the drum adapter 108, through a central passage 151 in the lower 129 and upper 145 cartridge adapters, where it enters the sensor adapter 132. Once the inside of the sensor adapter 132 is filled, the component passes into the space 152 in the cartridge assembly 126. The flow path is illustrated by a dashed line 211. The resin then enters a first passageway 153 (Figure 14) in the cartridge assembly 126 and the hardener enters a second passageway 154 in the cartridge assembly 126.

[0068] The first passageway 153 is positioned between the lower cartridge adapter 129 through which the resin enters (“resin lower cartridge adapter 129”) and a first gear pump arrangement 224 and the second passageway 154 is positioned between the lower cartridge adapter 130 through which the hardener enters (“hardener lower cartridge adapter 130”) and a second gear pump arrangement 225. In the exemplary embodiment shown in Figures 14 and 15 and with further reference to Figure 17 and the blown-up view of the first gear pump arrangement 224 illustrated therein, the first gear pump arrangement 224 and the second gear pump arrangement 225 are positioned within bores 226, 227 in the cartridge bottom 142 in a spaced apart relationship respectively from the resin lower cartridge adapter 129 and the hardener lower cartridge adapter 130. The first passageway 153 and the second passageway 154 extend respectively from the resin lower cartridge adapter 129 to the first gear pump arrangement 224 and from the hardener lower cartridge adapter 130 to the second gear pump arrangement 225.

[0069] A common passageway 165 according to the exemplary embodiments is positioned between and extends from the first gear pump arrangement 224 to the second gear pump arrangement 225. The description(s) of the positions and configurations of the first passageway 153, the second passageway 154, and the common passageway 165 according to the exemplary embodiments are to aid in understanding the exemplary configuration of the cartridge assembly 126 and do not limit the disclosure with respect to any particular boundaries, delineations, configurations, positions, etc., of any associated portion(s) or component(s). For example, the first passageway 153 and the second passageway 154 may be any portion of the cartridge bottom 142 into which one or more of the components passes via, e.g., the flow path 211 (shown in Figure 16 as passing through, among other things, the resin lower cartridge adapter 129 and the corresponding upper cartridge adapter 145), a corresponding flow path through the hardener lower cartridge adapter 130 and corresponding upper cartridge adapter 146, or another flow path consistent with the disclosure. [0070] The first passageway 153 and the second passageway 154 may take any shape, size, profile, orientation, etc. consistent with the disclosure. The first gear pump arrangement 224 and the second gear pump arrangement 225 may be positioned in any configuration — including relative respectively to the first passageway 153 and the second passageway 154 — sufficient to propel the component s) to flow from the first passageway 153 and the second passageway 154 to the outlet 140 and achieve sufficient mixing during the flow. In the exemplary embodiment shown in Figures 14 and 15, each of the first passageway 153, the common passageway 165, and the second passageway 154 are in fluid communication with each other, either directly or with the common passageway 165 intervening, through the first gear pump arrangement 224 and the second gear pump arrangement 225.

[0071] Each of the first gear pump arrangement 224 and the second gear pump arrangement 225 comprises a drive gear 155 and a driven gear 156 that fit within their respective bores 226, 227 in the cartridge bottom 142. The drive gear 155 and driven gear 156 are captured within the cartridge bottom 142 as shown, as well as in complimentary bores (not shown) in the cartridge top 141. The first gear pump arrangement 224 pumps resin from the first passageway 153 and the second gear pump arrangement 225 pumps hardener from the second passageway 154. The respective drive gears 155 of the first gear pump arrangement 224 and the second gear pump arrangement 225 are driven by corresponding motors 127, 128 (Figure 9) that are mounted to a plate 157 that, in turn, mounts in a quick release fashion to the cartridge assembly 126. In an exemplary embodiment, the plate 157 comprises a pin (not shown) that engages with a slot 228 in the cartridge assembly 103 and the drive shafts (not shown) of the motors 127, 128 pass through the bores 158 in the cartridge assembly 126 and engage with the drive gears 155 of the first gear pump arrangement 224 and the second gear pump arrangement 225. This exemplary embodiment is not limiting to a specific arrangement as one skilled on the art can understand that different methods can be used to make a quick release attachment.

[0072] With reference again to Figure 17, an enlarged isometric view of the exemplary first gear pump arrangement 224 is shown. The motor shaft (not shown) is square and passes through a hole 158 (Figure 11) in the cartridge top 141 and engages with a square hole 159 in the drive gear 155. An O-ring 160 seals between the drive gear 155 and the cartridge top 141 so that no component may exit the cartridge assembly 126. The drive gear 155 has an upper boss 161 that engages with the hole 158 in a rotatable fashion. A lower boss (not shown) engages with a blind hole in the cartridge bottom 142 in a rotatable fashion. The driven gear 156 has an upper boss 162 and lower boss (not shown) that engage respectively with a blind hole (not shown) in the cartridge top 141 and cartridge bottom 142 in a rotatable fashion. The drive gear 155 and driven gear 156 are spaced apart so that they mesh. In use, the motors 127, 128 respectively turn the drive gear 155 of the first gear pump arrangement 224 in a direction as shown by the arrow 163. The drive gear 155 is intermeshed with the driven gear 156 and so drives the driven gear 156 in a counter rotating direction as shown by the arrow 164. Component is captured in the spaces between the gear teeth, passes around the perimeter of the bore and enters the common passageway 165. This creates a low pressure side in the first passageway 153 and a high pressure side in the common passageway 165. The first and second gear pump arrangements 224, 225 are configured to precisely meter the resin and hardener at a predetermined ratio. The resin and hardener are combined in the common passageway 165 at the correct ratio. The combined resin and hardener then enter a mixing passageway 166 (Figures 14,15).

[0073] High volume gear pumps and their operation are well known in the art and are often used for hydraulic service and generally built into a complete unit including the gears, housings, inlet and outlet ports, as well as shims, side plates and other internal components. The housings are generally made from aluminum or other metal and the gears and other internal components from stainless steel. Due to the reactive nature of the resin and hardener, unlike the hydraulic fluid for which the first and second gear pump arrangements are designed, once the resin and hardener come into contact with each other they begin to cure. Some resins will even react with moisture in the air. The reacting components can contaminate the internal parts that they come into contact with and degrade performance. Cleaning the components after each use is time consuming and requires the use of quantities of solvent. Eventually, pumps and other components will need to be disassembled for complete cleaning. Because of these issues, certain embodiments of the cartridge assembly 126 according to the disclosure may be designed to be limited- or even single-use. In order to be economical, the internal pump components, for example, are simplified and reduced to the gears 155, 156 alone. The gears 155, 156 can be manufactured from any suitable material, such as metal, plastic, composite, elastomer, etc. One arrangement uses injection molded gears made from reinforced nylon. One arrangement uses extruded aluminum gears. Other arrangements can use various other materials and manufacturing processes. [0074] Components used with the current system can vary greatly in viscosity, and some can be substantially viscous, particularly in cool conditions. Resins and hardeners for use in flooring product can range from 100 to 20,000 centipoise, depending on the specific component and temperature. Conventional gear pumps have a known difficulty in pumping high viscosity fluids at high rates of flow. Figure 18 illustrates gears 167 of a conventional prior art design commonly used in gear pumps. The direction of rotation 168, 169 creates a low pressure side 170 and a high pressure side 171. Fluid that is captured in the space between the teeth 172 as the gears begin to mesh must be able to exit that space as the gears mesh completely and the volume in that space is reduced. Because of the tolerances in the design of gear pumps, many fluids, particularly low viscosity fluids, can escape and are able return to the high pressure side 171. High viscosity fluids have more difficulty flowing and cannot pass through the spaces as easily as low viscosity fluids. These fluids have difficulty escaping this space, particularly when pumped at high flow rates. The space 172 between the teeth becomes smaller as the gears attempt to mesh. If the fluid cannot escape the space, and since these fluids are incompressible, pressure builds up as the gears attempt mesh. As the pressure builds, it increases the torque required to turn the gears. This increase in required torque hinders the ability of the pump to operate. This causes the pump to slow, decreasing output and the ability to pump the fluid at a desired rate. This can even cause the pump to stall entirely. In conventional gear pumps that are designed for high viscosity fluid, this problem can be resolved by building channels and escape mechanisms, for example, in side plates as is known.

[0075] The exemplary gear pump arrangements 224, 225 according to the disclosure, on the other hand, do not have side plates or other components in which to build channels or escape mechanisms. Thus, the disclosure in an aspect is directed to the exemplary embodiment s) of gears 155, 156 for use with the gear pump arrangements 224, 225 in the exemplary cartridge assembly 126.

[0076] Figure 19 shows exemplary embodiments of the gears for use in the exemplary gear pump arrangements 224, 225. The gears 155, 156 rotate respectively in the directions 175 and 174, with 155 being the drive gear and 156 being the driven gear, creating a low pressure side 176 and high pressure side 177. The gears 155, 156 each include a plurality of teeth 229 having a shape including, without limitation and with respect to teeth on some conventional gear pump gears: 1) a length 178 that is generally shorter; 2) a maximum width 179 that is generally narrower; 3) an angled tip 188 that is generally narrower and more pointed; and, 4) a profile in which a degree of taper from the maximum width 179 to the angled tip 188 is generally greater. Accordingly, the teeth 229 of the exemplary gears 155, 156 interact to create a space 180 between adjacent meshed teeth 290. The space 180 allows fluid to escape back into the high pressure side 177. As the torque of the drive gear 155 impels the driven gear 156, a contact area 181 of respective adjacent meshed teeth 290 creates a seal and generally prevents fluid from flowing into the low pressure side 176. With the exemplary configuration and arrangement of the gears 155 and 156 and the resultant interaction between adjacent meshed gear teeth 290, fluid loss is nearly eliminated in operation of the gear pump arrangements 224, 225 in the exemplary cartridge assembly 126, and each rotation of the exemplary gears 155, 156 in the gear pump arrangement 224, 225 produces a desired output. In addition, the generally shorter and narrower teeth 290 according to the exemplary embodiment s) of the gears 155, 156 according to the disclosure provide a larger space or area 189 between adjacent teeth 290 on the same gear 155, 156, which allows more fluid to be captured and propelled and thereby increases the capacity of the pump for a given size gear. In one arrangement, the gears 155, 156 have a pitch diameter of approximately 1.25 inches, and the gear teeth 229 have a length 178 that is shortened by .006 inches and a width 179 that is narrowed by .008 inches, and a profile in which angled tip 188 has an angle of 60 degrees between the angled tip 188 a portion of maximum width 179. These dimensions are exemplary and may be chosen based on the size of the gears used, viscosity range and other factors.

[0077] To ensure a quality product, resin and hardener may be mixed into a homogenous mixture. The arrangement illustrated in Figures 14 and 15 utilizes a series of static mixing elements 182, 183, 184, 185, 186. These elements comprise a series of offset helical segments, as shown in Figure 20, joined together to form continuous elements that create a tortuous path for the combined resin and hardener to follow as it travels through the mixer. The resin and hardener mix together and become a homogenous mixture as they pass through these mixing elements. Figure 20 illustrates an isometric view of a segment of a static mixer 187 that may be used with the exemplary cartridge assembly 126. Static mixing elements 182, 183, 184, 185, 186 such as these are well known in the art and will not be discussed herein in detail. The diameter, design and total length of static mixing elements 182, 183, 184, 185, 186 for any arrangement may be chosen based on factors such as, without limitation, volume of output, specific chemistry being mixed, design constraints, etc. In the exemplary arrangement illustrated in Figures 14 and 15, the mixing elements 182, 183, 184, 185, 186 have a diameter of approximately 1 inch, and the combined length of mixing elements 182, 183, 184, 185, 186 is approximately 40 inches. The serpentine arrangement of the mixing elements 182, 183, 184, 185, 186 provides certain advantages over linear mixers. This arrangement allows the mixing path, and therefore the length of the resulting mixing chamber to be longer than can be achieved using a linear mixer arrangement. For purposes of this disclosure, “mixing chamber” refers generally to a collective overall space in which mixing takes place. Since the resin product continues to mix as it travels through the mixing chamber, a longer chamber provides more complete mixing of the product. For example, one exemplary arrangement of the cartridge assembly 126 has an overall size of approximately 24 inches long by 7 inches wide by 2 inches tall. The serpentine arrangement of the mixing elements 182, 183, 184, 185, 186 as shown in, e.g., Figures 14 and 15, allows a total mixing element length of approximately 40 inches. A mixing chamber of this length would be impractical if a linear mixing element were used.

[0078] Between dispense cycles, the resin product within the mixer tends to separate back into separate resin and hardener components. This is due to the difference in densities of the two components. The denser component settles to the bottom of the mixing chamber and the less dense component rises to the top. When the next dispense cycle begins, the first portion of product exiting the mixer is no longer thoroughly mixed. This means that a portion of the dispensed product will not cure properly. The substantially horizontal orientation of the mixer of according to the current disclosure has an advantage over vertically oriented mixers. When the components separate in a vertical mixer, all of the denser component ends up in the bottom of the mixer. Using for example, an epoxy resin product with a 2: 1 ratio of resin to hardener, the denser of the two, usually the resin, will settle into the bottom 2/3 of the mixer. The less dense of the two, usually the hardener, will rise to the upper 1/3 of the mixer. Since the components are separated through the length of a vertical mixer, they cannot re-mix as they are dispensed. The contents of the entire length of the mixer is dispensed as un-mixed components. With the mixer in a horizontal orientation, separation only occurs in the height of the mixing channel, rather than for its entire length. The separation occurs in the bottom 2/3 and top 1/3 of the channel height rather than length. When a subsequent dispensing cycle begins, only the product at the end of the mixer is dispensed in a less than homogeneous mixture. The resin and hardener within the rest of the mixing chamber are re-mixed prior to reaching the output port. This minimizes the effect of separation.

[0079] When the resin and hardener reach the end of the final mixing element 186, it has been mixed into a homogeneous product. The product exits the cartridge assembly and is dispensed through the outlet 140. To prevent product from seeping out of the outlet in between dispense cycles, a valve means is incorporated into the outlet 140. Figure 21 illustrates a side view of the outlet 140, and Figure 22 illustrates a cross sectional view of the outlet 140 taken through section 3-3 of Figure 21. Located within the outlet body 230 is a ball 190 that rests within a bore 191. A spring 192 attaches to the ball 190 at its lower end and to a dowel pin 193 at its top. An O-ring 194 creates a seal for the ball 190 as the spring 192 holds the ball 190 against the O-ring 194. In one arrangement, the ball 190 is 1.0 inch in diameter and the inner diameter of the O-ring 194 is .72 inches in diameter creating a seal area of approximately .40 inches. In one arrangement, the spring 192 exerts approximately 2.0 pounds of force on the ball 190. This means that the ball 190 remains sealed until the pressure exerted by the product reaches approximately 5 pounds per square inch. These exemplary dimensions and forces are not limiting. During a dispensing cycle the pressure within the cartridge 126 can reach 100 pounds per square inch or more. When the dispensing cycle ends, the pumps stop producing pressure. When the pressure at the outlet 140 drops below 5 psi the ball 190 seals against the O-ring 194 and prevents any additional product from exiting the outlet 140 between dispensing cycles. The pressure at which flow is stopped can be determined by the force of the spring 192, and/or the diameters of the ball 190 and O-ring 194. The disclosed arrangement is exemplary, and the system can be designed for any desired pressure.

[0080] A gear pump is a positive displacement device for which each revolution of the pump dispenses a specific volume of liquid. When used in a ratio control system such as this it is critical that the pumps maintain a consistent output. Internal leakage within the pump can cause inconsistency. Internal leakage can develop over time as the gears wear due to normal usage, and can also occur if a gear gets damaged, a foreign particle becomes caught within a gear, etc. Other mechanical issues may occur within the pump that create internal leakage. The greater the internal leakage, the less the pump will output per revolution. [0081] The ball 190, spring 192 and O-ring 194 arrangement in effect provides a pressure relief valve at the outlet 140 of the cartridge assembly 126. According to this arrangement, an exemplary method for determining the amount of internal leakage within each pump is disclosed. The cartridge assembly 126 may contain one or more pressure sensors (not shown) installed on an outlet side, or downstream therefrom, of the pumps. The pressure sensor measures the output pressure of the liquid exiting the pumps. The relief system design can be selected to determine a cracking pressure that is high enough to perform a test procedure. In the disclosed arrangement, this is 5 PSI, however, the system can be designed for any desired pressure. The pump must pressurize the component to 5 psi before the valve will open and the component can flow to the mixer.

[0082] In an aspect, each component supply will have a reference test number associated with it. This refence number is determined by the component’s viscosity and other flow characteristics. For example, a particular resin product may have a reference number of 2. The reference number indicates a rotational speed, in revolutions per minute, at which the pump will be driven against the closed valve. As the pump is driven, the internal pressure will increase at a rate that will depend upon the amount of the pump’s internal leakage. The controller measures the time that it takes for the resin to reach a predetermined test pressure, for example 3 psi, that is below the 5 psi cracking pressure of the pressure relief valve, so that no component flows through the valve during the test. The amount of time that it takes to reach this test pressure will determine the amount of internal leakage, and therefore, the condition of the pump. The longer it takes to reach the test pressure, the more internal leakage the pump has. The controller is configured to calculate the percentage of internal leakage based on the time that it takes to reach the test pressure.

[0083] The specific test procedure described here is an example of the way in which this system may be used. Other embodiments can be envisioned, such as driving the pump at an increasing rate until a predetermined pressure is reached, driving the pump for a specific number of rotations and measuring the resultant pressure, etc. The above tests may be used to provide a pass/fail determination of the condition of the pumps. If the internal leakage of the pumps is low enough to assure that a mix ratio can be held within specification, the dispensing system may operate normally. If the condition of the pumps is such that a mix ratio will be outside of specification, the controller can prohibit dispensing and inform the user that maintenance is required.

[0084] In another aspect, internal leakage data can be used to calculate a pump correction factor. The controller uses the correction factor to adjust the pump drive speeds during a dispensing cycle to compensate for internal leakage and produce the desired amount of correctly ratioed product. For example, if one pump in a system loses 5% of its output to internal leakage and the other pump loses 1%, the controller can increase the first pump’s drive speed by 5% and the second pump’s drive speed by 1% in order to compensate. If internal leakage increases to the point that increasing the pump drive speed can no longer produce the desired output, the controller can prevent the dispenser from beginning a dispensing cycle and alert the user that repair or replacement is necessary. The described tests may be performed between every dispensing cycle to assure that each dispensed batch is of the correct ratio. The test may also be performed any other time that dispensing is not in progress.

[0085] Aggregates are often added to resin flooring products to add durability and other attributes to the flooring product. Aggregate can contain cement, minerals and other additives. If aggregates are added to either the resin component or the hardener component prior to combining and mixing the resin and hardener, two issues arise; the ratios of resin and hardener must be adjusted to compensate for the aggregate, and the component with the aggregate must be continually mixed in order to keep the aggregate from settling, which can cause an uneven aggregate content in the product. Additionally, if resin and hardener are not thoroughly mixed when aggregates are added, preferential absorption may occur, meaning that more aggregates may be absorbed by one component than the other, changing the characteristics of the product. The dispensing system 100 can have the ability to add aggregate into the thoroughly mixed product after the product has exited the dispenser assembly 103 and prior to the product entering the bucket 105.

[0086] Figure 23 illustrates a front isometric view and Figure 24 illustrates a rear isometric view of an arrangement of a co-blender 106 that can be used with the dispensing system 100. This assembly is provided to supply aggregate or other dry powdered or granular additives in predetermined quantities at a predetermined rate into the combined resin and hardener product after they have been homogenously mixed, and prior to being dispensed into the bucket 105. Figure 25 illustrates a top view of a co-blender 106 with the top plate 196 removed. The co blender 106 comprises a front plate 195, a top plate 196, a hopper 197, an auger 198, a drive motor 199, an extension tube 200 and a t-fitting 201.

[0087] In use, aggregate is added to the hopper 197 prior to dispensing. As products exits the dispenser assembly 103, and prior to the product entering the bucket 105, it passes through the t- fitting 201. The drive motor 199 rotates the auger 198 and the screw action of the auger 198 drives the aggregate forward and into the t-fitting 201. The drive motor 199 can be any suitable motor capable of providing the speed and torque necessary to drive the auger. A servo motor with an encoder or a stepper motor may be used in the exemplary embodiments as the auger 198 must be controlled to provide a precise output of aggregate. One such motor is motor model MH275-12-D1-084 supplied by Servo Components of Newington, NH. In one arrangement, and without limitation, the auger 198 is driven in a range of about 200 rpm to about 600 rpm and requires about 100 lb-in of torque.

[0088] Figure 26 illustrates an isometric view of the auger 198 according to an exemplary embodiment. The exemplary auger 198 is a screw auger such as those known in the art. Other arrangements can utilize differing shapes and designs. The drive motor 199 is controlled by the controller during a dispensing cycle to drive a predetermined amount of aggregate into the t- fitting 201. Volume and flow rate of aggregate is determined by the flow rate of product from the dispenser assembly 103 and by the desired ratio of product to aggregate for a particular application. The ratio of product to aggregate can range, for example, from approximately 1:2 to approximately 2:1. As product is dispensed at its predetermined rate, aggregate is also dispensed at its predetermined rate. The aggregate must be mixed into the product to create a homogeneous product / aggregate mixture. This can be accomplished in multiple ways. In one arrangement, aggregate is simply driven into the passing product, which is collected in the bucket 105. The bucket 105 is then removed from the dispensing system 100, then the product and aggregate are mixed within the bucket 105 using, for example, a drill powered paddle mixer. In other arrangements, product and aggregate are mixed within the t-fitting 201 using a static mixer element similar to that used in the cartridge assembly 126. In other arrangements, an active mixer, such as a motor powered paddle, auger, etc. may be included as part of the t-fitting 201. [0089] The particle size within the aggregate can vary, with both large and small particles within the aggregate. These particles can separate, with the denser particles settling at the bottom of the hopper 197. To alleviate the settling, the auger 198 may be driven in reverse. This will drive the aggregate backwards and upwards and efficiently stir the particles.

[0090] Figure 27 illustrates an isometric view of an arrangement of a control box 104. The control box 104 may contain the power supply, controls and other components necessary to operate the automatic dispensing system 100. In this arrangement, the control box 104 has the capacity to hold and carry additional components during transport of the system. The control box 104 may be housed in a commercially available toolbox 202, for example Rigid model 54343 manufactured by Ridge Tool Company of Elyria, OH, that is modified as necessary for use. A telescoping handle 203 and a top lid (not shown) may be included, as well as wheels (not shown) to facilitate moving the control box 104 to a desired location. The control box 104 may contain a drum alignment plate 204 as well as a drive assembly 205 that includes the motors 127, 128, load cell 136, liquid sensors 133, 134, and associated brackets, cables (not shown), etc.

[0091] Figure 28 illustrates a top view of an exemplary control box 104 with the drum alignment plate 204 and drive assembly 205 removed. A separator plate 206 beneath the drum alignment plate 204 and drive assembly 205 separates an upper chamber from a lower chamber. Figure 29 illustrates a top view of an exemplary control box 104 with the separator plate 206 removed, exposing a lower chamber containing all controls and other components necessary to operate the dispensing system 100. These components can include an electronic control module 207, which controls all the functions of the dispensing system 100. This can be of any suitable type, such as custom PC board, embedded computer, etc. Stepper motor drivers 208, such as model MLA 10641 from Anaheim Automation of Anaheim, CA or other suitable driver operates the pump motors 127, 128 in accordance with instructions from the electronic control module 207. An air pump 209 creates the air pressure used to pressurize the supply reservoirs 101, 102.

A suitable pump is model AC0401 A-Al 110-El manufactured by Medo USA of Roselle, IL. A solenoid valve 210, such as model VT307W-5DZ1-01N-F manufactured by SMC Pneumatics of Yorba Linda, CA, controls the output of the air pump 209. Also included in the control box 104 are the tubing and cables (not shown) that are necessary to connect and control all components of the dispensing system. These are exemplary components that may be included in the control box 104. In various exemplary embodiments, one or more components as discussed above may be located outside of the control box, or the control box 104 may contain any additional or different components as necessary to operate any specific arrangement of the dispensing system 100. The system may be powered by battery, which may be contained within the control box 104, or powered by a line voltage connection.

[0092] Following is an exemplary sequence of set up and operation of a dispensing system according to the exemplary embodiments disclosed herein: a. Supply reservoirs 101, 102 of the desired chemistry are selected, placed onto drum dollies 107, and rolled to a desired location. b. The control box 104 is brought into place behind the supply reservoirs 101, 102 as seen in Figure 2. c. The drum alignment plate 204 is removed from the control box 104 and placed onto the supply reservoirs 101, 102 (as shown in FIG. 1), which locates the supply reservoirs 101, 102 in the correct orientation. d. Drum adapters 108 are inserted into the supply reservoirs 101, 102. If the resin contains pigment, the drum adapter 108 may be used to mix the component as described above. The drum adapters 108 are then screwed into place in the supply reservoirs 101, 102. e. A cartridge assembly 126 is placed on top of the alignment plate 204 so that the lower cartridge adapters 129, 130 connect to the top of the drum adapters 108. f. The drive assembly 205 containing the motors 127, 128 and other components is removed from the control box 104 and put into place on top of the cartridge assembly 126 so that the motor shafts engage with the square holes 159 in the drive gears 155, and other components are attached as needed. g. If used, a co-blender 106 is mounted to the system so that the t-fitting 201 engages to and below the outlet 140. Aggregate is added to the hopper 197. h. The system power is turned on. i. If so equipped, the electronic control module 207 reads the identification tags on the supply reservoirs 101, 102 and determines which components are being used. If not so equipped, the user enters the component information into a control panel (not shown). The electronic control module 207 determines the correct ratio and flow rates for the components being used. j. The air pump 209 pressurizes the supply reservoirs 101, 102 to a predetermined pressure. k. The user bleeds the air out of the system using the bleed screws 135, 136. l. A bucket 105 is placed onto the bracket 139. m. The system is now ready to dispense.

[0093] Following is a typical sequence of a dispensing cycle: a. The operator signals the dispensing system 100 to begin a dispensing cycle. This can be done using a control panel (not shown) on the system, through a wearable control device, via smart phone or other suitable method. b. The electronic control module 207 reads the signals from the liquid sensors 133, 134 and any other sensors that may be employed by the dispensing system 100 and determines whether conditions are correct to begin a dispensing cycle. If a problem is detected, dispensing is prevented and the user is signaled that correction is necessary. c. The electronic control module 207 drives the motors 127, 128 and individually controls the gear pumps to pump resin and hardener at predetermined flow rates to dispense a predetermined volume of component at a desired ratio. d. The resin and hardener combine within the cartridge, mix thoroughly as it passes through the mixing elements, then exit the cartridge. e. If aggregate is used, the electronic control module 207 powers the motor 199 that drives the auger 198 at a rate to dispense a predetermined quantity of aggregate at a predetermined rate into the product stream during the dispensing cycle. f. When the predetermined quantity of product has been dispensed, the electronic control module 207 stops the dispensing process. g. During non-dispense times, the electronic control module 207 can perform maintenance functions such as performing a pump test, reversing the auger 198 or other functions as required.

[0094] The steps in the above sequences should not be considered limiting and may be performed or ordered according to a particular application. [0095] Two component resin flooring is often used in warehouses, manufacturing facilities and other locations that are large in area, often many thousands of square feet. Large projects such as these often require multiple supply reservoirs 101 of resin and hardener. It is an inconvenient and time consuming process to stop to change supply reservoirs 101 during a project, particularly with the time sensitive nature of these resins. It is advantageous to be able to attach more than one supply reservoir to the dispensing system so that an entire project may be completed without the need to replace a supply reservoir 101.

[0096] With reference to FIG. 30, presented here is a transfer system 212 that places a second supply reservoir 101b adjacent to a first supply reservoir 101a, then transfers the contents of the second supply reservoir 101b into the first supply reservoir 101a as component is dispensed. In this manner, the entire contents of first supply reservoir 101a and the second reservoir 101b can be consumed without any downtime to change supply reservoirs 101.

[0097] Figure 30 illustrates a side view of an arrangement of such a transfer system 212. This figure illustrates one half of a dispensing system 100 for clarity. This could be either the resin or hardener side of the system, as both sides are the same. Two supply reservoirs 101a, 101b of the same component are located adjacent to each other. The front has been removed from the supply reservoirs 101a, 101b so that the drum adapters 108a, 108b are visible. Each has a drum adapter 108a, 108b mounted in the normal fashion. The dispenser assembly 103 (only partially visible) mounts to the connector portion 113a of the drum adapter 108a of a first supply reservoir 101a through a first transfer adapter 213. A second transfer adapter 214 mounts to the connector portion 113b of the second drum adapter 108b. An air supply tube 215 and a component transfer tube 216 connect the first transfer adapter 213 to the second transfer adapter 214. When a dispensing project is begun, the air pump 209 sends an air pressure supply to the dispenser assembly 103 as described previously and seen in Figure 16. The air passes through the lower cartridge adapter 129 and into the first transfer adapter 213, which includes an air path that is configured to divert the air into the air supply tube 115. The air enters the second transfer adapter 214, then passes through the connector portion 113b of the second drum adapter 108b and into the second supply reservoir 101b. The second supply reservoir 101b is pressurized, for example, to 3 psi. The pressurized air within the second supply reservoir 101b forces the component within to pass through the second drum adapter 108b, through the second transfer adapter 214, through the component transfer tube 216 and into the first transfer adapter 213, where it is diverted into the first supply reservoir 101a, in turn supplying component and pressurizing the first supply reservoir 101a. The pressure within the first supply reservoir 101a forces component through the first drum adapter 108a, through the first transfer adapter 213, into the lower cartridge adapter 129 and into the dispenser assembly 103, where it primes and supplies the pump. With each dispensing cycle, component is consumed from the first supply reservoir 101a, and replacement component is transferred from the second supply reservoir 101b. During operation, the second supply reservoir 101b is emptied of component first, at which point the pressurized air transfers from the second supply reservoir 101b into the first supply reservoir 101a, continuing normal operation until the first supply reservoir 101a is emptied of component.

[0098] Figure 31 illustrates a cross sectional side view of a detail of the connection of the dispenser assembly 103, first transfer adapter 213, first drum adapter 108a and first supply reservoir 101a. Figure 32 illustrates a cross sectional side view of a detail of the connection between the second transfer adapter 214, second drum adapter 108b and second supply reservoir 101b. The first and second drum adapters 108a, 108b attach to the first and second supply reservoirs 101a, 101b in the normal fashion. The first transfer adapter 213 mounts on top of the connector portion 113 of the first drum adapter 108a in the same manner that the dispenser assembly 103 would mount in a single supply system. The dispenser assembly 103 mounts on top of the first transfer adapter 213 in the same manner that it would mount to a drum adapter 108 in a single supply system. The second transfer adapter 214 mounts to the top of the second drum adapter 108b in the same manner in which a dispenser assembly 103 mounts to a drum adapter 108 in a single supply system.

[0099] Air from the air pump 209 passes through the dispenser assembly 103 as described previously. The air enters the first transfer adapter 213, which is configured with an air passageway 231 that diverts and directs the air into an outlet passageway 217. The air supply tube 215 (not shown in these figures) connects to the outlet passageway 217. The air travels through the supply tube 215 and enters the second transfer adapter 214 through an air inlet 218, then passes through the space 149 in the connector portion 113 of the second drum adapter 108b and into the second supply reservoir 101b, where it pressurizes the supply reservoir 108b. The air pressure above the component in the second supply reservoir 101b forces the component through the tubular portion 109 of the second drum adapter 108b, through a central bore 219 in the second transfer adapter 214 then through the component transfer tube 216 (not shown in these figures) and into an inlet port 220 of the first transfer adapter 213. The component then passes through the space 149 in the connector portion 113 of the first drum adapter 108a and enters the first supply reservoir 101a, where it pressurizes the first supply reservoir 101a and replaces component as it exits the first supply reservoir 101a through the tubular portion 109 of the first drum adapter 108a, through a central passageway 221 in the first transfer adapter 213 and into the dispenser assembly 103, where it is dispensed in the normal manner. As can be seen, the transfer system as disclosed can double the dispensing capability of a dispensing system 100. In the same manner as disclosed for the exemplary embodiment of a two-supply reservoir, three or more supply reservoirs 101 may be arranged if even more capacity is desired.

[0100] This disclosure, in various embodiments, configurations and aspects, includes components, methods, processes, systems, and/or apparatuses as depicted and described herein, including various embodiments, sub-combinations, and subsets thereof. This disclosure contemplates, in various embodiments, configurations and aspects, the actual or optional use or inclusion of, e.g., components or processes as may be well-known or understood in the art and consistent with this disclosure though not depicted and/or described herein.

[0101] The phrases "at least one", "one or more", and "and/or" are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions "at least one of A, B and C", "at least one of A, B, or C", "one or more of A, B, and C", "one or more of A, B, or C" and "A, B, and/or C" means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.

[0102] In this specification and the claims that follow, reference will be made to a number of terms that have the following meanings. The terms "a" (or "an") and "the" refer to one or more of that entity, thereby including plural referents unless the context clearly dictates otherwise. As such, the terms "a" (or "an"), "one or more" and "at least one" can be used interchangeably herein. Furthermore, references to "one embodiment", "some embodiments", "an embodiment" and the like are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term such as "about" is not to be limited to the precise value specified. In some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Terms such as "first," "second," "upper," "lower" etc. are used to identify one element from another, and unless otherwise specified are not meant to refer to a particular order or number of elements.

[0103] As used herein, the terms "may" and "may be" indicate a possibility of an occurrence within a set of circumstances; a possession of a specified property, characteristic or function; and/or qualify another verb by expressing one or more of an ability, capability, or possibility associated with the qualified verb. Accordingly, usage of "may" and "may be" indicates that a modified term is apparently appropriate, capable, or suitable for an indicated capacity, function, or usage, while taking into account that in some circumstances the modified term may sometimes not be appropriate, capable, or suitable. For example, in some circumstances an event or capacity can be expected, while in other circumstances the event or capacity cannot occur - this distinction is captured by the terms "may" and "may be."

[0104] As used in the claims, the word "comprises" and its grammatical variants logically also subtend and include phrases of varying and differing extent such as for example, but not limited thereto, "consisting essentially of and "consisting of." Where necessary, ranges have been supplied, and those ranges are inclusive of all sub-ranges therebetween. It is to be expected that the appended claims should cover variations in the ranges except where this disclosure makes clear the use of a particular range in certain embodiments.

[0105] The terms "determine", "calculate" and "compute," and variations thereof, as used herein, are used interchangeably and include any type of methodology, process, mathematical operation or technique.

[0106] This disclosure is presented for purposes of illustration and description. This disclosure is not limited to the form or forms disclosed herein. In the Detailed Description of this disclosure, for example, various features of some exemplary embodiments are grouped together to representatively describe those and other contemplated embodiments, configurations, and aspects, to the extent that including in this disclosure a description of every potential embodiment, variant, and combination of features is not feasible. Thus, the features of the disclosed embodiments, configurations, and aspects may be combined in alternate embodiments, configurations, and aspects not expressly discussed above. For example, the features recited in the following claims lie in less than all features of a single disclosed embodiment, configuration, or aspect. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of this disclosure.

[0107] Advances in science and technology may provide variations that are not necessarily express in the terminology of this disclosure although the claims would not necessarily exclude these variations.

Claims

CLAIMS What is claimed is:

1. A dispenser assembly for a floor coating, comprising: a cartridge, the cartridge including a first passageway in fluid communication with each of a first fluid inlet and a first pump, a second passageway in fluid communication with each of a second fluid inlet and a second pump, a common passageway in fluid communication with each of the first passageway and the second passageway, a mixing passageway in fluid communication with the common passageway, a mixer positioned within the mixing passageway, and an outlet in fluid communication with the mixing passageway; a first motor configured for driving the first pump; and a second motor configured for driving the second pump.

2. The dispenser assembly of claim 1, wherein the first pump includes a first drive gear and a first driven gear, and the second pump includes a second drive gear and a second driven gear.

3. The dispenser assembly of claim 2, wherein the first motor is configured for driving the first drive gear and the first drive gear is configured for driving the first driven gear, and the second motor is configured for driving the second drive gear and the second drive gear is configured for driving the second driven gear.

4. The dispenser assembly of claim 1, wherein the first passageway, the second passageway, the common passageway, and the mixing passageway are together configured for providing a path through which a mixture product is formed from a first fluid from the first fluid inlet mixed with a second fluid from the second fluid inlet.

5. The dispenser assembly of claim 4, wherein the first pump is configured for pumping the first fluid from the first passageway to the common passageway and the second pump is configured for pumping the second fluid from the second passageway to the common passageway.

6. The dispenser assembly of claim 4, wherein the outlet is configured for providing a path through which the mixture product exits the cartridge.

7. The dispenser assembly of claim 1, wherein the outlet includes an outlet body having a bore formed through the outlet body, the bore open to each of the mixing passageway and an outside of the cartridge, a ball positioned within the bore, in a spaced apart relationship from each of the mixing passageway, at the outlet, and the outside of the cartridge, a spring positioned within the bore, between the ball and the outside of the cartridge, the spring attached at a first end of the spring to the ball and at a second end of the spring to a structure positioned on a peripheral surface of the bore, within the outlet body, and a seal in contact with each of the peripheral surface of the bore and the ball, the seal positioned between the ball and the outside of the cartridge.

8. The dispenser assembly of claim 7, wherein the spring exerts a force on the ball, the force influencing the ball in a direction towards the outside of the cartridge and against the seal, the ball and seal together configured for preventing fluid flow through the outlet when a fluid pressure within the mixing passageway, at the outlet, is insufficient for overcoming the force.

9. The dispenser assembly of claim 1, wherein the mixer is a static mixer and defines a tortuous path configured to mix the first fluid with the second fluid.

10. The dispenser assembly of claim 1, wherein the mixer defines a serpentine shape.

11. The dispenser assembly of claim 1, wherein the cartridge includes a cartridge top joined to a cartridge bottom, and the first passageway, the second passageway, the common passageway, and the mixing passageway are defined at least in part by corresponding structures formed respectively on an inner side of the cartridge top and an inner side of the cartridge bottom, wherein the inner side of the cartridge top and the inner side of the cartridge bottom are adjacent within an interior of the cartridge when the cartridge top is joined to the cartridge bottom.

12. The dispenser assembly of claim 1, further comprising a liquid sensor, wherein the liquid sensor is configured for determining whether air is entrapped within the cartridge.

13. A dispenser assembly for a floor coating, comprising: a first fluid in a first reservoir; a second fluid in a second reservoir; a cartridge, the cartridge including a first passageway in fluid communication with the first reservoir, and a first pump positioned in the first passageway, a second passageway in fluid communication with the second reservoir, and a second pump positioned in the second passageway, a common passageway in fluid communication with each of the first passageway and the second passageway, a mixing passageway in fluid communication with the common passageway, and a mixer positioned within the mixing passageway; a first motor configured for driving the first pump; and a second motor configured for driving the second pump, wherein the cartridge is configured for receiving the first fluid in the first passageway and the second fluid in the second passageway, and forming a mixture product comprising a specified ratio of the first fluid to the second fluid.

14. The dispenser assembly of claim 13, wherein the first fluid is a resin and the second fluid is a hardener.

15. The dispenser assembly of claim 13, wherein the mixer is a static mixer and defines a tortuous path configured to mix the first fluid with the second fluid.

16. The dispenser assembly of claim 13, wherein the mixer defines a serpentine shape.

17. A method for dispensing a floor coating, comprising: receiving a first fluid in a first passageway of a cartridge, wherein a first pump is positioned within the first passageway; receiving a second fluid in a second passageway of the cartridge, wherein a second pump is positioned within the second passageway; pumping the first fluid, via the first pump, and the second fluid, via the second pump, into a mixing passageway of the cartridge, via a common passageway of the cartridge, wherein the common passageway is in fluid communication with each of the first passageway, the second passageway, and the mixing passageway; mixing the first fluid with the second fluid, with a mixer positioned within the mixing passageway, to form a mixture product; and collecting the mixture product through an outlet in fluid communication with each of the mixing passageway and an outside of the cartridge.

18. The method of claim 17, further comprising driving the first pump with a first motor and driving the second pump with a second motor.

19. The method of claim 17, wherein the step of mixing the first fluid with the second fluid includes mixing the first fluid with the second fluid in a specified ratio.

20. The method of claim 17, wherein the first fluid is a resin and the second fluid is a hardener.