CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority benefit of U.S. Provisional Patent Application Serial No. 63/081,954 filed September 23, 2020, entitled "INTERMEDIATE BULK CONTAINER, VALVE AND CONNECTOR SYSTEM," the complete disclosure of which, in its entirety is herein incorporated by reference.

BACKGROUND

[0002] Intermediate bulk containers, often referred to as IBC, are used to handle, store and transport bulk materials. Intermediate bulk containers are used for handling a wide variety of materials used in industry, which materials may be liquid or powder depending upon the IBC. Such intermediate bulk containers are reusable assemblies that include a container enclosure or tank that holds the material and is mounted on a base. The base typically is a pallet or pallet-like structure designed to be handled by a forklift, pallet jack or other similar material handling equipment. Intermediate bulk containers have also previously been referred to as IBC totes, IBC tanks, and pallet tanks. Intermediate bulk containers may be certified by the Department of Transportation for transport handling of different categories of products, and in size normally fall between that of a standard shipping drum and an intermodal tank container.

[0003] Intermediate bulk containers used in the handling of liquid product typically include a valve outlet that allows for the control of flow of the liquid. Such liquid flow control valves are normally located at the lower region of the container enclosure in order to provide for adequate drainage of the unit.

[0004] A problem associated with intermediate bulk containers is the proper connection and sealing of a liquid control valve with the tank. Leakage can provide a hazardous condition depending on the material being handled by the intermediate bulk container. Leakage may also result in damage to surrounding materials and require discarding the entire container contents. The present disclosure provides improvements. SUMMARY OF THE DISCLOSURE

[0005] Various details of the present disclosure are hereinafter summarized to provide a basic understanding. This summary is not an extensive overview of the disclosure and is neither intended to identify certain elements of the disclosure, nor to delineate the scope thereof. Rather, the primary purpose of this summary is to present some concepts of the disclosure in a simplified form prior to the more detailed description that is presented hereinafter.

[0006] The present disclosure is directed toward enhancing the seal of an intermediate bulk container valve assembly on the container. This is accomplished according to a preferred form of the present disclosure in a system that provides an intermediate bulk container with a valve assembly coupled thereto by a multipart connector system. The tank includes a tank outlet at a lower region of the container with an outlet orifice through the outlet. An outlet annular seal positioning wall extends from the outer end around the outlet orifice. The valve assembly is mounted on the tank outlet, with an inlet end region having an inlet orifice through a rearwardly facing seal surface. An inlet annular seal positioning wall extends from the inlet end region around the inlet orifice. The outlet annular seal positioning wall extends from the outer end a distance greater than the inlet annular seal positioning wall extends and the outlet annular seal positioning wall and inlet annular seal positioning wall are telescopingly mated. A sealing surface on the valve assembly is contacted by the outlet annular seal positioning wall when mounted on the tank. An elastomeric annular seal is positioned between the outer end and the inlet end region and positioned between the outlet annular seal positioning wall and inlet annular seal positioning wall. A multipart connector rotatably positioned around and coupling the inlet end region and outer end. A complete seal is formed between the annular seal and the annular seal positioning walls.

[0007] In some embodiments, the multipart connector comprises a first collar half and a second collar half, wherein the second collar half is substantially a mirror image of the first collar half. In a further embodiment, the first and second collar halves each comprise opposing radially extending elongated clamping tabs, each clamping tab having a contacting surface configured to abut the contacting surface of the other half. In another further embodiment, each clamping tab includes at least two holes that substantially align and configured to receive a fastener therethrough to join the first and second collar halves. In another further embodiment, the multipart connector comprises interior threads sized and shaped to engage with external threads of the outlet. In another further embodiment, the valve assembly includes a valve body having an inlet end and outlet end and an adaptor adjacent to an inlet end configured to form a leak resistant seal with the outlet of the intermediate bulk container, wherein the inlet annular seal positioning wall is integral to the adaptor. In another further embodiment, the adaptor includes a substantially rectangular base plate configured to abut with and mount to the inlet end of the valve body and a substantially cylindrical body extending from the base plate and terminating in an annular flange that forms a substantially circular connecting plate for sealingly engaging the outlet of the intermediate bulk container. In another further embodiment, the valve assembly comprises a ball valve. In another further embodiment, the valve assembly includes a valve body having an inlet end and outlet end and an outlet adaptor adjacent to the outlet end and configured to form a leak resistant seal therebetween, wherein the outlet adaptor includes a substantially cylindrical body that houses a ball, the ball configured to prevent fluid backflow through the outlet adaptor.

[0008] According to another aspect of the present disclosure the multipart connector is a split ring connector with internal threads that are threaded onto external threads on the tank outlet. The split ring connector is formed in at least two parts with joining tabs at each end to provide locking surfaces joined by fasteners. The split ring connector rotates on the valve assembly.

[0009] These and other objects, advantages, and features of the present disclosure will become apparent by review of the following specification in conjunction with the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The following figures are included to illustrate certain aspects of the present disclosure, and should not be viewed as exclusive embodiments. The subject matter disclosed is capable of considerable modifications, alterations, combinations, and equivalents in form and function, without departing from the scope of this disclosure.

[0011] FIGURE 1 is perspective view of an intermediate bulk container with a valve assembly and a multipart collar connector system in accordance with the present disclosure.

[0012] FIGURE 2 is a fragmentary perspective view of the system of FIG. 1.

[0013] FIGURE 3 is a rear perspective view of the valve assembly and connector of FIG. 1.

[0014] FIGURE 4 is a frontal perspective view of another exemplary valve assembly and multipart connector system in accordance with the present disclosure.

[0015] FIGURE 5 is a side elevation cross-sectional view of the valve assembly and multipart connector system of FIG. 4.

[0016] FIGURE 6 is a rear perspective view of the multipart connector system and adapter of FIG. 4.

[0017] FIGURE 7 is an end elevation view of the multipart connector system and adapter of FIG. 6.

[0018] FIGURE 8 is a side elevation cross-sectional view along plane A-A of FIG. 7.

[0019] FIGURE 9 is a rear perspective view of a part of the multipart connector system and adapter of FIG. 6. [0020] FIGURE 10 is a rear perspective view of a part of the multipart connector system and adapter of FIG. 9 with the outlet of the industrial bulk container.

[0021] FIGURE 11 is a perspective cross-sectional view of the multipart connector system and adapter with the outlet of the industrial bulk container.

[0022] FIGURE 12 is a side elevation cross-sectional view of the multipart connector system and adapter with the outlet of the industrial bulk container of FIG. 11.

[0023] FIGURE 13 is a rear perspective view of the adapter of FIG. 4.

[0024] FIGURE 14 is a rear elevation view of the adapter of FIG. 4.

[0025] FIGURE 15 is a side elevation view of separated parts of the multipart connector system of FIG. 4.

[0026] FIGURE 16 is a plan view of separated parts of the multipart connector system of FIG. 4.

[0027] FIGURE 17 is a perspective view of the valve assembly of FIG. 3 with a safety seal applied to the handle.

DETAILED DESCRIPTION

[0028] A more complete understanding of the components, processes and apparatuses disclosed herein can be obtained by reference to the accompanying drawings. These figures are merely schematic representations based on convenience and the ease of demonstrating the present disclosure, and are therefore not intended to indicate relative size and dimensions of the devices or components thereof and/or to define or limit the scope of the exemplary embodiments.

[0029] Although specific terms are used in the following description for the sake of clarity, these terms are intended to refer only to the particular structure of the embodiments selected for illustration in the drawings and are not intended to define or limit the scope of the disclosure. In the drawings and the following description below, it is to be understood that like numeric designations refer to components of like function.

[0030] Referring now to Fig. 1, an intermediate bulk container or IBC 10 includes an enclosure or tank 12 mounted on a base illustrated as pallet 14. The tank 12 defines an interior volume configured to store a quantity of a liquid. In some embodiments, the tank 12 is configured to hold up to a volume of about 3 cubic meters (793 US Gal.) although capacities are generally between 1040 and 1,250 liters (275 and 330 Gal). In some embodiments, and as illustrated, the tank 12 is substantially cube-shaped. The IBC 10 also includes a valve assembly 16 coupled proximate to a lower end 21 of tank 12. The valve assembly 16 controls the outflow of liquid bulk material stored in the tank 12. In some embodiments, the IBC 10 is configured for stacking of multiple units. That is, an upper end 22 of tank 12 is configured to provide upper engaging surfaces that allow for stacking of another IBC on top of IBC 10, and at least partially mate with the lower engaging surfaces of pallet 14. For example, the upper end 22 may have a shape that is complementary to and configured to receive a bottom surface 23 of the pallet 14. The Pallet 14 is a rigid generally planar support structure that supports tank 12 and may include lower surface features configured to at least partially mate with the upper end 22 of tank 12 of another IBC. In some embodiments and as illustrated in FIG. 1, the bottom surface 23 of the pallet 14 may include at least one projection 25 configured to engage a substantially complementary recess 27 in the upper end 22.

[0031] The tank 12 is generally made of a material of sufficient structural rigidity to support the weight of another fully laden IBC stacked on top of tank 12. In some embodiments, the tank 12 is formed from a heavy- duty plastic material to provide a liquid impermeable enclosure for holding the liquid bulk material to be handled. In further embodiments, the tank 12 is composed of high-density polyethylene. It is to be appreciated that the material composition is not limiting and that other materials may be substituted herein, including, for example, composites and metals. [0032] In some embodiments and as illustrated in Fig. 1, the pallet 14 includes fork receiving channels 29 that are located and shaped to accept forks (sometimes referred to as tines) of a forklift or other material handling device and provides structural rigidity to provide for the movement and handling of IBC 10 by the forklift. Alternatively and not illustrated, the IBC 10 may include a metal cage or other rigid enclosure that encloses tank 12 and provides the stacking support and a location for stacking another IBC on top of IBC 10.

[0033] With reference to Figs. 1 and 2, at a lower end 23 of tank 12, proximate the pallet 14 is an outlet recess 24 formed in part by complimentary regions of tank 12 and pallet 14. Recess 24 provides a coupling location for the valve assembly 16 in order to shroud and protect the valve assembly 16 from damage while in use for storage and during transport. At the lower end 23 of tank 12 is an outlet tube 26 that extends from a depending channel along the lower surface of tank 12 in order to provide for the complete drainage of tank 12. The outlet tube 26 may include sidewalls that are formed by extensions of the external surface of the tank 12. Alternatively, the outlet tube 26 may comprise a hole in the tank 12 and an annular flange that is secured about the hole. The flange extends away from the external surface of the thank wall to provide sidewalls of the outlet tube 26. The sidewalls of the outlet tube 26 provide a surface for removably connecting an accessory such as a valve assembly and/or spout. The outboard end of outlet tube 26 includes a set of external threads 28 illustrated in Figs. 10 and 12). The external threads 28 are generally used to couple with multipart connector 18 as described in greater detail below.

[0034] The end-facing surface 30 of outlet tube 26 includes a ring seat 32 formed as a protruding circular flange. Ring seat 32 is an annular flange around the outlet of outlet tube 26 to provide a seating region for O-ring 20. The ring seat 32 has a generally cylindrical outer wall 34. That is, the annual outer wall 34 extends from the outer end-facing surface 30 of the outlet tube 26 and is configured to position a sealing member (O-ring). The O-ring 20 is configured to be compressed against the cylindrical outer wall 34 and endfacing surface 30 when valve assembly 16 is connected to the outlet tube 26 of the tank 12. [0035] As described herein, a valve coupling system includes a multipart connector 18 carried on valve assembly 16 to couple valve assembly 16 with tank 12. An O-ring seal 20 is compressed between valve assembly 18 and tank 12 to provide a seal at the connection region. The configuration and structure of the multipart connector 18 and engaging regions of valve assembly 16 and tank 12 create a highly functional, complete seal and thus, mitigate if not eliminate leakage. The structure of the valve coupling system provides for rapid and ease of assembly onto IBC 10 with reduced error in the final assembly.

[0036] With reference to Figs. 1-5, the valve assembly 16 includes a valve body 40 that encompasses a valve gate or ball 44. In the exemplary embodiment of Fig. 5, the valve assembly 16 is a ball valve and gate 44 is a ball gate. Alternatively, other forms of valves and valve gates may be used without departing from the scope of this disclosure. A set of gate seats 46 provide a complimentary surface upon which the outer surface of gate 44 rests, thereby forming a liquid impermeable barrier through valve body 40 when gate 44 is in the closed position. A handle 42 is connected to a stem 48 such that rotation of handle 42 also rotates stem 48. Stem 48 passes through a bonnet 56 which closes the opening through which gate 44 is assembled, and the lower end of stem 48 is connected to gate 44 such that rotation of stem 48 also rotates the gate 44 between an open or closed position. Therefore, rotation of handle 42 allows for gate 44 to be selectively rotated between an open or closed position. When in the open position, fluid enters the valve body 40 and passes through gate 44 before exiting the valve body 40.

[0037] To prevent unintended fluid flow, valve assembly 16 includes a handle locking button 50 with a depending pin 52 protruding from its lower surface. When the locking button 50 is depressed against a spring 54, the depending pin 52 engages handle 42 with stem 48. Handle 42 is configured to not rotatably engage stem 48 when button 50 is not depressed and depending pin 52 is not engaged. While depending pin 52 is engaged, handle 42 rotatably locks with stem 48 so that rotation of handle 42 rotates stem 48 in order to shift ball 44 between closed and open positions. [0038] With reference to Figs. 3, and 8-14, located at the inlet end of valve body 40 is an inlet adaptor 60 that cooperates in forming a leak resistant seal with outlet tube 26 on tank 12. The inlet adaptor 60 is formed with a generally square or rectangular base plate 62 that abuts with and mounts to valve body 40. In some embodiments, the base plate 62 mounts to the valve body 40 via fasteners. Integrally formed with plate 62 is a cylindrical body 64 that protrudes laterally. The cylindrical body 64 terminates in an annular flange 66 that forms a circular connecting plate. A forward anchoring surface 68 on flange 66 faces opposing base plate 62. The opposite rear-facing surface of flange 66 is a sealing surface 70 that engages end surface 30 on outlet tube 26. Protruding laterally around the inlet opening 71 of adaptor 60 is a ring seat 72. The ring seat 72 is an annular seal positioning wall extending from the sealing surface 70 and integrally formed with flange 66 as a cylindrical shape having planar sides that form a seat and engagement surface for O-ring seal 20.

[0039] With reference to Figs. 3, 5, 6, 8-12 and 16-17 a multipart connector 18 is configured to couple the valve assembly 16 to the outlet tube 26 of tank 12. The multipart connector 18 includes two mating coupling collar halves 74. Collar halves 74 are generally mirror images, which combine to form a substantially circular collar used in the coupling of the outlet tube 26 and inlet adaptor 60. The inner surface of collar halves 74 include interior threads 76 sized and shaped to engage with the external threads 28 on the outlet tube 26. Extending radially from each end of each collar half 74 is an elongated clamping tab 78 that substantially extends along the width W of the collar half. Each clamping tab 78 includes holes 80 configured to align with the holes 80 of the opposed collar half 74 and receive a set of four connecting bolts 82 that join collar halves 74. In some embodiments, each clamping tab includes at least two holes 80. In some embodiments, the contacting surfaces of the clamping tabs 78 on one collar half 74 include positioning pegs 84 configured to engage peg seats 86 to aid in aligning each collar half 74. That is, a mating set of peg seats 86 on the clamping tabs 78 of the other collar half 74 mate with and engage pegs 84 to positively establish proper alignment and connection of collar halves 74 and speed assembly. [0040] With reference to Figs. 8-12 The outboard end of coupling collar halves 74 may include an annular lip 88. When assembled onto inlet adaptor 60, annular lip 88 protrudes between base plate 62 and connecting flange 66. The rearward-facing surface 89 of annular lip 88 engages against anchor surface 68 in order to draw adaptor 60 against end surface 30. The Annular lip 88 rotates freely around cylindrical body 64 as collar halves are threaded onto outlet threads 28.

[0041] In some embodiments, the outer surface of the collar halves 74 is knurled or striated in order to provide a solid friction grip and provide for hand assembly of valve assembly 16 onto tank outlet 26. In some embodiments and with reference to Figs. 15 and 16 extending rearwardly from one mating set of clamping tabs 78 is an end tab 90. End tab 90 may include an aperture which provides a connection point for a safety seal 92 (as illustrated in Fig. 17), which in turn couples with a hole in handle 42. The safety seal 92 provides a tamper seal to insure product is not improperly removed from the IBC 10, as well as may prevent unintended rotation of handle 42.

[0042] With reference to Figs. 8, 11 and 12, the ring seat 72 of inlet adaptor 60 may have a diameter less than that of ring seat 32 of the outlet tube 26. In these embodiments, when the valve assembly 16 is mounted on outlet tube 26 the ring seat 72 is positioned within ring seat 32 of the outlet tube. The cross-sectional diameter of the material making up O-ring 20 is greater than the protruding width of ring seat 32 on outlet 26 and is greater than the protruding width of ring seat 72 on inlet adaptor 60. The protruding width of ring seat 32 on outlet 26 is greater than the protruding width of ring seat 72 on inlet adaptor 60. End surface 30 therefore makes positive contact and fully engages with sealing surface 70 while the ring seat 72 is out of contact with outlet 26. This provides complete compression and sealing by 0- ring 20 and a complete sealing engagement between O-ring 20, end surface 30, and sealing surface 70.

[0043] With reference to Fig. 5, the outlet of valve body 40 may include outlet adaptor 100 that forms a leak resistant seal with the outlet of the valve body 40. The outlet adaptor 100 may be formed with a generally square or rectangular base plate 102 that abuts with and mounts to valve body 40. The Outlet adaptor 100 includes a cylindrical body 104 that houses a ball 106 configured to prevent fluid backflow through the adaptor 100. In the event of fluid backflow, the force exerted by the fluid pushes ball 106 into the inlet opening of outlet adaptor 100 such that ball 106 covers the inlet opening to the outlet adaptor and forms a liquid impermeable barrier that prevents fluid backflow into the valve body 40.

[0044] In some embodiments and with reference to Figs. 4 and 5, a grate 108 within the outlet of the outlet adaptor 100 provides a stop for ball 106, and prevents the ball 106 from dislodging from the outlet adaptor 100. While fluid is flowing through the outlet adaptor 100 from the outlet adapter inlet to the outlet adaptor outlet, the fluid flow pushes ball 106 into grate 108. Grate 108 seats ball 106 while still allowing fluid to flow around the outer surface of the ball 106 and through the outlet of the outlet adaptor 100. Just as the ball 106 functions to prevent fluid backflow into the valve body 40, alternatively an outlet backflow check valve 110 or an alternative check valve 112 may similarly be located in the cylindrical body 104 and used for similar function preventing unintended backflow through valve assembly 16.

[0045] With reference to Figs. 2, 4 and 5, the outlet of outlet adaptor 100 also includes a narrowed cylindrical cap locking region 114 which is configured to lock a cap 120 over the outlet of adaptor 100. Cap 120 fits over the outboard end of adaptor 100 and forms a removable closure with a liquid impermeable barrier at the outlet of outlet adaptor 100. Cap 120 carries a set of locking levers 124 that, once the cap 120 is seated on the cap locking region 114, may be pivoted to a closed position. On each of levers 124 is an eccentric raised surface that protrudes into cap locking region when pivoted to the closed position and seat against adaptor 100. When used in this manner, the locking levers 124 act as a lever by pushing against a flange on the cap locking region 114 and simultaneously compress the cap 120 against the cap locking region 114, thereby creating a liquid impermeable barrier. The locking levers 124 also each carry at their free end a locking seal ring 122 which, when locking levers 124 are in the locked position, allow for the placement a band or seal 126, thereby creating a tamper-evident seal for cap 120. In some embodiments, a lanyard 128 is connected to pallet 14 that run through a hole in a protrusion of cap 120, thereby preventing accidental loss of the cap 120.

[0046] With reference to Figs. 3-5 the valve assembly 16 includes a set of body connecting bolts 4 extend through and compress together the inlet adaptor plate 62 and the outlet adaptor plate 102. Because the valve assembly 16 is positioned between the inlet adaptor plate 62 and the outlet adaptor plate 102, the resulting compression enhances the seal between the valve assembly 16 and each of the inlet adaptor 60 and the outlet adaptor 100.

[0047] In use valve assembly 16 is mounted on outlet tube 24 of tank 12. Valve body 40 is oriented in the desired position and joined collar halves 74 are turned until they reach a sealed position. In the sealed position O-ring 20 is compressed between outlet tube end surface 30 and facing sealing surface 70. O-ring 20 is also compressed between telescopingly received ring seats 32 and 72. Sealing surface 70 on inlet adaptor 60 is drawn back against end surface 30 adding to the sealing abutment provided by O-ring 20.

[0048] Changes and modifications in the specifically described embodiments can be carried out without departing from the principles of the present invention, which is intended to be limited only by the scope of the appended claims, as interpreted according to the principles of patent law including the doctrine of equivalents.

[0049] To aid the Patent Office and any readers of this application and any resulting patent in interpreting the claims appended hereto, applicants do not intend any of the appended claims or claim elements to invoke 35 U.S.C. 112(f) unless the words "means for" or "step for" are explicitly used in the particular claim.