Patent Application
20140054322
The present invention relates generally to dispensers and refill units for dispensers and more particular to off-axis foam dispensers and refill units for off-axis foam dispensers.
Inverted foam dispensers are generally configured to provide a user with an amount of soap or sanitizer in the form of foam upon actuation of the dispenser. Inverted foam dispensers generally convert liquid material, such as liquid soap or sanitizer, into foam by aerating the liquid material as it is dispensed. Air is generally injected into the liquid material to form air bubbles in the liquid, causing the formation of foam. Inverted foam dispensers may include a replaceable refill container that is replaced after the liquid material therein is consumed by the user. Prior art inverted foam dispensers typically have a liquid inlet and a foam outlet that lie along a common axis. Accordingly, to move the foam outlet to a position that is suitable to dispense the foam on an object, the prior art offsets the neck of the container from the center of the container, which results in difficulties in manufacturing the containers, and/or containers that may not be aesthetically pleasing.
Exemplary embodiments of inverted dispenser systems and refill units are disclosed herein. An exemplary embodiment of a self-contained inverted dispensing system includes a dispenser housing. A replaceable refill unit is inserted at least partially in the housing. The replaceable refill unit has a container. The container has a neck portion. A horizontal foam pump is secured to the neck portion. The pump has an inlet orientated along an inlet axis. The pump has a liquid pump chamber and a stationary outlet orientated along an outlet axis. A fluid passage extends from the pump chamber to the outlet. The inlet axis is offset from the outlet axis and the outlet axis is located closer to the front of the dispenser than the inlet axis. An actuator is also located within the housing. In addition, an air compressor is also included in the system. The air compressor has an air passage to direct air into the fluid passage to mix the air with the fluid. The actuator is configured to drive the horizontal pump toward the front of the dispenser to dispense a fluid and the pump moves toward the back of the dispenser to recharge the pump chamber within the pump.
Another exemplary embodiment of a touch-free inverted dispensing system includes a housing and a refill unit having a stationary outlet for dispensing a fluid. The refill unit is configured to fit at least partially within the housing. The housing has a back side and a front side. The front side is located a first distance from the back side of the housing. The stationary outlet of the refill unit is located a second distance from the back side of the housing. In some embodiments, the second distance is between about 65% to 90% of the first distance. In some embodiments, the second distance is between about 70% to 80% of the first distance, and in some embodiments, the second distance is about 75% of the first distance.
An exemplary embodiment of a refill unit for an inverted dispenser includes a container that includes a neck. A horizontal foam pump is secured to the neck. The horizontal foam pump has a liquid inlet located proximate the neck of the container. A liquid pump chamber located downstream of the inlet. An outlet is located downstream of the liquid pump chamber. The outlet is offset from the inlet along at least two axis. An air compressor having an air chamber is also included. An air passage places the air compressor in fluid communication with a fluid passage of the pump. At least a portion of the air passage is located at a bottom of the air chamber. A one-way air inlet valve located at least partially within the air chamber to allow air to flow into the air chamber. The one-way air inlet valve has a cracking pressure that is high enough to cause at least a portion of the air flowing into the air chamber to be drawn in from the outlet when the air chamber is recharged.
These and other features and advantages of the present invention will become better understood with regard to the following description and accompanying drawings in which:
Container 112 has a central axis and is symmetrical the neck 201 of container 112 has a center that lies along the central axis of the container. Exemplary container 112 is a blow molded container. It has been discovered that it is easier to blow mold a container, such as container 112, if the neck 201 of the container 112 is located in the center of the container 112. Having the neck 201 in the center of the container 112 results in a more even thickness of the container walls. In addition, the appearance of the container 112 is more aesthetically pleasing because the walls can be more transparent uniform and not deflect light in an irregular pattern due to uneven flow of blown bottle. Flow lines build up in containers with offset necks resulting in an unattractive appearance. Prior art containers for inverted foam dispensers often have the neck of the container offset because prior art pumps have their inlets and outlets along a common vertical axis and to dispense fluid in a preferred location in the dispensing zone 120, the neck of the prior art containers are offset from the center of the container.
In the exemplary embodiment of the of the dispensing system 100 the container 112 is exposed and accordingly, the appearance of the container 112 is very important. In addition, because the container 112 is disposed of when it is empty, manufacturing costs are of concern when manufacturing the container 112. Blow molding of the container 112 is an inexpensive method of manufacturing the container 112 and having the neck located in the center of the container 112 provides the most aesthetically pleasing container possible with such a manufacturing process.
As illustrated in
Pump housing 202 includes a cavity 213. Located within cavity 213 is a sleeve 214. A liquid piston 218 moves in a back and forth reciprocating motion within sleeve 214 to increase and decrease the volume of pump chamber 216. Similarly, located within cavity 213 is an air piston sleeve 253. Air piston 252 moves in a back and forth reciprocating motion within air piston sleeve 253 to increase and decrease the volume of air chamber 250.
The liquid piston 218 is connected to liquid piston stem 219. Liquid piston stem 219 is connected to air piston 252. Accordingly, movement of air piston 252 also moves liquid piston 218. Air piston 252 also includes connector 254. Connector 254 mates with lost motion connector 272 when the refill unit 110 is inserted into dispenser housing 202.
Foam pump 130 includes an insert 225. The components of insert 225 are shown in
Connected to housing 202 and located below insert 225 is outlet nozzle 230. Outlet nozzle 230 retains insert 225 within housing 202. In this exemplary embodiment, outlet nozzle 230 is funnel shaped and, as foam flows through outlet nozzle 230 the velocity of the foam is increased helping to enrich the foam.
Located between air compressor chamber 250 is an air outlet passage 258. Air outlet passage 258 is elongated and located at the bottom of air chamber 250. In some embodiments, air outlet passage 258 includes a stepped down portion 259 where the air outlet passage 258 connects to pump housing 259. This stepped down portion may trap and retain residual foam and liquid that is sucked back into air chamber 250 as air piston 252 is moved back to its charged position.
In some embodiments, the dispenser housings 102, 302 (
In some embodiments, a one-way air inlet valve 256 is located in the body of air piston 253. In some embodiments, a one-way air inlet valve (not shown) is located in a wall of air piston sleeve 253. One-way air inlet valve 256 has a cracking pressure that is selected so that when air piston 252 is moved from a fully discharged position toward the fully primed or charged position (as illustrated in
Container 112 is a non-collapsible container and therefore needs to be vented to prevent vacuum pressure from preventing the pump 130 from operating properly. In this exemplary embodiment, a one-way air inlet valve 242 is provided to vent the container 112. Once vacuum pressure in container 112 exceeds the cracking pressure of one-way air inlet valve 242, one-way air inlet valve 242 opens and allows air to flow from air chamber 240 into container 112. Air is able to enter air chamber 240 through channels (not shown) in collar 242. Additional detailed descriptions of structures for venting methods and for additional venting methods are provided in U.S. Non-Provisional patent application Ser. No. 13/747,909 filed on Jan. 23, 2012 and entitled Pumps with Container Vents, which is incorporated in its entirety herein by reference.
In this exemplary embodiment, dispenser housing 102 includes a lost motion connector 272. Lost motion connector 272 is connected to actuator 270 and both are secured to dispenser housing 202 and remain with dispenser housing 202 when the refill unit 210 is removed. Actuator 270 moves in a linear back and forth motion and is driven by motor 276 and associated gearing.
Lost motion connector 272 may be adjustable in the field or at the factory. In addition, lost motion connector 2782 may have settings that range from no lost motion all the way up to a maximum lost motion. At “no lost motion” the pump dispenses a full or maximum dose. If the lost motion connector 272 is set at its maximum lost motion setting, the pump its dispenses the smallest dose allowable. Additional applicable lost motion connectors are more fully described in co-pending U.S. Provisional Patent Application Ser. No. 61/720,490 filed on Oct. 31, 2012 and entitled Foam Pumps with Lost Motion and Adjustable Output Foam Pumps, which is incorporated herein in its entirety by reference. In some embodiments, the lost motion connector 272 is not needed and actuator 270 directly connects to connector 254.
During operation, a controller (not shown) detects an object is present in dispensing zone 120 through sensor 106 and causes motor 276 to operate actuator 270 and dispense a dose of foam. Dispenser housing 202 includes batteries 278, 280. In some embodiments, batteries 278, 280 have sufficient power to actuate the actuator 270. In such embodiments, the batteries may be replaceable.
In some embodiments dispenser housing 202 includes a rechargeable device (not shown), such as, for example, a bank of capacitors (not shown), or one or more rechargeable batteries (not shown) and the refill unit 110 includes a disposable battery 282 secured to refill unit 110 by retainer 284. Dispenser housing 202 includes a connector (not shown) for connecting to the disposable battery. The connector may be, for example, a set of conductors that contact a mating set of conductors on the disposable battery 282 as is known in the art.
Housing 102 includes circuitry that allows disposable battery 282 to be used to charge the rechargeable device to power the actuator 270. Exemplary embodiments of refill units with disposable batteries and circuitry for such exemplary embodiments are shown and described in co-pending U.S. Non-Provisional patent application Ser. No. 13/770,360, filed on Feb. 19, 2013 and entitled Power Systems For Touch Free Dispensers and Refill Units Containing a Power Source, which is incorporated in its entirety herein by reference. In such a case, one or both of batteries 278, 280 may be permanent batteries that remain with the dispenser throughout the life of the dispenser housing 202. The exemplary dispenser system 100 includes a bank of capacitors that are charged in parallel and placed in series to operate actuator 270, which is fully described in the above referenced co-pending application.
Other offset foam pumps having both an air chamber and a liquid chamber that may be used in the exemplary dispensing system 100 (and 300 described in detail below) include the foam pumps shown and described in Provisional Patent Application Ser. No. 61/695,140 filed on Aug. 30, 2012 and entitled Horizontal Pumps, Refill Units and Foam Dispensers and in U.S. Provisional Patent Application Ser. No. 61/719,618 filed on Oct. 29, 2012 and entitled Horizontal Pumps, Refill Units and Foam Dispensers. Both of these applications are incorporated in their entirety herein by reference.
In addition, in some embodiments, an air compressor is permanently affixed to dispenser housing 102. In such an embodiment, liquid pumps having an inlet for receiving air from the air compressor affixed to the dispenser housing 102 are used in the dispenser systems disclosed herein. Exemplary pumps, refill units and air compressors that may be used are shown and described in U.S. Provisional Patent Application Ser. No. 61/692,290 filed on Aug. 23, 2012 and entitled Horizontal Pumps, Refill Units and Foam Dispensers with Integral Air Compressors, which is also incorporated in its entirety herein by reference.
The design of the offset axis pumps allow the container 112 to have the neck 201 located on a center of the container 112 and allows the outlet 230 to be located at a distance X away from the back surface 131 of dispenser housing 102 to the center of the outlet nozzle 230. Thus, a user may place her hands in a location suitable for foam to be properly dispensed on them from outlet 230. In one embodiment, the distance from the back surface 131 to the center of the outlet nozzle is about 3 inches and the distance from the back surface to the front surface 133 is about 4 inches. In some embodiments, the distance X from the back surface 131 to the center of the outlet nozzle 230 is between about 60% and 90% of the distance Y from the back surface 131 to the front surface 133. In some embodiments the distance X is between about 70% and 80% of the distance Y. In some embodiments, the distance X is about 75% of the distance Y.
In operation, inverted foam dispenser housing 102 is mounted to a wall (not shown), placed on a stand (not shown) or set on a counter (not shown). A user may adjust the lost motion mechanism 272 to dispense full dose or to dispense a smaller dose depending on the location of the device and the user's requirements. A refill unit 110 is lowered into housing 102 so that connector 254 is received by lost motion connector 272 and the dispenser system 100 is ready to operate.
Upon detection of an object in the dispensing zone 120 by sensor 106, a controller (not shown) causes motor 252 and associated gearing move the air piston 252 and liquid piston 218 towards the front of dispenser housing 102 thereby compressing the liquid pump chamber 216 and the air pump chamber 250. Liquid flows out of liquid pump chamber 216 around sleeve 214, past one-way liquid outlet valve 220 of insert 225, through liquid passages 221, 222 where it mixes with air flowing from air compressor chamber 250, air passages 258, 228. The air/liquid mixture passes through first screen 224 where the mixture is aerated and forms a foam as it enters area 226. The foam mixture is then forced through a second screen 224 and flows through outlet 230. Outlet 230 narrows and, accordingly, the velocity of the foam is increased as it is dispensed.
Upon completion of the dispense cycle, actuator 270 is moved backward by motor 276 and associated gearing. The lost motion connector 272 engages connector 254 to move air piston 252 and liquid piston 218 back to their fully primed position. Lost motion connector 272 may immediately engage connector 254 (if it is set at “no lost motion”) or it may move a predetermined distance, based on the dispense dose setting of lost motion connector 254, before engaging connector 254 to move pistons 252 and 218 rearward.
As air piston 252 moves rearward, air, foam, and residual liquid in passage 228, area 226 and outlet 230 are drawn into air passage 258 to prevent dripping of liquid out of the outlet nozzle 230 after the dispense cycle. In some embodiments, the residual fluid is retained in area 259 of the air passage 258. Once sufficient vacuum pressure develops in air pump chamber 250 due to the resistance to the air flow through the outlet nozzle 230, screens 224 and passage 228, one-way air inlet valve 256 opens allowing air to flow into air pump chamber 250. Once actuator 270 reaches its rearmost position, the foam pump 130 is primed and ready for its next dispense cycle.
In addition, inlet valve 210 is illustrated as a wiper valve that is normally closed. As discussed above inlet valve 210 may be a normally open or a normally closed inlet valve. Foam pump 330 is connected to the neck 401 of container 312 by collar 404. In this embodiment, collar 404 does not include channels for allowing air to enter an air chamber. The remaining components of pump 330 are substantially the same as the components of pump 130. Similarly, the internal components of housing 302 are substantially the same as those described above with respect to housing 202. In addition, the incorporated references are equally applicable to this exemplary embodiment unless noted otherwise.
In this exemplary embodiment of the of the dispensing system 300 the container 312 is exposed through the window. Accordingly, the appearance of the container 312 is important. Moreover, because container 312 is specifically designed for a controlled collapse and designed to collapse with a lower vacuum pressure than prior art collapsible containers, it is very desirable to have all of the walls a uniform thickness as opposed to having some walls thicker than others. In addition, because the container 312 is disposed of when it is empty, manufacturing costs are of concern when manufacturing the container 312. Blow molding of the container 312 is an inexpensive method of manufacturing the container 312 and having the neck located in the center of the container 312 provides the most aesthetically pleasing and uniform container possible with such a manufacturing process.
As described above, other offset foam pumps having both an air chamber and a liquid chamber that may be used in the exemplary dispensing system 300 include the foam pumps shown and described in co-pending Provisional Patent Application Ser. No. 61/695,140 filed on Aug. 30, 2012 and entitled Horizontal Pumps, Refill Units and Foam Dispensers and co-pending U.S. Provisional Patent Application Ser. No. 61/719,618 filed on Oct. 29, 2012 and entitled Horizontal Pumps, Refill Units and Foam Dispensers, which are both incorporated in their entirety herein by reference.
In addition, an air compressor may be permanently affixed to dispenser housing 302. In such an embodiment, liquid pumps having an inlet for receiving air from the air compressor affixed to the dispenser housing 302. Exemplary pumps that may be used are shown and described in U.S. Provisional Patent Application Ser. No. 61/692,290 filed on Aug. 23, 2012 and entitled Horizontal Pumps, Refill Units and Foam Dispensers with Integral Air Compressors, which is also incorporated in its entirety herein by reference.
Just as with the exemplary dispensing system 100, the design of the offset axis pumps allow the container 312 to have the neck 301 located on a center of the container 312 and allow the outlet 430 to be located at a distance X, which is far enough away from the back surface 331 of dispenser housing 102 to the center of the outlet nozzle 430 for a user to place her hands in a location suitable for foam dispensed from outlet 430 onto her hands.
In one embodiment, the distance from the back surface 331 to the center of the outlet nozzle is about 3 inches and the distance from the back surface to the front surface 133 is about 4 inches. In some embodiments, the distance X from the back surface 331 to the center of the outlet nozzle 430 is between about 60% and 90% of the distance Y from the back surface 331 to the front surface 333. In some embodiments the distance X is between about 70% and 80% of the distance Y. In some embodiments, the distance X is about 75% of the distance Y.
While various inventive aspects, concepts and features of the inventions may be described and illustrated herein as embodied in combination in the exemplary embodiments, these various aspects, concepts and features may be used in many alternative embodiments, either individually or in various combinations and sub-combinations thereof. It is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Unless expressly excluded herein, all such combinations and sub-combinations are intended to be within the scope of the present inventions. Still further, while various alternative embodiments as to the various aspects, concepts and features of the inventions—such as alternative materials, structures, configurations, methods, circuits, devices and components, software, hardware, control logic, alternatives as to form, fit and function, and so on—may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Those skilled in the art may readily adopt one or more of the inventive aspects, concepts or features into additional embodiments and uses within the scope of the present inventions even if such embodiments are not expressly disclosed herein. Additionally, even though some features, concepts or aspects of the inventions may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative values and ranges may be included to assist in understanding the present disclosure; however, such values and ranges are not to be construed in a limiting sense and are intended to be critical values or ranges only if so expressly stated. Moreover, while various aspects, features and concepts may be expressly identified herein as being inventive or forming part of an invention, such identification is not intended to be exclusive, but rather there may be inventive aspects, concepts and features that are fully described herein without being expressly identified as such or as part of a specific invention. Descriptions of exemplary methods or processes are not limited to inclusion of all steps as being required in all cases, nor is the order in which the steps are presented to be construed as required or necessary unless expressly so stated.
This non-provisional utility patent application claims priority to and the benefits of U.S. Provisional Patent Application Ser. No. 61/692,290 filed on Aug. 23, 2012 and entitled Horizontal Pumps, Refill Units and Foam Dispensers with Integral Air Compressors; U.S. Provisional Patent Application Ser. No. 61/695,140 filed on Aug. 30, 2012 and entitled Horizontal Pumps, Refill Units and Foam Dispensers; U.S. Provisional Patent Application Ser. No. 61/736,594 filed on Dec. 13, 2012 and entitled Collapsible Container; U.S. Provisional Patent Application Ser. No. 61/720,490 filed on Oct. 31, 2012 and entitled Foam Pumps with Lost Motion and Adjustable Output Foam Pumps; U.S. Provisional Patent Application Ser. No. 61/719,618 filed on Oct. 29, 2012 and entitled Horizontal Pumps, Refill Units and Foam Dispensers; U.S. Non-Provisional patent application Ser. No. 13/747,909 filed on Jan. 23, 2013 and entitled Pumps with Container Vents; and U.S. Non-Provisional patent application Ser. No. 13/770,360, filed on Feb. 19, 2013 and entitled Power Systems For Touch Free Dispensers and Refill Units Containing a Power Source. All of these applications incorporated herein by reference in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61692290 | Aug 2012 | US | |
| 61695140 | Aug 2012 | US | |
| 61736594 | Dec 2012 | US | |
| 61720490 | Oct 2012 | US | |
| 61719618 | Oct 2012 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 13747909 | Jan 2013 | US |
| Child | 13787474 | US | |
| Parent | 13770360 | Feb 2013 | US |
| Child | 13747909 | US |
