U.S. patent application number 12/208274 was filed with the patent office on 2009-01-01 for dispensing system and method, and injector therefor.
This patent application is currently assigned to Willow Design, Inc., a California corporation. Invention is credited to Constance Mae Louis, William Michael Louis.
Application Number | 20090000024 12/208274 |
Document ID | / |
Family ID | 40452463 |
Filed Date | 2009-01-01 |
United States Patent
Application |
20090000024 |
Kind Code |
A1 |
Louis; William Michael ; et
al. |
January 1, 2009 |
DISPENSING SYSTEM AND METHOD, AND INJECTOR THEREFOR
Abstract
The disclosed dispensing system, and method may be used in
combination with a faucet in communication with a water supply via
a water line, and includes a liquid dispensing device adapted to
create a liquid such as liquid soap, and water mixture in the water
line. The dispensing device may include an injector, and a soap
container for the liquid soap or other. The system may provide for
storage of liquid soap or other, and may also have the injector in
line with the faucet water line. The injector may create strong
vortices that effectively commingle the liquid soap or other liquid
with water into a thoroughly mixed solution that is discharged at
the faucet outlet.
Inventors: |
Louis; William Michael;
(Encinitas, CA) ; Louis; Constance Mae;
(Encinitas, CA) |
Correspondence
Address: |
DUCKOR SPRADLING METZGER & WYNNE;A LAW CORPORATION
3043 4th Ave.
SAN DIEGO
CA
92103
US
|
Assignee: |
Willow Design, Inc., a California
corporation
|
Family ID: |
40452463 |
Appl. No.: |
12/208274 |
Filed: |
September 10, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11280577 |
Nov 16, 2005 |
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12208274 |
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60993878 |
Sep 14, 2007 |
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61069443 |
Mar 13, 2008 |
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61070986 |
Mar 27, 2008 |
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61134328 |
Jul 8, 2008 |
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61135259 |
Jul 18, 2008 |
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Current U.S.
Class: |
4/676 ;
222/1 |
Current CPC
Class: |
E03C 1/046 20130101 |
Class at
Publication: |
4/676 ;
222/1 |
International
Class: |
E03C 1/04 20060101
E03C001/04 |
Claims
1. An injector for mixing fluids, comprising a first side of the
injector including a fluid inlet, a constricted portion, and a
first vortex generating portion; and a second side of the injector
for mating with the first side of the injector and including a
constricted portion and a vortex generating portion, wherein the
constricted portions of each side create a constrictor and the
vortex generating portions of each side are located opposite each
other when the first and second sides are assembled.
2. The injector of claim 1, wherein the vortex generating portions
of each side each include a shelf with a slot disposed upstream
from the constricted portion.
3. The injector of claim 1, wherein each side of the injector
further includes a second vortex generating portion.
4. The injector of claim 3, wherein the vortex generating portions
of each side each include a first vane disposed upstream from the
constricted portion, and the second vortex generating portions of
each side each include a second vane disposed downstream from the
constricted portion.
5. The injector of claim 4, wherein the first vanes are adapted to
create turbulence in a first direction and the second vanes are
adapted to create turbulence rotating in a second direction,
wherein the second direction is the opposite of the first
direction.
6. The injector of claim 1 further including an integrated check
valve disposed downstream the constricted portion, the check valve
including a check valve ball, a check valve cage, and a check valve
channel.
7. The injector of claim 6 further including a proximity sensor
adapted to detect the check valve ball.
8. The injector of claim 1, wherein the first side and the second
side of the injector include a plurality of corresponding alignment
bumps and alignment recesses for correctly aligning the first side
and the second side during bonding.
9. The injector of claim 1, wherein the fluid inlet includes a seep
blocker to prevent passage of a first fluid when no pressure is
applied to the first fluid.
10. The injector of claim 9, wherein the seep blocker includes an
X-shaped cut.
11. The injector of claim 9, wherein the seep blocker includes an
I-shaped cut.
12. The injector of claim 1, wherein the second side of the
injector includes a third fluid inlet.
13. A user programmable faucet, comprising: a spout for dispensing
fluid; a manual handle for controlling rate and temperature of
fluid dispensed via the spout; a first switch for controlling the
introduction of soap into the dispensed fluid; a second switch for
selecting the type of soap introduced into the dispensed fluid; a
programming button for programming the operation modes for at least
one of the first and second switches; and a programming display for
displaying the programming status.
14. The user programmable faucet of claim 13 further comprising a
third switch for selecting the operating mode of the faucet.
15. The user programmable faucet of claim 13, wherein the operating
modes of the faucet include manual, automatic, and sensor mode.
16. The user programmable faucet of claim 13 further comprising a
sensor adapted for activating fluid flow through the spout.
17. The user programmable faucet of claim 13 further comprising at
least one display associated with one of the switches.
18. A hand washing system, comprising: a faucet having a spout for
dispensing fluids; a soap injector disposed within the spout; and a
soap dispensing device adapted to provide soap to the soap
injector, the soap dispensing device including a soap pump and a
soap container, wherein the soap injector is adapted to create a
soap and water mixture within the spout of the faucet.
19. The hand washing system of claim 18, wherein the faucet
includes at least one handle to control water flow.
20. The hand washing system of claim 18, wherein the faucet
includes at least one sensor to control water flow.
21. The hand washing system of claim 18, wherein the soap
dispensing device includes an activator adapted to control the soap
pump.
22. The hand washing system of claim 18, wherein the soap
dispensing device further includes a second soap pump and a second
soap container.
23. A hand washing system, comprising: a faucet in communication
with a water supply via a water line; a no-touch soap sensor
disposed on the faucet; and a soap dispensing device adapted to be
activated by the no-touch soap sensor and create a soap and water
mixture in the water line, the soap dispensing device including an
injector, a soap pump, and a soap container.
24. The hand washing system of claim 23, further comprising an
automatic button adapted to transition the operation of the faucet
between normal operation and no-touch operation; and a no-touch
sensor adapted to automatically dispense fluid from the faucet
during no-touch operation of the faucet.
25. A hand washing retrofit kit for converting an existing faucet
in communication with a water supply via a water line into a hand
washing system, comprising: a control panel adapted to be mounted
adjacent the faucet; a soap dispensing device adapted to introduce
soap into the water line and activated by the control panel, the
soap dispensing device including an injector, a soap pump, a
microcontroller, and a soap container.
26. The hand washing retrofit kit of claim 25, wherein the control
panel communicates wirelessly with the soap dispensing device.
27. The hand washing retrofit kit of claim 25, wherein the control
panel includes a soap switch.
28. The hand washing retrofit kit of claim 25, wherein the control
panel includes an ON/OFF switch, a soap switch, a hot water dial,
and a cold water dial.
29. The hand washing retrofit kit of claim 25, wherein the soap
dispensing device includes connectors for attaching to both a hot
water line and a cold water line of the water line.
30. The hand washing retrofit kit of claim 25, wherein the control
panel includes a second soap switch, and the soap dispensing device
includes a second soap pump and a second soap container.
31. A hand washing system for a faucet in communication with a
water supply via a water line, comprising: a soap injector disposed
within the water line; a soap dispensing device adapted to provide
soap to the soap injector, the soap dispensing device including a
soap valve and a soap container; and wherein the soap is expelled
from the soap container using a propellant.
32. The hand washing system of claim 31, wherein the propellant is
a liquid.
33. The hand washing system of claim 31, wherein the propellant is
a gas.
34. The hand washing system of claim 31, wherein the system is used
with a second faucet, and further comprising a second soap injector
in communication with the soap dispensing device.
35. The hand washing system of claim 31, further comprising a
no-touch soap sensor.
36. The hand washing system of claim 31, wherein the propellant is
water from a bleed water line of the water line.
37. The hand washing system of claim 36 further including a soap
flow restrictor to meter the soap flow rate to the soap injector in
relation to the water flow rate.
38. A method of dispensing fluids from a hand washing system having
a soap injector and a faucet with an outlet end, comprising:
receiving a soap request from a user to initiate a faucet soaping
sequence; and precharging the faucet by filling the faucet volume
between the soap injector and the outlet end of the faucet with a
soap and water mixture prior to the user placing their hands in a
position to begin washing their hands.
39. The method of claim 38 further comprising the step of flushing
the faucet by filling the faucet volume between the soap injector
and the outlet end of the faucet with water at the end of the
faucet soaping sequence.
Description
RELATED APPLICATION
[0001] This application is a continuation-in-part application of
U.S. Utility patent application Ser. No. 11/280,577, which is
hereby incorporated by reference in its entirety. This application
claims priority to U.S. Provisional Patent Application Ser. Nos.
60/993,878; 611069,443; 61/070,986; 61/134,328; and 61/135,259,
which are hereby incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates in general to dispensing
devices. It more particularly relates to a dispensing device which
may be utilized to mix two fluids.
[0004] 2. Background Art
[0005] There is no admission that the background art disclosed in
this section legally constitutes prior art.
[0006] There have been a variety of techniques and devices to
facilitate the washing of a person's hands. For example, reference
may be made to U.S. patents and published applications as follows:
U.S. Pat. No. 5,199,118; U.S. Pat. No. 6,236,953; U.S. Pat. No.
6,426,701; and U.S. patent application 2007/0157978.
[0007] There have been a variety of concerns or problems associated
with the mixing or dispensing of two fluids, such as a liquid soap
and water. For example, where there is a conventional hand cleaning
basin, including those in rest rooms and kitchens, whether at home,
restaurant, retail store, hotel, hospital rooms, and others, there
are common problems in dispensing, handling, storing and cleaning
up liquid hand soap.
[0008] Conventionally, many commercial establishments have
installed infrared detector activated no-touch water faucets and
no-touch liquid soap dispensing systems as well. This helps
alleviate many aesthetic and sanitary problems for both customers
and rest room cleanup crews. But there are still major drawbacks
for some applications.
[0009] In washing their hands, users oftentimes reach to operate a
liquid soap dispenser for soap. There are many different and
inconsistent ways of pressing, pulling up or down to eject liquid
soap. If the dispenser is wall mounted to the side of the sink,
excess soap may dribble down to the floor or into a wastebasket.
There are often problems, especially with the manual systems, of
obtaining a sufficient amount but not too much, liquid soap.
[0010] If the dispenser is on the wall opposite to or adjacent to
the sink, the excess liquid soap may spill onto the sink or the
counter, and create an unwanted unsightly mess. The dispenser may
be positioned on the counter and the excess soap may pool thereon
in an undesirable way. In any case, in many applications the
inadvertent spilling or accumulation of excess soap can be
unsightly and a source of constant clean-up and irritation.
[0011] As far as soap to be used for hand washing, concentrated
liquid soaps, such as Basic H (Shaklee Corp., Pleasanton, Calif.),
are much more efficient to use and less contaminating to the
environment. The overall cost is less expensive because of the
greatly reduced volume and weight affecting manufacturing,
shipping, and storage. Use of concentrated liquid soap results in a
great savings of water and time, because they mix quicker with
water, lather up more easily, and rinse off much more quickly.
[0012] According to the Centers for Disease Control and Prevention
(CDC), the correct way to wash hands thoroughly is to first wet
them, and then to apply soap. Next, the hands are rubbed together
to mix soap and water, scrubbing all surfaces to dislodge germs.
Finally, the hands are rinsed well to remove soap and germs, and
then dry the hands.
[0013] Many people wash their hands "incorrectly." They first apply
soap onto the hands, and then turn on the water, which immediately
rinses much of the soap off before washing can even begin. In
either case, the water and soap come from separate sources, are
applied sequentially, and are mixed by rubbing the hands.
[0014] At best, the prevailing correct procedure has a number of
draw backs in certain circumstances associated with it. Water,
being applied first, may wet most of the hand surfaces, including
under the fingernails, making it difficult for the soap to
penetrate these hard-to-reach crevices, because surface tension of
the water can prevent or at least greatly inhibit the liquid soap
from entering the cracks and crevices, as did the water.
Standardized testing methods used in the United States to determine
the efficacy of surgical hand scrubs focus on the survival of
bacteria on exposed skin surfaces. Fingernail crevices are excluded
from testing by careful nail clipping and cleaning. Studies seem to
suggest that subungual areas of the hand harbor high concentrations
of bacteria. The water passage in the faucet can become
contaminated under certain circumstances by pathogens, which can
persist there undetected, to be spread to users during rinsing.
Microbes harbored inside the faucet often may survive rigorous
external cleanings.
[0015] Much of the volume of most or many hand washing solutions
may be filler added to the soap composition to make it easier for
users to control the amount of soap dispensed and as an aid in
spreading or distributing it about their hands. There also may be a
psychological aspect in that concentrated soaps may not give users
the feeling that they are applying sufficient solution to properly
perform the cleaning function. Filler, which adds to the bulk,
weight and viscosity, also adds to the cost of manufacture,
transportation, and storage. Filler also may make mixing the
solution on the hands more difficult and takes longer. Because some
of the solution may never really become well mixed, rinsing also
may take longer, resulting in wasting of water The excess soap and
water may then flow into our waste water systems and is not
ecologically desirable. The longer it takes to complete the whole
hand washing process, the more likely the washing of one's hands
may be performed inadequately and quickly, or may be skipped
entirely. Even healthcare workers in hospitals may skip hand
washing due to the time consuming nature of the process. Hence the
CDC promotes the supplemental use of antiseptic gels because they
may be more convenient than washbasin washing. However, regular
hand washing may still be necessary to remove dirt and viruses.
[0016] In an attempt to facilitate hand washing, several systems to
dispense soap and liquids into the water stream have been proposed.
U.S. Pat. No. 6,471,847 B2, titled Household Liquid Dispensing
System, describes a system for dispensing a household liquid
through an outlet of a household water system. It can be utilized
for showers, bathtubs, laundry tubs and sinks. It has an exterior
storage unit of considerable size and complexity with controls to
affect both the rate and time fluid or soap is added to the water
flow.
[0017] The focus of the system is on the dispensing of soap and
requires conscious monitoring of the procedure. The system utilizes
either a venturi or gravity feed system to add the liquid to the
water. In either case, the water pressure and flow rate have a
strong effect on the mixture ratio of fluid to water, and are
dependent upon a fairly high speed of water through the system. The
soap is not mixed with the water before exiting the outlet, such as
a spray head. So both the quantity of soap introduced and degree of
mixing with water may be variable for at least some
applications.
[0018] U.S. Pat. No. 5,961,049, titled Shower Spray with Admixture
of Ingredients and Air, accomplishes much the same function as the
above cited patent, but is limited by describing the venturi method
only. The system has very small liquid storage chambers; however,
it can also add air to the mix.
[0019] A more common approach, in which the soap and water are not
mixed together, but discharged in proximity is described in U.S.
Pat. No. 5,114,048, titled Faucet Assembly Having Integral Liquid
Product Dispenser. As stated in the patent, the dispenser
discharges the liquid products adjacent to the flow of water from
the faucet assembly. An advantage to this system appears to be that
the soap discharge is over the washbasin.
[0020] U.S. Pat. No. 5,031,258, titled Wash Station and Method of
Operation, discloses a system for automating substantially the
entire water/soap discharge operation in an effort to streamline
hand washing. It too discharges soap and water selectively from
separate outlets at the end of a faucet. Hence it has the same
limited advantage over current practice of entirely separate water
and soap dispensers as the previously cited patent.
[0021] Chemical Injector systems are used to inject fluid chemicals
directly into water stream products. Examples are devices sold by
Hammonds Technical Services, Inc., Houston Tex. These fluid-powered
motor additive injection systems are for relatively large flow
rates, starting with 7 gallons per minute. Using a motor driven by
the fluid stream, the amount of additive will always match the
existing flow rate, maintaining a constant proportion. It is
interesting to note that since the injection point of these systems
is disposed upstream of the fluid motor, thorough blending of
product and additive may be achieved.
[0022] A system for injecting or controllably metering detergent in
a dishwashing system, is disclosed in U.S. Pat. No. 5,218,988,
titled Liquid Feed System, which describes the use of a peristaltic
pump to meter a chemical at the injector port.
[0023] Numerous systems that inject one fluid into the moving
stream of a second fluid, such as garden sprayers, rely solely upon
a pressure drop in the injector to draw or suck, fluid into the
mainstream. This pressure drop may be so reduced at the flow rates,
that it may not be a reliable injection mechanism for some
applications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The features of this invention and the manner of attaining
them will become apparent, and the invention itself will be best
understood by reference to the following description of certain
embodiments of the invention taken in conjunction with the
accompanying drawings, wherein:
[0025] FIG. 1 is a partial section, pictorial view of an embodiment
of the present invention having manually controlled hot and cold
water handles, and a soap injector disposed within the faucet
spout;
[0026] FIG. 2 is a system diagram of a faucet having manually
controlled hot and cold water handles, and a soap injector in the
faucet spout, illustrated in FIG. 1;
[0027] FIG. 3 is a pictorial view of another embodiment of the
present invention, a no-touch faucet, with all functions, including
that of hot and cold water flow rates, water flow activation, as
well as initiation of the soap dispensing sequence, all controlled
by the user interacting at a distance with several sensors;
[0028] FIG. 3A is a sectional view of the indicated portion of FIG.
3;
[0029] FIG. 4 is a system diagram of a no-touch faucet as
illustrated in FIG. 3;
[0030] FIG. 5 is a pictorial view of yet another embodiment of the
present invention, a faucet having electronic control of water flow
and temperature, no-touch or automatic activation of flow from the
faucet, as well as two different soap solutions;
[0031] FIG. 6 is a system diagram of a faucet having the controls
and functionality illustrated in FIG. 5;
[0032] FIG. 7 is a pictorial view of still another embodiment of
the present invention, having a separate electronic control
retrofitted to operate a conventional manual faucet, so that an
existing installed faucet can be upgraded to have the functionality
of the present invention;
[0033] FIG. 8 is a system diagram of the faucet retrofit
illustrated in FIG. 7;
[0034] FIG. 9 is a left exploded view of the soap injector
partially shown in FIG. 1;
[0035] FIG. 9A is a perspective sectional view of the soap injector
of FIG. 9;
[0036] FIG. 9B is an enlarged detail view of the indicated portion
of FIG. 9A;
[0037] FIG. 9C is an enlarged view, rotated 180.degree., of the
seep blocker 138 illustrated in FIG. 9;
[0038] FIG. 10 is a system diagram of an experimental testbed for
the present invention;
[0039] FIG. 11 is a perspective view of an alternative embodiment
of the right side of the injector 140 shown in FIG. 9;
[0040] FIG. 11A is an enlarged perspective exploded partial view of
the bottom portion of the left and right sides of the injector, the
right side of which is shown in FIG. 11;
[0041] FIG. 11B is an enlarged perspective sectional partial view
of the two bottom portions of the injector shown in FIG. 11A;
[0042] FIG. 12 is a pictorial view of yet another embodiment of the
present invention, a user programmable faucet, having two soap
selector dials, a soap button, a pointing device, and display areas
for all of the controls;
[0043] FIG. 13 is a pictorial view of yet another embodiment of the
present invention, having the soap dispensing components in a
system box with a soap refill container;
[0044] FIG. 14 is a system diagram of yet another embodiment of the
present invention, that is a faucet retrofit for a standard manual
lavatory faucet, with the plumbing components in a system box, such
as shown in shown in FIG. 13;
[0045] FIG. 15 is a left exploded view of yet another embodiment of
the present invention, a soap injector with an integrated check
valve;
[0046] FIG. 15A is a left assembly view of the injector components
shown in FIG. 15, with the check valve ball in strong flow
position;
[0047] FIG. 15B is a left assembly sectional view of the injector
components shown in FIG. 15A, but with the check valve ball in no
flow position;
[0048] FIG. 16 is an orthographic sectional view of yet another
embodiment of the present invention, a soap injector with
integrated check valve and inductive proximity sensor, with the
check valve ball in back flow position;
[0049] FIG. 17 is a system diagram of yet another embodiment of the
present invention, that couples a point of use water heater with a
soap dispensing system in a system box;
[0050] FIG. 18 is a system diagram of yet another embodiment of the
present invention, that utilizes bleed water pressure to expel soap
from the soap container.
[0051] FIG. 19 is an orthographic sectional view of the soap
container indicated in FIG. 18 with a full refill before attaching
to the system box;
[0052] FIG. 19A is an orthographic sectional view of the soap
container indicated in FIG. 18 and shown in FIG. 19, but attached
to the system box and with a nearly empty soap bag; and
[0053] FIG. 20 is a system diagram of yet another embodiment of the
present invention, that utilizes a liquid and/or gas propellant to
expel soap from the soap container. Single water and soap sources
feed multiple faucets.
DESCRIPTION OF CERTAIN EMBODIMENTS OF THE INVENTION
[0054] It will be readily understood that the components of the
embodiments as generally described and illustrated in the drawings
herein, could be arranged and designed in a wide variety of
different configurations. Thus, the following more detailed
description of the embodiments of the system, components and method
of the present invention, as represented in the drawings, is not
intended to limit the scope of the invention, as claimed, but is
merely representative of the embodiments of the invention.
[0055] A method and system are disclosed for integrated water and
soap dispensing. According to an embodiment of the invention, the
disclosed dispensing system may include or be combined with a
faucet in communication with a water supply via a water line and a
dispensing device adapted to create a mixture of a liquid such as
soap with water in the water line. The soap dispensing device may
include an injector, and a liquid container for storing a liquid
such as a liquid soap or other.
[0056] In accordance with another disclosed embodiment of the
invention, there is provided a user programmable faucet. The
programmable faucet may include a spout for dispensing fluid, a
manual handle for controlling rate and temperature of fluid
dispensed via the spout, a first switch for controlling the
introduction of soap into the dispensed fluid, a second switch for
selecting the type of soap introduced into the dispensed fluid, a
programming button for programming the operation modes for at least
one of the first and second switches, and a programming display for
displaying the programming status.
[0057] According to another aspect of a disclosed embodiment of the
invention, there is provided an injector for mixing fluids. The
injector may include a first side and a second side. The first side
of the injector may include a fluid inlet, a constricted portion,
and a first vortex generating portion. The second side of the
injector may mate with the first side of the injector and include a
constricted portion and a vortex generating portion. The
constricted portions of each side create a constrictor and the
vortex generating portions of each side may be located opposite
each other when the first and second sides are assembled.
[0058] In accordance with still another disclosed embodiment of the
invention, there is provided a hand washing system, which may
include a faucet having a spout for dispensing fluids, a soap
injector disposed within the spout, and a soap dispensing device
adapted to provide soap to the soap injector, the soap dispensing
device including a soap pump and a soap container. The soap
injector may be adapted to create a soap and water mixture within
the spout of the faucet.
[0059] In accordance with yet another disclosed embodiment of the
invention, there is provided a hand washing system. The hand
washing system may include a faucet in communication with a water
supply via a water line, a no-touch soap sensor disposed on the
faucet, and a soap dispensing device adapted to be activated by the
no-touch soap sensor and create a soap and water mixture in the
water line. The soap dispensing device may include an injector, a
soap pump, and a soap container.
[0060] According to yet another aspect of the disclosed embodiment
of the invention, there is provided a hand washing retrofit kit for
converting an existing faucet in communication with a water supply
via a water line into a hand washing system. The kit may include a
control panel adapted to be mounted adjacent the faucet and a soap
dispensing device adapted to introduce soap into the water line and
activated by the control panel. The soap dispensing device may
include an injector, a soap pump, a microcontroller, and a soap
container.
[0061] In accordance with the invention, the soapy mess common to
washbasins may be eliminated. Hand washing may be quick and easy:
Press a button and soapy water comes out of the faucet. To rinse,
hold your hands under the same faucet for an automatic flow of
water. It may also improve sanitation and hygiene (public health)
by making washing quicker, easier, more effective, and therefore
more often actually done.
[0062] The present invention may effectively deal with most of the
problems associated with current hand washing practice; [0063] (1)
The water/soap mixture may be applied to dry hands, easily and
quickly wetting all surfaces and is drawn by surface tension into
cracks in the skin and under the nails. It may flow very easily,
being of low viscosity and in abundant supply. Disinfectant action
may be much more complete and effective. Virtually no time may be
wasted, because mixing and spreading of the solution takes but
moments. [0064] (2) Antiseptic hand wash solutions, if used, may
tend to disinfect the water passage in the faucet. [0065] (3)
Concentrated soap may be used without need for any fillers. The
generous volume of water/soap mixture may be psychologically
satisfying by itself. Reduced bulk of soaps used in commercial,
public and home situations may lead to significant economies in
manufacture, transportation and storage. Because of more the
efficient application, less soap may be used. Reduced hand rubbing
time necessary to mix, clean and rinse may results in water
savings, too. [0066] (4) The whole hand washing process may be
shortened and made much more convenient and pleasant, so it may be
done more effectively and skipped much less often. This may improve
our sanitation and hygiene with consequent health benefits.
[0067] The present invention may lend itself to applications in
addition to those illustrated here, but be easily understood in
light of the flexibility and power of the system. Much of this
adaptability and usefulness may derive from the use of electronics
and imbedded microprocessors that facilitate sophisticated behavior
to accommodate a wide range of anticipated and unanticipated uses.
For instance, the separate retrofit control 314, shown in FIG. 7,
may be placed at some distance from the delivery spout, located
where most convenient for users with special needs, accommodating
to their restricted range of reach and other factors. Many with
physical limitations find conventional mechanical faucet mechanisms
difficult or impossible to manipulate. It may be relatively easy to
adapt alternate kinds of interfaces to the soap dispensing system,
such as voice activation or electronic control mechanisms with very
low force and range of movement requirements, using potentiometer-
or rheostat-type dials, and force sensing surfaces and switches
that can be provided in a range of sizes and sensitivities--which
may be customized to individual users by simply changing
microprocessor programming. Non-traditional input controls--at
least in the realm of plumbing and water faucets--may be the use of
sliders (such as commonly seen on sound boards for audio systems)
and touch sensitive flat panel displays. Such computer-type
displays may facilitate fully user customizable input to faucet
systems that could be useful in experimental testing, such as to
determine the efficacy of various "soaps" in cleaning and
disinfecting. Not only would such systems provide complete control
and repeatability, but also may facilitate documentation of all
events. Such a system is anticipated by the testbed system depicted
in FIG. 10. Another use of the retrofit control 314, shown in FIG.
7, may be for showers. The control may be mounted on vertical
surfaces, such as shower enclosures.
[0068] Some of the design features shown in the various embodiments
of the present invention may find useful application to systems
that do not dispense soap. An example may be the no-touch faucet
system shown in FIG. 3, that may control the flow of hot and cold
water without any physical contact by the user. Another design
feature of general application is illustrated in FIG. 1. The manual
water handles may intersect with the escutcheon in such a way that
there is a smooth surface without any crack or crevice into which
fluids, dirt, or pathogens can lodge. This may be very important,
because in conventional practice, the movable handle is separated
from the escutcheon or fixed portion of the faucet by some sort of
gap to allow movement or rotation. In FIG. 1, this gap may be
filled in by a flexible silicone gasket that allows the necessary
movement of the handle so that the user can still manipulate the
faucet controls, but the gasket may be somewhat compressed in
installation so that the seal is impervious to fluids and dirt. In
addition the surface composed of the gasket and faucet structure
around the gasket may be smooth and without interruption to allow
easy and complete cleaning of the external faucet surfaces.
[0069] The gasket design as described above may work in consort
with the unique property of the present invention to control
pathogens that often contaminate the various external and internal
surfaces of most faucets often surviving rigorous external
cleanings. The soap solution as it is regularly discharged from the
faucet, may tend to act upon pathogens in the faucet water passage,
greatly reducing the spreading to users during rinsing.
[0070] It may be important that soap dispensing systems have a
method to instantly terminate the soap dispensing function. For
safety reasons, such as the need for water to cool a burn or flush
poison out an eye, there may need to be a "kill" button, or some
other intuitive way to instantly terminate the soap mode. Placing a
finger on the soap sensor for several seconds may work. Another way
may be moving the hand into and out of the sensing area of the soap
sensor. A quick succession of two or more taps on the soap switch
may accomplish the same thing, depending upon the user interface
provided.
[0071] Feedback is important to soap dispensing systems, so that
the user knows what is actually happening--if the faucet is
actually delivering a soap mixture or water only. Of course, if the
soap is a type that generates a lot of bubbles when the user is
soaping up, then the bubbles may be an indication of soap. In
addition to bubbles, there may be other ways to make the dispensing
of soap more obvious. Dye may be added to the concentrated soap, so
that the water may be slightly colored when the soap solution is
coming out of the faucet. The color may be more apparent when seen
in against a white basin with some depth of water in it. The soap
bubbles may also carry the color of the soap. If more than one kind
of soap is available from the faucet, each may have a distinctive
color, for instance yellow for hand soap and green for produce
soap. There may be downsides from using dye--in order to make it
obvious enough to even the casual observer, quite a bit of dye may
be used, adding to the volume of the concentrated soap. Dye may be
considered objectionable or disturbing to users, and may even dye
something exposed to the soap solution that is highly water
absorbent and of a very light color. Of course the dye may normally
go down the drain into the wastewater as a contaminant. Another way
to color the water, but without using dye may be to have a colored
light source, such as an LED installed in the end of the faucet,
conducting light into the water flow. There may a number of novelty
products on the market sold for fun and entertainment that do just
that, turning running water from a faucet a bright color, such as
blue. Some products may be controlled by the water temperature,
blue indicating cold and red hot water. Aside from coloring the
water itself, a flashing light proximate to the soap activating
control may indicate that soap is in the process of being
dispensed.
[0072] The soap dispensing system may be added to bidets, so that
the cleaning or washing process proceeds with more efficacy than
possible with water-only as conventionally done. The additive
concentrate should be selected so that it is non-irritating to
sensitive tissues. Various solutions may be made available for
different situations and differing aesthetic tastes, since bidets
are very personal devices.
[0073] Referring to FIG. 1, an embodiment of the present invention
as normally seen by a user looking down onto a countertop and
washbasin is shown. The integrated soap and water dispensing system
may include a soap injector 20 located internally inside the faucet
spout, between a delivery end of spout 28, and the base of spout
30. A manual hot water handle 32, and a manual cold water handle
34, may be manipulated by a user to control water delivered by a
water line 24, to the injector 20. A soap button remote 36, located
on the countertop 38, may be pressed by the user to initiate soap
delivery by a soap line, 26 also connecting to injector 24, where
the delivered soap and water may be thoroughly mixed, to flow out
of the spout into the washbasin 40. A soap indicator 37 on the soap
button remote 36 may be an LED light that flashes when the faucet
is actively dispensing soap. The rotatable hot water handle 32 may
be separated from the escutcheon 31 by a red gasket 33, made of
flexible silicon, which may form a contiguous surface with them,
sealing the gap. In a similar manner, the rotatable cold water
handle 34 may be separated from the escutcheon 31 by a red gasket
35. The gasket colors, red and blue, may serve to identify the hot
and cold water handles.
[0074] Referring now to FIG. 2, a system diagram of the present
invention of FIG. 1, the operation of the faucet is conventional,
unless or until the user presses the soap button remote 36,
bringing the below countertop components into play. But before
then, the hot water supply 42 and cold water supply 44 may feed
water to their respective manual hot and cold water valves 32 and
34, which may be controlled by the user manipulating the respective
handles for each valve. As in a conventional faucet hot and cold
water flows come together at the base of the spout 30, and continue
up the spout to be discharged at the delivery end of the faucet 28.
But, in this embodiment of the present invention, the water flow
may pass through the soap injector 20, before being discharged.
When the user presses the soap button remote 36, a signal may be
transmitted to the microcontroller 50, the switch data may be sent
by radio signals, in which case the soap button remote 36, if it
contains a battery powered transmitter (not shown), may be moved
about freely within radio range of a receiver (not shown)
associated with the microcontroller 50. If the soap button remote
(in the system diagram, "soap switch") 36 is fixed in place on the
countertop 38, the connection may be by electric wire, eliminating
the radio link. The microcontroller 50 may be preprogrammed to
operate the soap delivery system which may have a soap pump 46,
which may send soap stored in the soap container 48 through the
soap line to injector 26. The soap injector 20 may mix the soap
into the water flow before the mixture is discharged. NOTE: This
and the other system diagrams are diagrammatic and do not show
electric components such as power supplies, electric lines, motors,
and electronic circuitry; nor do they show various displays
providing feedback to the user, some of which may be controlled by
the microcontroller, and others integrated with the input devices
and operated directly without mediation. Among the several types of
pump that would be suited for the soap pump 46 may be small
peristaltic tubing pumps, such as dosing pumps supplied by
Automated Aquarium Systems, Inc., Tustin, Calif. Such pumps may be
highly resistant to back pressure that may occur should the faucet
be blocked when water is flowing into the soap dispensing system.
They may make a positive seal, so soap may not be accidentally
discharged to the injector 20.
[0075] Referring now to FIG. 3, another embodiment of the present
invention as normally seen by a user looking down onto a countertop
and washbasin is shown. This no-touch faucet may not only feature a
fully automatic no-touch soap dispensing system, but also no-touch
hot and cold water control. The automatic sensor 170 may control
flow from the faucet in the conventional automatic faucet
way--turning on when the sensor detects an object (normally hands)
over the washbasin. The soap sensor 68 may trigger the soap
dispensing system function when a hand is held or waved over the
sensor. A soap indicator 169 may be an LED light that flashes when
the faucet is actively dispensing soap. For hot water, the user may
easily place an open hand, face down, above the hot water symbol
158, controlling the hot water flow rate by varying how far the
hand is above the hot water symbol 158, which may be atop and
centered on the hot water raised spherical surface 162. Within the
several-inch range that the hot water sensor 154 responds to, the
higher the hand, the more hot water. Moving the hand within close
range (less than an inch) above the hot water symbol 158 shuts off
the hot water. The user may instantly control or modulate the water
flow by moving a hand horizontally into the sensing area, which,
for easy visualization by users, may be described as a column
several inches wide extending from just above the hot water raised
spherical surface 162. The hot water display 164 may show how
strong the water flow is. When the display is dark, the water may
be off; when the full semi-circular width is all bright red, the
water may be full on. Intermediate flow rates may be indicated by a
smaller colored area, such as shown here by the cold water display
166. (There is a cold water sensor 156, on the side of the faucet
opposite the hot water sensor, but it is not shown in this figure.)
Cold water may be controlled in the same manner as hot water, but
with the user's hand above the cold water symbol 160. Note: The hot
water symbol 158 and the raised spherical surface 162 may be visual
clues, targets, or reference points to the user, and may be
otherwise non-functional. Both the hot water sensor 154 and the
cold water sensor 156 may be composed of an array of infrared
sensors, each designed to detect objects within a specific volume
of space with overlapping zones, so that taken as a whole, the
array may sense the location of a hand with sufficient resolution
to satisfy users that they have good control over water flow. When
flow has already been established by the user, the hot and cold
water flows may maintain the same rate until either a preset period
of time has lapsed without additional user input, in which case, to
conserve water and to reduce the possibility of water damage from a
continuously running faucet, the faucet may automatically shut off,
or the other case being when the user reintroduces a hand above a
water control sensor, such as the hot water sensor 154. In the
latter case, the system may recalibrate itself, so that it takes
the new hand position above the sensor as setting the current rate
of flow. This may be true, so long as the user introduces the hand
within the normal operating range of the sensor. Thus, the user may
actually feel "in control" of the water flow. Easily moving the
hand up or down may have the expected effect--either increasing or
decreasing the flow--not suddenly jumping to a different rate,
because the user has not introduced the hand precisely at the same
distance over the target, such as the hot water symbol 158, that
the hand had been when the rate was set previously. Of course this
may change the range of hand movement available before reaching
both of the extremes (off and full-on), but may be instinctively,
if not intellectually understood by the user. An analogy would be
that when a user reaches out to adjust the flow of water with a
manual handle or knob that is essentially circular without any
protruding handle, the user may simply turn it one way or the other
to effect the desired change, without paying attention to how far
(degrees of rotation) that the faucet is already turned from the
closed position. Some systems like this have to be counterintuitive
(intellectually) to interface correctly with the people's intuitive
(instinctive) behavior.
[0076] Referring now to FIG. 3A, which clearly shows the somewhat
subtle cross-section of the raised spherical surface 162.
[0077] Referring now to FIG. 4, a system diagram of the present
invention of FIG. 3, the operation of the faucet may be designed to
be "transparent" to the user. That means they may not have to think
about how to use it--it just works in ways that are obvious and
expected. Of course, even in appearance, it may differ from
conventional faucets, primarily by not having any handle to control
hot and cold water flow. To a large degree, the system design,
including how it is programmed may be essential to achieving the
goal of satisfying the user. Starting with the hot water supply 142
and the cold water supply 144, the flow of water through the faucet
and intervening soap dispensing system may be controlled by
proportional solenoid valves, which are not simply on/off valves as
typically associated with solenoids, but fully proportional with a
smooth range of flow rates from full open to closed. IQ Valves, a
division of Technocraft, Inc., Melbourne Fla. may be a source of
such products. A microcontroller 188 may control these valves with
inputs from the hot water sensor 154, the cold water sensor 156,
the soap sensor 168, and the automatic sensor 170. Also controlled
by the microprocessor may be the soap pump 146 for delivering soap
from the soap container 148 to the soap injector 120 from which
water or a soap solution flows out of the faucet spout 152.
[0078] Referring again to FIGS. 3 and 4, a system and method to
quickly and easily program or reprogram the microcontroller 188, is
described. Taking advantage of the capabilities of the automatic
sensor 170, which may include two-way communication, bringing a
hand held, portable device (not shown) within the operating range
and in front of the sensor 170, may enable the portable device,
which is equipped with a sensor with similar capabilities to
exchange information. The portable device may store computer code
that contains instructions for the microcontroller to affect the
desired behavior of the soap dispensing system. The operator of the
portable device may activate control(s) so that the device detects
signals (such as infrared) sent out by the sensor 170 in normal
detection function. In response, the portable device may send out a
coded signal that may be read by the sensor 170, and interpreted as
the signal for the sensor 170 communicating with the
microcontroller 188, as components of the soap dispensing system,
to receive and store programming information. After transmission of
a coded signal sequence, the soap dispensing system may send back
to the portable device an encoded value that corresponds to a check
function of the programming information package it was sent. If the
portable device reads the same encoded value it had calculated
would be associated with the information it had just sent, it may
tell the soap dispensing system that the exchange is completed.
This entire sequence may take a matter of seconds and involve no
physical contact between the programming device and the soap
dispensing system, so that a number of soap dispensing systems may
be programmed in a short time by one person.
[0079] Referring now to FIG. 5, another embodiment of the present
invention as normally seen by a user looking down onto a countertop
and washbasin is shown. This tilt handle kitchen faucet 292 may
function like a conventional mechanical faucet until the automatic
button 204, is pressed, making the faucet responsive to the
automatic sensor 294, then the faucet may function like a
conventional automatic faucet. The faucet mode may be indicated by
the automatic mode indicator 206. Pressing either the soap #1
switch 296 or soap #2 switch 200 may activate the soap dispensing
system, so the faucet may also dispense soap. Pressing on an
already selected soap switch, as indicated by the soap #1 indicator
298 or the soap #2 indicator 202 may switch the faucet back to
water only. The soap #1 indicator 298 and the soap #2 indicator 202
may flash when the faucet is actively dispensing the respective
selected soap. The automatic sensor 294 may not be fixed, but
rotate with the spout. This may be convenient and easily understood
by the user. The single handle water control 290 may be moved by
the user up-and-down for flow control, hot and cold water 290A, and
pivoted from side-to-side for temperature control, hot and cold
water 290B. This type of handle and motions are conventional, but
in this embodiment of the present invention, the lever motions may
not be directly linked to mechanical valving, but may operate
electronic input devices such as potentiometers, which may send
electrical signals to the microcontroller 288, which may be
programmed to respond in various ways to user inputs, not
necessarily in direct proportion to input by the user. For
instance, when the faucet is delivering soap #1 as a mixture, which
might be a produce cleaning soap, the flow rate may be
automatically reduced for better control in washing off fruit or
vegetables. When the user presses the soap #1 switch 296, to return
the faucet to water only, the flow rate may then be automatically
increased to the previously user established rate. If so
programmed, even while delivering a soap mixture, the user may
retain the ability to control the flow rate by means of the single
handle water control 90. When the faucet is delivering water only,
the user may always retains full control over water flow by means
of the single handle water control 290.
[0080] Referring now to FIG. 6, a system diagram of the present
invention of FIG. 5, it may be quite similar to FIG. 4, but with
FIG. 6 having two additional inputs, the automatic button 204 and
the soap #1 switch 296, which may be used to operate the soap #2
pump 280, requiring the two soap injector 274, which has two soap
lines to injector 220 instead of one.
[0081] Referring now to FIG. 7, another embodiment of the present
invention as normally seen by a user looking down onto a countertop
and washbasin is shown. What's new here is not the kitchen faucet
312--it's completely conventional, and works like a standard
mechanical faucet--until the retrofit control 314, is turned on by
pressing the retrofit control on/off switch 320. This retrofit
control 314 may be attached to the sink top surface 308 or
countertop with electrical connections passing through a hole to
the soap dispensing system under the counter. When the retrofit
control 314 is on, as may be indicated by the retrofit control
on/off indicator 322, the hot water dial 316 and cold water dial
318 may control water and soap solution temperature in the
conventional way. Pressing any of the three buttons or switches,
the water only switch 324, the soap #1 switch 396, or the soap #2
switch 300, may activate that particular discharge. Another press
may turn it off; pressing one of the other two buttons may
immediately switch to that discharge. Selection of soap #1 may be
indicated by the soap #1 indicator 398; and selection of soap #2
may be indicated by the soap #2 indicator 302. Before using the
retrofit control 314, the manual hot water handle 332 on the faucet
312 may be turned off, and the manual cold water handle 334 may be
turned on full, thus assuring that all the fluids delivered by the
faucet 312 pass through or come from the soap dispensing system. In
order to return to full manual operation of the faucet 312, the
retrofit control 314 may be turned off by pressing the retrofit
control on/off switch 320. Should the manual cold water handle 334
be closed either by accident or by intent while the soap dispensing
system is in operation, water pressure may build up within the soap
dispensing system to the pressure of the higher of the two incoming
lines (from the hot water supply 342 or from the cold water supply
344). Because of this, the soap dispensing system may be able to
withstand such pressures which can range up to over 100 psi.
Normally, embodiments of the present invention are not exposed to
other than minimal internal pressure, because they may deliver
fluids to a line that is open all the way to the delivery end of
the spout. In "normal" operation, with the retrofit control 314
turned off, the proportional solenoid valve for hot water 384 may
be closed, and the proportional solenoid valve for cold water 386
may be open. These valves may be respectively, "normally closed,"
and "normally open"--the states of the valves when no electric
current is applied to operate them. This, in "normal" operation,
the cold water may be routed through the soap dispensing system at
the full pressure of the cold water supply 344. An easy-to-install
retrofit kit may make it possible for those who wish, to keep their
existing faucet and still upgrade to the soap dispensing
system.
[0082] Referring now to FIG. 8, a system diagram of the present
invention of FIG. 7, it is clear that both the water from the hot
water supply 342 and from the cold water supply 344 may be diverted
through the soap dispensing system before entering the faucet 312
through the cold water line. The hot water "T" connector 326 may be
spliced into the original hot water line; the original cold water
line may be cut, and the cold water connector 328 may splice the
line to the soap dispensing system at the hot water proportional
solenoid valve 384; the retrofit water connector 330 may connect
the soap dispensing system to the cold water line extending to the
faucet 312. The hot water check valve 332 and the cold water check
valve 333 may eliminate the possibility that water could flow back
into either the hot water supply 342 or the cold water supply 344
looping through the soap dispensing system. This may happen if the
user closed the manual cold water handle 334 when both hot and cold
water are entering the soap dispensing system. The check valves may
also stop any stray soap from entering the water supply--which may
be mandated by plumbing code.
[0083] Referring now to FIG. 9, an exploded view, internal details
of the soap injector 420 are shown. There may be two halves or
sides to the injector, the left side of injector 434, and the right
side of injector 440. As shown here, only the left side of injector
434 may have a soap hole 436, a soap line to injector 426, and a
seep blocker 438. This type of injector may deliver only one kind
of soap. The two soap injector 374, as indicated in FIGS. 8 and 10
may be essentially the same, but with both halves the same as the
left side of injector 434, so both sides have a soap hole 436, a
soap line to injector 26, and a seep blocker 438. Each side of the
injector 20 or the two soap injector 374 may have a clockwise vane
450 and a counterclockwise vane 442, which may act upon the fluids
flowing through the injector so they are thoroughly mixed together
into a consistent solution. The two sides of the injector may be
located in correct alignment for bonding by several alignment bumps
446, that fit into several alignment recesses 444.
[0084] Referring now also to FIG. 9A, a perspective sectional view
of the soap injector 20. The water flow into injector 454 may enter
through the water line to injector 24, which is bonded to the
injector 20. The soap flow into injector 452 may come in through
the soap line to injector 26. The flow out of injector to faucet
456 may exit through the water line to faucet 22, which is bonded
to the injector 20.
[0085] Referring now to FIG. 9B, an enlarged detail view of the
indicated portion of FIG. 9A, the details of the attachment of the
soap line to injector 26 are shown. It may terminate in the base of
soap line to injector 458, which may be bonded to the left side of
injector 434, capturing the seep blocker 438, which may be made of
a flexible material, such as silicone rubber.
[0086] Referring now to FIG. 9C, the opposite side of seep blocker
438, shown in FIG. 9 is enlarged to the same scale as FIG. 9B.
There may be a cut 460 in seep blocker, which may be a clean cut
(no material removed) through the thin membrane, allowing the
passage of soap when pressure is applied by the soap pump 376. In
this case the cut may be in the form of an "X", while other forms
of cut may be used, such as a simple "I" cut, which may be
conceived of as the "X" with one leg left off. The "X" type of cut
may open with less pressure than the "I" cut. The purpose of the
seep blocker 438 may be to keep soap in the soap line to injector
26 from seeping or diffusing into the water in the injector when no
soap is being pumped. The conical space downstream of the seep
blocker 438 may be part of the seep hole 436, and designed to allow
the flexing of the membrane and it's opening to allow soap to pass
through. This space may be very small, so that only a minuscule
amount of soap can commingle with water standing in the injector.
Thus a water only discharge may have so little soap that it will be
of no consequence in normal operation. This may also keep soap from
getting into the plumbing upstream of the soap dispensing system
should there be a failure in water pressure. If this were not so,
some kind of anti-siphon valve may be required in soap dispensing
system installations that connect with municipal water supplies.
The normal position of the seep blocker 438 may be with the cut in
seep blocker closed due to the plastic memory of the flexible
material. Varying the thickness and type of cut in the membrane may
vary the force of closure. Even very thin membranes may be quite
resistant to allowing the passage of soap.
[0087] Referring now to FIG. 10, a system diagram of the present
invention in the form of a testbed or experimental setup is shown.
This system is disclosed because some of the features may be useful
not only for technical and scientific studies beyond the
development and documentation of soap dispensing systems
themselves, but may also have application in industrial settings. A
feature of this system may be the presence of the flow meter 470.
This may provide essential feedback, actually measuring the true
rate of water flow through the system. In other systems, certain
assumptions are made, primarily concerning the incoming pressure
from the water lines. Based on empirical experience for most
purposes, a reasonable prediction can be made as to flow rates (as
controlled by the proportional solenoid valves) that will occur at
certain valve settings. In such cases, obviously, both knowing the
water line pressure and minimizing deviations from that line
pressure may result in more predictable soap dispensing system
performance. In general such other systems assume water flow rates
and inject soap accordingly to achieve the desired mix of soap and
water. The experimental testbed may also feature a pressure
regulator 462, which may stabilize water in the system at a set
pressure for consistent results. Most relatively inexpensive
regulators have a tendency to leak, so that the pressure internal
to the soap dispensing system may build up to be higher than
anticipated when the proportional solenoid valve 386 is throttled.
The solution may be a controlled leak, determined by setting of the
manual ball valve 464, emptying the "leaked" water into the drain
468. The rate of leakage may be determined visually observing the
rate of water flow into the drain 468. Pressure build up in the
line upstream of the proportional solenoid valve 86 may make the
valve somewhat unstable in it's response. In other words, the valve
may most accurately meter water flow when water pressure feeding it
is known and relatively constant. The pressure test gage 466 may
allow for monitoring of the pressure upstream of the proportional
solenoid valve 386.
[0088] Operation of the testbed confirmed several sequencing
related elements of special import to effective operation of the
present invention:
[0089] Faucet precharging occurs by providing a short burst of soap
solution immediately after the user initiates a soap request. The
purpose of this short burst of soap solution is to fill the faucet
volume between the injector and the outlet end of the faucet with
the soap mixture, so that when the user places their hands under
the faucet, the proper soap mixture may be all they receive. If
this was not done, the volume between injector and outlet would
normally be filled with water only, so if the user placed hands
under the faucet to soap up, they might first receive some water
before the soap solution arrived, so that some of the initial
wetting of the hands could be with water only, which may adversely
affect the hand washing process.
[0090] The faucet precharging may occur in response to the user
activating the soap button. After activation of the soap button,
soap may be immediately provided to the soap injector and the water
valve may be controlled to allow a flow of water through the soap
injector to create a soap and water mixture for a predetermined
period of time. During this predetermined period of time, the water
only filled in the volume between the soap injector and the outlet
end of faucet may be forced out of the faucet and replaced by the
soap and water mixture. At the end of the predetermined period of
time, the flow of soap to the soap injector and flow of water
through the in soap injector may be stopped. Once the user
initiates washing their hands, the soap and water mixture may
immediately flow from the faucet.
[0091] Faucet flushing occurs at the end of the faucet soaping
sequence and may normally not be noticed by the user, and may have
minimal effect on the cleaning process. The purpose of this action
is comparable to Faucet Precharging, but with the purpose of
filling the volume between injector and outlet with water only, so
that the next time the faucet discharges fluid, it may be water
only, which is appropriate for the next discharge, which is Faucet
Watering.
[0092] During the faucet soaping sequence, soap may be provided to
the soap injector and the water valve may be controlled to allow
water to flow through the soap injector for a first predetermined
period of time to provide the soap and water mixture out the faucet
to facilitate the user washing their hands. At the end of the
faucet soaping sequence, the flow of soap to the soap injector may
be stopped while the flow of water through the soap injector may
continue for a second period of time. During this second period of
time, the soap and water mixture may be purged from the soap
injector and the volume between the soap injector and the outlet
end of the faucet and replaced with water only to insure that water
only flows from the faucet during the next flow of fluid from the
faucet.
[0093] It is to be noted that both faucet precharging and faucet
flushing may require less water if the volume of the faucet water
passageway from the injector to the outlet end of the faucet is at
a minimum. A smaller diameter and shorter water passageway may thus
be desirable. In this regard, the faucet illustrated in FIG. 1, in
which the injector is in close proximity with the faucet discharge
may be a nearly optimal design.
[0094] Referring to FIG. 11, a perspective view, internal details
of the right side of an alternative embodiment of the soap injector
20 is shown. The right and left sides of the injector may be
similar, in the same way the right and left sides of the injector
shown in FIG. 9 may be similar: either one side or both sides may
have a soap hole 436, a soap line to injector 26, and a seep
blocker 438 as shown in FIG. 9. The two sides of the injector also
may be located in correct alignment for bonding by several
alignment bumps 446, that fit into several alignment recesses 444,
again as shown in FIG. 9. But instead of utilizing vanes to act
upon the fluids flowing through the injector, this embodiment may
utilize two slots, slot in right side of injector 476 and slot in
left side of injector 480, both of which are in their respective
shelves, shelf in right side of injector 474 and a shelf in the
left side of injector (not shown). Again, please note that both the
right and left sides of the injector may be identical. Water
entering the injector may pass through both slots and may be
directed in a counterclockwise rotation by the angled shape of the
slot. This rather violent swirling action may act upon the fluids
flowing through the injector so they may be thoroughly mixed
together into a consistent solution. The soap may enter this
injector in the same manner soap enters the injector shown in FIG.
9. However, there may be no additional mechanical stirring devices,
either vanes or slots downstream of the soap injection. The
swirling and turbulence created by the slots may be sufficient to
accomplish the mixing.
[0095] Referring now to FIG. 11A, an enlarged perspective exploded
sectional view of the bottom portion of the left and right sides of
the injector. The bottom portion of sectioned left side of injector
478 and the bottom portion of sectioned right side of injector 482
are shown oriented as they may be before being bonded together. The
slot in left side of injector 480 is also shown.
[0096] Finally, referring to FIG. 11B, an enlarged perspective
sectional view of the two bottom portions of the injector, 478 and
482 of FIG. 11A are shown here bonded together, with a seam between
left and right sides of injector 484, where the two sides come
together. This figure shows the relationship of the two slots, 476,
and 480.
[0097] FIG. 12 is a pictorial view of a user programmable faucet,
but may still be usable as a "standard faucet". By manipulating the
pointing device 698, and referring to the display/programming and
status 600, the degree of sophistication in programming may be
selected by the user, such as increasing the concentration of soap
for handwashing or creating a unique sequence of
soaping/pausing/rinsing for cleaning a number of items in assembly
line fashion. The faucet may respond differently to different
users--one wanting a lot of soap for handwashing and long time for
scrubbing up--another choosing little soap and a quick scrub time.
Or the soap switch 690 may be programmed to give a "quickie wash"
when given a tap and a "standard wash" when pressed normally. The
display/programming and status 600 may show any desired
information, including new or updated material provided by soap
manufacturers to facilitate use of their products; here it shows
the amount of the various products in the under counter
containers.
[0098] The display on the right side of the faucet base may have
three areas: the left display area/soap switch 692 relating to the
soap switch 690; the middle display area/selector dial 1 694
relating to the selector dial 1 686; and the right display
area/selector dial 2 696 relating to the selector dial 2 688. An
initial press on the soap switch 190 may be programmed to turn on
the faucet, with subsequent single presses selecting the chosen
type of soap as selected by selector dial 1 686, as indicated in
the display area/selector dial 1 694--as shown here, PRODUCE. Two
or more quick presses may turn off the soap so that the faucet
delivers water only. Turning selector dial 2 688 through 3 detent
positions from left to right may select the mode; MANUAL, AUTOMATIC
(as shown here), or SENSOR.
[0099] Referring to FIG. 13, a pictorial view of a system box with
injector 802, and replaceable soap refill container 808 is shown.
Also refer to FIG. 14, a system diagram showing the system box 802
of FIG. 13 in a soap dispensing system. The system box 802 may
normally be attached under the counter with the line from the hot
water supply 842 disconnected from the faucet and reconnected to
the "in" connection (from supply) shown in FIG. 13. A new hose may
be connected between the system box 802 and the hot water side of
the faucet, and the manual hot water valve 832. The soap refill
container 808 may be screwed in place on the system box with
injector 802, and a soap button remote 36 as shown in FIG. 1 may be
placed on the counter top 38, also shown in FIG. 1. After attaching
a new refill, the priming switch 804 may be pressed to purge air
out of the system, and the soap dial 806 may be set for the desired
concentration. The refill light 810 may come on when the soap level
in the soap refill container 808 drops below a predetermined level,
giving the user sufficient warning to refill before running out of
soap.
[0100] When the soap refill container 808 is unscrewed from the
system box with injector 802, the soap intake tube 812 may be
exposed. This tube may draw soap from the container to feed the
soap pump 846. But it may also function as a sensor to determine
when the level of soap lowers to a point when the event is signaled
to the microcontroller 888. The non-conductive plastic soap intake
tube may have two conductive strips on either side separated by
several millimeters. These strips may run the length of the tube,
each connecting inside the soap refill container 808 to electronic
circuitry that determines if there is current flow between the two
strips. The electronics may detect an open or closed circuit with
the water in the soap acting as a conductor bridging the two
strips. Actually, the conductors may be in two segments, an upper
part of conductor 814 and a lower part of conductor 818, separated
by a conductor cut 816 that electrically isolates the two parts of
the conductors. The cut in the strips may determine the critical
soap level Once the soap drips below the conductor cut 816, the
circuit may be open without any current flow between the strips.
(The continuation of the conductive strips below the cut may purely
be for convenience in manufacture. It may be easier to mechanically
remove a small section of the strips in a simple and quick
machining operation than removing the entire conductor below the
cut.)
[0101] Referring to FIG. 15, a left exploded view of a soap
injector with an integrated check valve shows the three components
of the check valve: a stainless steel check valve ball 726, a tough
plastic check valve cage 724, and a flexible (silicone rubber)
check valve channel 728. These components may be captured inside
two check valve injector case sides 722, with a venturi 723, and
two counterclockwise vanes 742 for mixing soap and water. FIG. 15A,
a left assembly view of the components of FIG. 15, shows that with
sufficient flow of water through the injector, the check valve ball
in strong flow position 730 may be carried up against the check
valve cage stop 732 at the top of the check valve cage 724 allowing
water to pass through the injector. As shown in FIG. 15B, a left
assembly section view of the components shown in FIG. 15A, when
water flow stops, the check valve ball may be drawn down by
gravity, settling onto a tapered hole in the check valve channel
728. The check valve ball in the no flow position 734 may rest on
the curved intake lip making a secure seal. Any reverse flow or
backflow caused by a service interruption in water may draw the
ball down into the check valve channel 728. The gentle taper may
allow the ball easy entry with very low backpressure. As shown in
FIG. 16, an orthographic sectioned view of a soap injector with
integrated check valve and inductive proximity sensor, with even
higher suction, the check valve ball in back flow position 740 may
finally stop at the radiused end of the hole, where water enters
the injector. The ball may be forced up, out of the channel with
resumption of normal water flow pressure. The unique design with
the flexible channel may distinguish this check valve. The chosen
durometer of the rubber and the taper of the hole may determine the
pressures necessary to firmly lodge and dislodge the ball.
[0102] Conventional check valves have a spring pressing on the ball
to force it against a metal or hard plastic bore hole. Check
valves, often double check valves, are backflow prevention devices
designed to protect water supplies from contamination. Such valves
are commonly required at the building level, and lacking such,
residential installations of soap dispensing systems, as in the
present invention, in which soap and water delivery systems are
connected, will likely be required by plumbing codes to have a
check valve device associated with them.
[0103] FIG. 16, an orthographic sectioned view of a soap injector
with integrated check valve and inductive proximity sensor shows
the check valve ball in back flow position 740 located in the
sensing field 738 of the inductive proximity sensor 736 that may
detect the presence of the stainless steel target when it enters
the sensing field 738, which may detect the ball when it is between
the no flow position 734 and the back flow position 740. The
inductive proximity sensor 736 may not detect the presence of the
target when it is in the strong flow position 730, allowing for the
operation of the soap pump to inject soap into the water. Whenever
the ball is detected by the sensor, the microcontroller may be
programmed so that the soap pump will not operate. Thus the user
may press on the soap switch, but the system may not respond. This
may also happen with cold water flow rates too low for a proper mix
of soap and water, which, appropriately, will not lift the check
valve ball 726 out of the sensing field 738. Another reason for
having this lock out behavior of the soap pump with low or no flow
water situations may be to avoid a build-up of pressure inside the
injector that could cause rupture or other system failure. If soap
were pumped and the manual hot water valve is closed, there may be
no place for the soap to go.
[0104] FIG. 17 is a system diagram showing a point of use water
heater coupled with a soap dispensing system. The system may
perform as a conventional point of use water heater until the soap
switch 936 is clicked. The flow meter 970 and temperature sensor
942 may be integral with most water heaters 944, so that the heater
may maintain the desired water temperature over a range of water
flow rates as determined by the user manipulating the manual hot
water valve 932. (The greater the flow rate, the more heat may be
required to heat the water.) Note that this system may allow the
user to obtain water at a different temperature when selecting the
soap dispensing function than was flowing just prior to clicking
the soap switch 932. This is appropriate because the faucet may be
being used for a different function--washing, as opposed to rinsing
for example.
[0105] We may take advantage of the flow meter 970 to modulate the
rate of soap pumping to adjust the flow of soap up or down with the
water flow rate, maintaining a constant soap concentration at all
flow rates above some preset minimum.
[0106] FIG. 18 is a system diagram of a soap dispensing system that
may utilize bleed water pressure to expel soap from the soap
container. No soap pump may be needed! This system may take
advantage of the inherent flow restricting property of the venturi
design of the injector. Comparing pressures upstream and downstream
of the injector venturi, the pressure will be greater upstream.
Depending upon system requirements, the internal shape of the
injector may be actually designed to create additional drag on the
water passing through to boost the relative pressure differential.
FIG. 18 shows the bleed water line coming off before the Injector.
In practice, it may be convenient to integrate the bleed line into
the injector 1020 itself. The pressure applied to inject soap into
the water stream may vary dynamically with the flow rate out of the
faucet. The system may automatically maintain a stable
proportionality or dilution of soap with water!
[0107] Water flowing through the bleed water line may enter the
attached container with soap bag 1046, displacing soap from the
container. A soap valve 1050 may turns the soap flow on or off, so
that the delivery of soap may occur only when desired for correct
system operation. A soap flow restrictor 1048 may be used to meter
the soap flow rate in relation to the water flow rate. There may be
various size fixed or interchangeable restrictors with variously
sized orifices, as appropriate for the viscosity and type of soap
and purpose of the soap to control the flow rate. A needle valve
may be appropriate for this purpose to precisely regulate
relatively small flow rates. The soap dial 1006 may allow the user
to set the soap concentration.
[0108] FIG. 19 details the container with soap bag 856, showing a
full soap bag 856 before attaching the refill container 852 to the
refill plug 858, which is part of the system box with the injector
802 of FIG. 13. The user may insert the soap connector 854 into a
socket in the middle of the refill plug 858. Then the user may
attach the container to the system box. An O-ring 860 may seal the
connection.
[0109] After attachment, the user may press the purge button, which
may causes the system to operate as if dispensing soap for an
extended interval, such as 15 seconds, to fill the space above the
soap bag 856 with water from bleed water line 878. In normal use,
the consumption of soap leads to the situation shown in FIG. 19A,
in which bleed water has come in by the bleed water line 874, with
water serving as a propellant to enter the space above the empty
portion of soap bag 870. This may displace the air trapped in the
system when the refill container 852 was attached. The air may
easily escape out the air vent 864, past the ball float (vent open)
at 862. But when the bleed water reaches the ball float, it may
float up--ball float (vent closed) at 880 and seals the air vent
864. Incoming water 878 from bleed water line may force soap out
the soap line with soap 876, so that it may be mixed with water in
the injector.
[0110] FIG. 20 is a system diagram of a soap dispensing system that
utilizes a liquid and/or gas propellant to expel soap from the soap
container. Single water and soap sources feed multiple faucets.
Soap may be forced out of the soap container 1282 with propellant
and soap to the injectors 1220 by a propelling or pressurizing
agent. Liquefied gas may have the advantage of maintaining a
consistent pressure as the gas expands to displace the soap.
[0111] The soap may be physically separated from the gas by a
piston barrier or contained within a flexible bag (bag-in-can)
similar to the arrangement of FIG. 19, guaranteeing that only pure
product may be dispensed. Propellant and soap refills may be
supplied in a single container, as in pressurized aerosol cans,
which, after being secured to the system box with injector 802,
supply soap as needed. Alternatively, a non-pressurized refill
container may contain only soap with system pressurization coming
from a separate container, replaced at longer intervals.
[0112] The system is designed with standard rates of water and soap
flow when dispensing a soap/water mixture. If desired, water only
flow rates may be user controlled.
[0113] From the description above, a number of features of the
present invention may be present in the disclosed and other
embodiments of the present invention. One or more of these features
include, but are not limited to the following for the integrated
soap dispensing system: [0114] (a) The operation of the system by
users may be as simple, as quick and as effective as possible. This
is important because most users do not consider hand washing a
pleasant experience to be indulged in for pleasure, like showering.
The system may minimally obtrude on the appearance of the wash
station which also makes it more attractive to users and those who
must maintain it too. [0115] (b) The system may be unique in its
precision in metering and thoroughly mixing soap and water,
something that becomes more important when sanitation and hygiene
are considered. The mixing of soap and water in other systems is
haphazard and may be very poorly accomplished. [0116] (c) The
system may also be unique in that the soap dispensing side of the
system interacts with and may override the water only side of the
system, so that the soap dispensing mode may be initiated at any
time by the user, even when water is already flowing from the
faucet, and so that there may be an interval after soap dispensing
is completed, during which time the water only flow cannot be
initiated by the user. [0117] (d) The faucet, or the discharge tube
or nozzle of the faucet may be repeatedly washed by the water/soap
solution, and if the soap is a disinfectant, providing disinfectant
action internally in the faucet, tending to keep the faucet free of
contaminants.
[0118] While particular embodiments of the present invention have
been disclosed, it is to be understood that various different
embodiments are possible and are contemplated within the true
spirit and scope of the appended claims. There is no intention,
therefore, of limitations to the exact abstract or disclosure
herein presented.
* * * * *