U.S. patent application number 13/792034 was filed with the patent office on 2014-02-27 for horizontal pumps, refill units and foam dispensers with integral air compressors.
This patent application is currently assigned to GOJO Industries, Inc.. The applicant listed for this patent is Nick E. Ciavarella, John J. McNulty, James E. Motyka, Robert L. Quinlan, Todd A. Spiegelberg. Invention is credited to Nick E. Ciavarella, John J. McNulty, James E. Motyka, Robert L. Quinlan, Todd A. Spiegelberg.
Application Number | 20140054323 13/792034 |
Document ID | / |
Family ID | 50147101 |
Filed Date | 2014-02-27 |
United States Patent
Application |
20140054323 |
Kind Code |
A1 |
McNulty; John J. ; et
al. |
February 27, 2014 |
HORIZONTAL PUMPS, REFILL UNITS AND FOAM DISPENSERS WITH INTEGRAL
AIR COMPRESSORS
Abstract
Foam dispensers having integral air compressors with connectors
to connect with a disposable refill unit, disposable refill units
and liquid pumps are disclosed herein. A refill unit includes a
container and a liquid pump. The liquid pump includes a liquid
chamber defined at least in part by a liquid inlet valve and a
liquid outlet valve. A piston that reciprocates horizontally in the
liquid chamber. A mixing chamber is located downstream of the
liquid chamber. The mixing chamber is in fluid communication with
the liquid chamber and has an air inlet. A sanitary seal is located
proximate the air inlet to prevent liquid from contaminating the
air compressors.
Inventors: |
McNulty; John J.; (Broadview
Heights, OH) ; Quinlan; Robert L.; (Stow, OH)
; Ciavarella; Nick E.; (Seven Hills, OH) ; Motyka;
James E.; (Cuyahoga Falls, OH) ; Spiegelberg; Todd
A.; (North Ridgeville, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
McNulty; John J.
Quinlan; Robert L.
Ciavarella; Nick E.
Motyka; James E.
Spiegelberg; Todd A. |
Broadview Heights
Stow
Seven Hills
Cuyahoga Falls
North Ridgeville |
OH
OH
OH
OH
OH |
US
US
US
US
US |
|
|
Assignee: |
GOJO Industries, Inc.
Akron
OH
|
Family ID: |
50147101 |
Appl. No.: |
13/792034 |
Filed: |
March 9, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61692290 |
Aug 23, 2012 |
|
|
|
Current U.S.
Class: |
222/190 |
Current CPC
Class: |
A47K 5/14 20130101; B05B
11/3001 20130101; B05B 7/0025 20130101; B05B 11/3087 20130101; A47K
5/1211 20130101; B05B 11/3015 20130101 |
Class at
Publication: |
222/190 |
International
Class: |
A47K 5/14 20060101
A47K005/14 |
Claims
1. A disposable refill unit for a foam dispenser that has an
integral air compressor comprising; a container; a liquid pump
secured to the container; the liquid pump having a liquid chamber
defined at least in part by a liquid inlet valve and a liquid
outlet valve; a liquid piston that reciprocates horizontally in the
liquid chamber; a mixing chamber located downstream of the liquid
chamber; an air inlet in fluid communication with the mixing
chamber; a sanitary seal located proximate the air inlet, the
sanitary seal allows air to enter the mixing chamber and prevents
liquid from exiting the mixing chamber through the air inlet.
2. The disposable refill unit of claim 1 further comprising a
sleeve located at least partially within the liquid chamber and at
least a portion of the liquid piston reciprocates within the
sleeve.
3. The disposable refill unit of claim 2 further comprising one or
more ribs located on the sleeve or on one or more walls of the
liquid chamber.
4. The disposable refill unit of claim 1 wherein the liquid inlet
valve and the liquid outlet valve are offset from one another.
5. The disposable refill unit of claim 1 wherein the liquid outlet
valve is located closer to the front of the disposable refill unit
than the liquid inlet valve.
6. The disposable refill unit of claim 1 further comprising a
connector for connecting the liquid pump air inlet to an air outlet
of an air compressor.
7. The disposable refill unit of claim 1 wherein the refill unit is
configured to be lowered into a dispenser along a vertical
axis.
8. The disposable refill unit of claim 1 wherein the liquid pump
further comprises one or more sealing members that form at least a
part of a channel for delivering air to the air inlet when the
refill unit is installed in a foam dispenser.
9. The disposable refill unit of claim 1 wherein the liquid piston
is movable to a plurality of positions within the liquid chamber
and a head of the piston is located on one side of the outlet valve
when the piston is in a first position and the head of the piston
is located on the opposite side of the outlet valve when the piston
is in a second position.
10. The disposable refill unit of claim 1 further comprising a suck
back chamber in fluid communication with the mixing chamber.
11. A disposable refill unit for a foam dispenser that has an
integral air compressor comprising; a container; a liquid pump
secured to the container; the liquid pump having a liquid chamber
defined at least in part by a liquid inlet valve and a liquid
outlet valve; a mixing chamber located downstream of the liquid
chamber; an air inlet in fluid communication with the mixing
chamber; a sanitary seal located proximate the air inlet, the
sanitary seal allows air to enter the mixing chamber and prevents
liquid from exiting the mixing chamber through the air inlet;
wherein the container, the liquid pump and the sanitary seal are
disposable.
12. The disposable refill unit of claim 11 wherein the liquid inlet
valve and the liquid outlet valve are offset from one another.
13. The disposable refill unit of claim 11 wherein the liquid
outlet valve is located closer to the front of the refill unit than
the liquid inlet valve.
14. The disposable refill unit of claim 11 wherein at least one of
the inlet valve and outlet valve are located off of a center line
of the container.
15. The disposable refill unit of claim 11 wherein the liquid pump
comprises one or more sealing members, wherein when the disposable
refill unit is installed in a foam dispenser, the one or more
sealing members form at least a portion of an air passageway.
16. The disposable refill unit of claim 11 further comprising a
suck back chamber in fluid communication with the mixing
chamber
17. A disposable refill unit comprising: a container of foamable
liquid; a pump secured to the container; the pump having a pump
housing; an aperture through an upper surface of the pump housing;
a liquid inlet valve; the liquid inlet valve including a stem
portion; the stem portion having a projection member; the liquid
inlet valve including a sealing member; a pump chamber located
within the pump housing, wherein the aperture extends from the
upper surface of the pump housing to the pump chamber; wherein the
projection member of the liquid inlet valve stem is located at
least partially within the pump chamber and the sealing member of
the liquid inlet valve is located above the upper surface of the
pump housing; and one or more liquid inlet passages located in the
housing between the upper surface and the pump chamber; wherein the
sealing member is located upstream of the one or more liquid inlet
passages.
18. A disposable refill unit for a foam dispenser that has an
integral air compressor comprising; a container for holding a
foamable liquid; a liquid pump secured to the container; the liquid
pump having a liquid chamber defined at least in part by a liquid
inlet valve and a liquid outlet valve; a sleeve located at least
partially within the liquid chamber; a liquid piston that
reciprocates horizontally in the liquid chamber and in contact with
the sleeve; a mixing chamber located downstream of the liquid
chamber; an air inlet in fluid communication with the mixing
chamber; wherein the center of the liquid outlet valve is off-set
from the center of the liquid inlet valve.
19. The disposable refill unit of claim 18 further comprising a
member having a first wiper valve oriented in a first direction and
a second wiper valve oriented in s second direction that is
different then the first direction and wherein the first wiper
valve is the liquid outlet valve and the second wiper valve is an
air inlet valve.
20. The disposable refill unit of claim 19 wherein the movement of
the piston is substantially normal the direction of the fluid flow.
Description
RELATED APPLICATIONS
[0001] 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. This application is incorporated herein by reference
in its entirety.
TECHNICAL FIELD
[0002] The present invention relates generally to liquid pumps,
refill units for foam dispensers and foam dispenser systems, and
more particularly to horizontal liquid pumps, refill units and foam
dispensers having integral air compressors.
BACKGROUND OF THE INVENTION
[0003] Liquid dispenser systems, such as liquid soap and sanitizer
dispensers, provide a user with a predetermined amount of liquid
upon actuation of the dispenser. In addition, it is sometimes
desirable to dispense the liquid in the form of foam by, for
example, injecting air into the liquid to create a foamy mixture of
liquid and air bubbles. As a general matter, it is usually
preferable to reduce the space taken up by the pumping and foaming
apparatus within the overall dispenser system. This maximizes the
available space for storing the liquid, and has other benefits.
SUMMARY
[0004] Pumps, foam refill units and foam dispenser systems are
disclosed herein. Embodiments of disposable refill units for foam
dispensers that have an integral air compressor are provided. One
embodiment includes a container and a liquid pump. The liquid pump
includes a liquid chamber defined at least in part by a liquid
inlet valve and a liquid outlet valve. A piston reciprocates
horizontally in the liquid chamber. A mixing chamber is located
downstream of the liquid chamber. The mixing chamber is in fluid
communication with the liquid chamber and has an air inlet. A
sanitary seal is located proximate the air inlet to allow air to
enter the mixing chamber and prevent liquid from exiting the mixing
chamber through the air inlet
[0005] Another embodiment of a disposable refill unit for a foam
dispenser is disclosed that has an integral air compressor and
includes a container and a liquid pump. The liquid pump has a
liquid chamber defined at least in part by a liquid inlet valve and
a liquid outlet valve. A mixing chamber is located downstream of
the liquid chamber. The mixing chamber includes an air inlet and a
sanitary seal located proximate the air inlet. The sanitary seal
allows air to enter the mixing chamber and prevents liquid from
exiting the mixing chamber through the air inlet. The container,
the liquid pump and the sanitary seal are disposable without
disposing of the air compressor.
[0006] Embodiments of foam dispensers for receiving replaceable
refill units are also disclosed. One embodiment of a foam dispenser
includes a housing, an actuator and an air compressor. In addition,
the dispenser includes a connector that releasably connects the air
compressor to an air inlet on a disposable refill unit when the
disposable refill unit is installed in the foam dispenser and
disconnects from the disposable refill unit when the refill unit is
removed. The actuator is configured to move horizontally and
actuate the air compressor. In addition, a refill unit mounting
bracket is included to receive and releasably retain a replaceable
refill unit.
[0007] In addition, pumps and refill units having a novel liquid
inlet valve are also disclosed herein. In one embodiment, a refill
unit includes a container of foamable liquid and a pump secured to
the container. The pump includes a pump housing having a first
aperture therethrough. A liquid inlet valve is provided through the
first aperture. The pump also includes one or more liquid inlet
passages through the housing. The liquid inlet valve includes a
stem portion. The stem portion includes a projection member on one
end and a sealing member on the other. The projection member fits
through the aperture from outside of the pump housing and the
sealing member is located upstream of the one or more liquid
inlets.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] 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:
[0009] FIG. 1 illustrates a dispenser system 100 having an air
compressor 150 attached thereto and a refill unit 110 installed
therein.
[0010] FIG. 2 illustrates a prospective view of the generic
dispenser 101 having an air compressor 150 attached thereto;
[0011] FIG. 3 illustrates a cross-section of an exemplary
embodiment of a refill unit 110 for use in a dispenser system 100
showing a portion of a container 112 for holding a fluid and a
liquid pump 120;
[0012] FIG. 4 illustrates a cross-section of an exemplary
embodiment of a refill unit 110 installed in a dispenser 100 and
mated with air compressor 150;
[0013] FIG. 5 illustrates another exemplary embodiment dispenser
system 500 with a refill unit 510 installed therein;
[0014] FIG. 6 illustrates a cross-section of an exemplary
embodiment of the dispenser 500 for use in a dispenser system 500
that includes an air compressor 550 secured thereto;
[0015] FIG. 7 illustrates a plan view of an exemplary embodiment of
an air compressor 550 for use in a dispenser system 500;
[0016] FIG. 8 illustrates a cross-section of an exemplary
embodiment of a refill unit 510 including a container 512 and
liquid pump 520;
[0017] FIG. 9 illustrates a cross-section of an exemplary
embodiment of the refill unit 510 installed in a dispenser 501
mated with air compressor 550;
[0018] FIG. 10 illustrates a cross-section of an exemplary
embodiment of a pump 1000 for use in a refill unit of a foam
dispenser in a discharged position;
[0019] FIG. 11 illustrates a cross-section of the exemplary
embodiment of a pump 1000 for use in a refill unit of a foam
dispenser in a charged position; and
[0020] FIG. 12 illustrates a cross-section of another exemplary
pump 1200.
DETAILED DESCRIPTION
[0021] FIG. 1 illustrates an exemplary embodiment of a foam
dispensing system 100 with a side of the housing being transparent.
Foam dispensing system 100 includes a disposable refill unit 110
installed in a foam dispenser 101. The disposable refill unit 110
includes a container 112 connected to a liquid pump 120. Liquid
pump 120 includes an air inlet 124. The disposable refill unit 110
may be placed within housing 102 of the dispenser 101 and
releasably placed in fluid communication with air compressor 150.
The term air compressor is used interchangeably herein with the
term "air pump."
[0022] The foam dispenser system 100 may be a wall-mounted system,
a counter-mounted system, an un-mounted portable system movable
from place to place or any other kind of foam dispenser system.
Foam dispenser 101 includes an air compressor 150 secured thereto.
Air compressor 150 may be permanently mounted to foam dispenser
101. Air compressor 150 includes a conduit or air passage 152, with
a connector 154 for releasably connecting to the air inlet 124 of
liquid pump 120. Optionally, connector 154 may be secured to pump
120. In one embodiment, connector 154 is a two-part connector, and
one part is connected to pump 120 and the other to air passage 152.
In one embodiment, the connector 154 is made up of a male fitting
on one of the liquid pump air inlet 124 or the air passage 152 of
air compressor 150 and a female fitting on the other. Accordingly,
refill unit 110 and pump 120 may be removed from dispenser housing
102 and discarded without removal of the air compressor 150.
Connector 154 may be a quick-release connector, a releasable
snap-fit connector, a releasable compression-fit connector, a
slip-fit connector or a sealing member such as, for example, a foam
or flexible member that compresses to form a seal between air
passage 152 and pump 120. The air compressor 150 may be any type of
air compressor such as, for example, a compressible bellows, a
rotary air compressor, a piston air compressor, a fan, a
compressor, a positive displacement pump or the like.
[0023] The container 112 forms a liquid reservoir 114. The liquid
reservoir 114 contains a supply of a foamable liquid within the
disposable refill unit 110. In various embodiments, the contained
liquid could be for example a soap, a sanitizer, a cleanser, a
disinfectant or some other foamable liquid. In the exemplary
disposable refill unit 110, the liquid reservoir 114 is formed by a
collapsible container 112, such as a container made of thin plastic
or a flexible bag-like container. In other embodiments, the liquid
reservoir 114 may be formed by a rigid housing member, or have any
other suitable configuration for containing the foamable liquid
without leaking. The container 112 may advantageously be
refillable, replaceable or both refillable and replaceable. In
other embodiments, the container 112 may be neither refillable nor
replaceable.
[0024] In the event the liquid stored in the reservoir 114 of the
installed disposable refill unit 110 runs out, or the installed
refill unit 110 otherwise has a failure, the installed refill unit
110 may be removed from the foam dispenser system 100. The empty or
failed disposable refill unit 110 may then be replaced with a new
disposable refill unit 110 including a liquid-filled reservoir 114.
The air compressor 150 remains located within the foam dispenser
101 while the disposable refill unit 110 is replaced. In one
embodiment, the air compressor 150 is also removable from the
housing 102 of the dispenser 101, separately from the disposable
refill unit 110, so that the air compressor 150 may be replaced
without replacing the dispenser 101, or alternatively to facilitate
removal and connection to the refill unit 110. As described in more
detail below, sanitary sealing may be used to isolate the air
compressor 150 from the portions of the liquid pump 120 that
contact liquid, so that the air compressor 150 mechanism does not
contact liquid during operation of the foam dispenser system
100.
[0025] The housing 102 of the dispenser 101 further contains one or
more actuating members 104 to activate the liquid pump 120 and air
compressor 150. As used herein, actuator or actuating mechanism
includes one or more parts that cause the dispenser 101 to move
liquid, air or foam. Actuator 104 is generically illustrated
because there are many different kinds of pump actuators which may
be employed in the foam dispenser system 100. The actuator of the
foam dispenser system 100 may be any type of actuator such as, for
example, a manual lever, a manual pull bar, a manual push bar, a
manual rotatable crank, an electrically activated actuator or other
means for actuating the liquid pump 120 and air compressor 150
within the foam dispenser system 100. Electronic actuators may
additionally include a sensor to provide for a hands-free dispenser
system with touchless operation. Various intermediate linkages
connect the actuator member 104 to the pump 120 and or air
compressor 150 within the system housing 102.
[0026] The exemplary liquid pump 120 and air compressor 150 are
horizontal pumps. That is, the pumps are actuated by a
substantially horizontal movement. The external actuator 104 may be
operated in any manner, so long as the intermediate linkages
transform that motion to a substantially horizontal motion to
activate the liquid pump 120 and air compressor 150. As
illustrated, dispenser 101 includes a manual actuator lever 104
that is secured to housing 102 by a hinge 103. In one embodiment,
actuator lever 104 includes a pivotal contact element 105 that
contacts actuator arm 156 to activate the pump 120 and air
compressor 150. Pump 120 includes a dispensing nozzle 122 which
extends below the bottom of housing 102. In addition, a refill
retaining bracket 180 is secured to housing 102. Refill retaining
bracket 180 releasably retains the refill unit 110 in foam
dispenser 101. Refill unit 110, including the liquid pump 120 and
outlet nozzle 122 may be readily inserted and removed from foam
dispenser 101 without removing the air compressor 150 from the foam
dispenser. Accordingly, all of the elements that contact liquid,
"wet parts," may be disposed of without the need to dispose of
components that do not contact liquid.
[0027] FIG. 2 illustrates a prospective view of an embodiment of
dispenser 101. Dispenser 101 includes a housing 102, which is
illustrated as transparent for purposes of clairity. Housing 102
includes a front portion 205 that is attached by hinge 203. Front
portion 205 of housing 102 rotates down to facilitate inserting a
refill unit (not shown) into dispenser 101. As discussed with
respect to FIG. 1, front portion 205 of housing 102 includes an
actuator lever 104. Housing 102 includes an opening 220 in the
bottom thereof which allows nozzle 122 to dispense foam to an
object located below dispenser 101. Secured to housing 102 is air
compressor 150.
[0028] In one embodiment, air compressor 150 includes a cylinder
208. Cylinder 208 includes a side wall and a bottom wall. A piston
206 fits within cylinder 208 and sealing member 401 (FIG. 4)
creates a seal between the outside wall of piston 206 and the
inside wall of cylinder 208. Secured to piston 206 is an actuator
arm 156. Actuator arm 156 includes a pair of extensions 202, which
are linked to cross member 204. Air compressor 150 also includes
air compressor outlet 152 that releasably engages with liquid pump
120. In one embodiment, air compressor 150 includes an air inlet
404 (FIG. 4) and one-way air inlet valve 406. One-way air inlet
valve 406 allows air to enter air compressor 150 to recharge the
air chamber 410. In addition, in one embodiment, air compressor 150
includes a biasing member 402 to move the piston 206 to its
outermost position and recharge the air chamber 410.
[0029] FIG. 3 illustrates a cross-section of an exemplary
embodiment of a refill unit 110 that includes pump 120 and
container 112. Container 112 includes a neck portion 302. Pump 120
is connected to the neck 302 of container 112 by a press fit
connection. Optionally, a cap (not shown) may connect pump 120 to
container 112. Still yet, other means such as, for example, a
compression fit, welding, adhesive, friction fit, etc. may be used
to join pump 120 with container 112.
[0030] Pump 120 includes a pump housing 306 that contains a liquid
chamber 320. Pump housing 306 includes an inlet opening 312. A
one-way liquid inlet valve 314 is located in the inlet opening 312.
The upper portion of liquid inlet valve 314 includes slots (not
shown) for liquid to pass through and flow into inlet opening 312.
Optionally, additional liquid inlet openings may be provided.
One-way liquid inlet valve 314 may be any type of valve such as,
for example, a flapper valve, a conical valve, a plug valve, an
umbrella valve, a duck-bill valve, a slit valve, a mushroom valve
or the like. One-way liquid inlet valve 314 allows liquid to flow
into liquid chamber 320 and prevents liquid from flowing out of
liquid chamber 320 back into container 112. Pump housing 306
includes a liquid outlet opening 330 that has a one-way liquid
outlet valve 332 associated therewith. One-way liquid outlet valve
332 may be any type of valve such as, for example, a flapper valve,
a conical valve, a plug valve, an umbrella valve, a duck-bill
valve, a slit valve or a mushroom valve, so long as it opens under
pressure to allow liquid to exit the liquid chamber 320, but does
not let air, liquid or foam enter the liquid chamber 320 through
opening 330.
[0031] Located at least partially within liquid chamber 320 is a
sleeve 324. The sleeve allows the pump housing 306 to be cheaply
manufactured without tight tolerances and even have dips or
recesses in the pump chamber. In some embodiments, the pump housing
306 has uneven cross-section, uneven fill. The sleeve is made with
more precision and has tighter tolerances and is inserted into the
pump chamber 320. A liquid tight seal prevents liquid from flowing
out of liquid chamber 320 around sleeve 324 and out of pump 120 and
secures sleeve 324 to pump housing 306. The liquid tight seal may
be formed by having end cap 358 of sleeve 324 fit snuggly within
liquid chamber 320 near the one end. End cap 358 seals the opening
and retains piston 350. Optionally, end cap 358 may be secured to
the housing 306 by an adhesive, by welding or the like.
[0032] A passageway 360 exists between the outside of sleeve 324
and the inside wall of liquid chamber 320. The passageway 360
allows liquid to flow into and out of the liquid chamber 320, which
includes the interior of sleeve 324. Sleeve 324 may be cylindrical
or may have outwardly extending ribs to engage the wall of the
liquid chamber 320. Ribs (not shown) may facilitate the creation of
multiple passageways 360 in the open areas created by the ribs.
[0033] Sleeve 324 allows inlet valve 314 and outlet valve 332 to be
placed along any point of liquid chamber 320. Accordingly, the
liquid inlet opening 312 and liquid outlet opening 330 may be
advantageously positioned. In addition, piston head 352 may travel
past inlet valve 314 and outlet valve 332. For example, in one
embodiment, the liquid outlet opening 330 is located near the front
of the refill unit 110 so that the foam may be dispensed at
location that is further away from the back of the dispenser 100.
In one embodiment, the liquid inlet opening 312 is located near the
front of the refill unit 101. This flexibility allows the pump 120
to be easily modified for different applications. It also allows
for flexibility in the design of the container 112. For example,
the neck 302 of the container 112 may be located towards the front
of the refill unit 110 rather than in the center of the refill unit
110. In some embodiments, the liquid inlet opening 312 and liquid
outlet opening 330 are offset from one another. In one embodiment,
the liquid outlet opening 330 is located closer to the front of the
refill unit 110 than the liquid inlet opening 312. In one
embodiment, sleeve 324 is not required; however, in that
embodiment, the liquid inlet and liquid outlets are located so that
the stroke of the piston 360 does not cause piston head 352 to pass
the liquid inlet 312 and liquid outlet 330 during operation.
[0034] In the embodiment illustrated in FIG. 1 the inlet and outlet
valves 314, 332 are aligned on a centerline of the container 112.
In one embodiment, one or both of the inlet and outlet valves 314,
332 are located off of the centerline of the container 112. In
another embodiment, both the inlet and outlet valves 314, 332 are
located off of the centerline of the container 112. One or both may
be located closer to the front of the container. In such
embodiments, the neck 302 of the container 112 may also be offset
from the centerline of the container 112. In one embodiment, the
neck 302 of the container 112 is offset towards the front of the
container. As used herein, "offset from the centerline of the
container" means that the object is offset from at least one
centerline, not necessarily from all potential centerlines of the
container.
[0035] Pump 120 includes a liquid piston 350. Liquid piston 350 has
a piston head 352 that has a liquid piston seal 356. Liquid piston
seal 356 may be any type of seal such as, for example, a wiper
seal, an o-ring, a gasket or the like. Liquid piston seal 356
engages the inside wall of sleeve 324. Preferably, liquid piston
seal 356 has enough contact against sleeve 324 so that liquid does
not pass by the seal, but the contact is limited so that less
energy is necessary to move the piston 350. Pump 120 may include a
biasing member (not shown) to move piston 350 outward when no
horizontal force is being applied to the piston 350. Optionally,
piston 350 may have an engagement member (not shown) that engages
with actuator arm 156 to move piston 350 to its outermost position,
when no force is being applied to the actuator arm 156.
[0036] Pump housing 306 includes mixing chamber 336 located
downstream of outlet opening 330. As fluid passes by one-way outlet
valve 332, it enters mixing chamber 336. Mixing chamber 336
includes an air inlet 124. In some embodiments, air inlet 124
includes a one-way valve 338. One-way valve 338 may be any type of
one-way valve such as, for example, those identified above. One-way
inlet valve 338 is a sanitary valve in that it prevents liquid or
foam from traveling past and contaminating air compressor 150 or
other parts that remain with the dispenser 101 when the refill unit
110 is removed from the dispenser 101. It is desirable to keep the
parts that remain with the dispenser 101 free from contamination
with the liquid or fluid to prevent bacteria from growing in the
dispenser 101. Thus, a user need only replace the refill unit 110
including the wet parts without the need for replacing the air
compressor 150.
[0037] In some embodiments, the air pump(s) or air compressor(s)
disclosed herein include an air inlet having a one-way air inlet
valve therethrough. The one-way air inlet valve allows air to enter
the air pump to recharge the air pump. In some embodiments, the air
inlet is located inside of the foam dispenser housing so that air
from inside of the dispenser is used to feed the air pump. Using
air from inside the dispenser may help to prevent moisture from
entering the air pump through the air inlet and air inlet valve. In
some embodiments, a vapor barrier is provided at the air inlet. A
vapor barrier allows air to pass through the air inlet and enter
the air pump, but prevents moisture from entering the air pump. A
suitable vapor barrier is a woven one-way vapor barrier such as,
for example, Gortex.RTM., that is arranged so that vapor does not
enter the air pump.
[0038] In some embodiments, the air pump(s) or air compressor(s)
include an antimicrobial substance molded into their housing. One
suitable antimicrobial substance contains silver ions and/or copper
ions. A silver refractory, such as, for example, a glass, oxide or
silver phosphate may be used. One suitable commercially available
product is Ultra-Fresh, SA-18, available from Thomson Research
Associates, Inc. Other suitable antimicrobial materials that may be
used in the air pump include, but are not limited to Vinyzene.TM.,
available from the Dow Chemical Company, and Bisafe, a silane-based
antimicrobial product available from the RTP Company. The
antimicrobial substance prevents mold or bacteria from growing
inside of the air pump or air compressor. Optionally several
different types of antimicrobial substances may be used alone or in
combinations with other antimicrobial substances, such as for
example, a combination of a leaching antimicrobial and a
non-leaching antimicrobial. Suitable leaching antimicrobials may
include, for example, silver, nanosilver or copper may be used.
Suitable non-leaching antimicrobials include, for example, silver
based and triclosan based antimicrobials. Silver, copper,
combinations of silver and copper alone, combinations of silver,
copper and other antimicrobials may be used. The use of the terms
silver and copper used herein are not intended to limit the types
of copper or silver to metal, and is intended to cover metal salts
and other variants of copper and silver.
[0039] Downstream of mixing chamber 336 is a foaming cartridge 340.
In one embodiment, foaming cartridge 340 has a housing with one or
more screens located therein. Optionally, foaming cartridge 340 may
be replaced with one or more screens, a sponge or other porous
member. In addition, secured to pump housing 306 is outlet nozzle
122.
[0040] As can be seen from the Figures, pump 120 is compact. The
narrower diameter of liquid chamber 320 is more efficient in that
it takes less energy to move a given volume of fluid than a larger
diameter liquid chamber having the same volume but a larger
diameter. Using less energy allows for a longer battery life for an
electronic dispenser. In addition, the compact profile reduces
shipping costs. Further, the ability to reuse the air compressor
provides sustainability and is "green" in that it reduces the
amount of plastic that ends up in landfills.
[0041] FIG. 4 illustrates refill unit 110 installed in dispenser
housing 102 and pump 120 is releasably mated with air compressor
150. To install the refill unit 110, the dispenser housing 102 is
opened up and the refill unit 110 is lowered downward. As the
refill unit 110 is lowered, the liquid pump air inlet 124 aligns
with the air compressor outlet 152. In one embodiment, as the two
components align the refill unit 110 is pushed toward the back of
the dispenser, the liquid pump air inlet 124 slides into air
compressor outlet 152 and is snug enough to form a seal. In
addition, piston 350 fits within actuator arm 156 so that cross
member 204 will engage piston 350 when actuator lever 104 is moved
horizontally.
[0042] During operation, the foam dispensing system 100 is
activated by moving actuator lever 104. Actuator lever 104 causes
liquid piston 350 and air piston 206 to move horizontally toward
the rear of the foam dispensing system 100. Movement of liquid
piston 350 horizontally reduces the volume of liquid chamber 320.
Once the pressure is sufficient to overcome the cracking pressure
of liquid outlet valve 332, the pressurized liquid flows through
passage 360 through passage 330, past liquid outlet valve 332 and
travels into mixing chamber 336. Movement of air piston 206 reduces
the volume of the air chamber 410 and pressurizes the air in the
air chamber 410. The pressurized air passes through air compressor
outlet 152, past sanitary valve 338, through liquid pump air inlet
124 and mixes with the liquid in mixing chamber 336 to form a
liquid/air mixture. The liquid/air mixture is forced through
foaming cartridge 340 and is dispensed through nozzle 122 as a
foam.
[0043] Upon release of actuator lever 104, the biasing member 402
in the air compressor 150 urges air piston 206 away from the rear
of dispenser system 100 and expands the volume of air chamber 410.
Sanitary valve 338 prevents air from entering the air chamber 410
through the air compressor outlet 152. Accordingly, air is drawn
into air chamber 410 through air inlet 404 past one-way air inlet
valve 406. In addition, liquid piston 330 is urged outward away
from the rear of the dispenser system 100. As liquid piston 330
moves outward, liquid chamber 320 expands creating a vacuum. The
vacuum pressure seals liquid outlet valve 330 and once the vacuum
pressure is sufficient to overcome the cracking pressure of liquid
inlet valve 314, liquid flows from container 112 past liquid inlet
valve 314 through the passage 360 and into liquid chamber 320. The
pump 120 and air compressor 150 are now primed and ready for the
next dispense cycle.
[0044] FIG. 5 illustrates another exemplary embodiment of a foam
dispensing system 500. Foam dispensing system 500 includes a
disposable refill unit 510 for use in a foam dispenser 501. The
disposable refill unit 510 includes a container 512 connected to a
liquid pump 520. Liquid pump 520 includes an air inlet 824 (FIG.
8). The disposable refill unit 510 may be placed within a housing
502 of the dispenser 501 and releasably placed in fluid
communication with an air compressor 550. The foam dispenser system
500 may be a wall-mounted system, a counter-mounted system, an
un-mounted portable system movable from place to place or any other
kind of foam dispenser system. Foam dispenser 501 includes an air
compressor 550 secured thereto (see FIG. 6). Air compressor 550 may
be permanently mounted to foam dispenser 501. Air compressor 550
includes a conduit or air passage 620 (FIG. 6), with an annular
receptacle 554 for releasably connecting to the air inlet 824 of
liquid pump 520. The releasable connection is achieved by sliding a
portion of the liquid pump 520 into annular receptacle 554.
Accordingly, refill unit 510 and pump 520 may be removed from
dispenser housing 502 and discarded without removal of the air
compressor 550. Air compressor 550 is a dual piston air compressor;
however, the air compressor 550 may be any type of air compressor
such as, for example, a bellows air compressor, a rotary air
compressor, a piston air compressor, a fan, a compressor, a blower
or the like. It may be a single air compressor or may be multiple
air compressors.
[0045] The container 512 forms a liquid reservoir 514. The liquid
reservoir 514 contains a supply of a foamable liquid within the
disposable refill unit 510. In various embodiments, the contained
liquid could be for example a soap, a sanitizer, a cleanser, a
disinfectant or some other foamable liquid. In the exemplary
disposable refill unit 510, the liquid reservoir 514 is formed by a
collapsible container 512, such as a plastic container or a
flexible bag-like container. In other embodiments, the liquid
reservoir 514 may be formed by a rigid housing member, or have any
other suitable configuration for containing the foamable liquid
without leaking. The container 512 may advantageously be
refillable, replaceable or both refillable and replaceable. In
other embodiments, the container 512 may be neither refillable nor
replaceable.
[0046] In the event the liquid stored in the reservoir 514 of the
installed disposable refill unit 510 runs out, or the installed
refill unit 510 otherwise has a failure, the installed refill unit
510 may be removed from the foam dispenser system 500. The empty or
failed disposable refill unit 510 may then be replaced with a new
disposable refill unit 510 including a liquid-filled reservoir 514.
The air compressor 550 remains located within the foam dispenser
501 while the disposable refill unit 510 is replaced. In one
embodiment, the air compressor 550 is also removable from the
housing 502 of the dispenser 501, separately from the disposable
refill unit 510, so that the air compressor 550 may be replaced
without replacing the dispenser 501, or alternatively to facilitate
removal and connection to the refill unit 510. Optionally, air
compressor 550 may be mounted to the liquid pump 520 and disposed
of along with the refill unit 510. As described in more detail
below, sanitary sealing may be used to isolate the air compressor
550 from the portions of the liquid pump 520 that contact liquid,
so that the air compressor 550 mechanism does not contact liquid
during operation of the foam dispenser system 500.
[0047] The housing 502 of the dispenser 501 further contains one or
more actuating members 504 to activate the pump 520 and air
compressor 550. As used herein, actuator or actuating mechanism
includes one or more parts that cause the dispenser 501 to move
liquid, air or foam. There are many different kinds of pump
actuators which may be employed in the foam dispenser system 500
such as, for example, a manual lever, a manual pull bar, a manual
push bar, a manual rotatable crank, an electrically activated
actuator or other means for actuating the liquid pump 520 and air
compressor 550 within the foam dispenser system 500. Electronic
pump actuators may additionally include a sensor to provide for a
hands-free dispenser system with touchless operation. Various
intermediate linkages connect an actuator member to the pump 520
within the system housing 502.
[0048] The exemplary liquid pump 520 and air compressor 550 are
horizontal pumps. That is, they are actuated by a substantially
horizontal movement. The external actuator 504 may be operated in
any manner, so long as the intermediate linkages transform that
motion to a substantially horizontal motion on the liquid piston
850 and air piston 606. Dispenser 501 includes a manual actuator
lever 504 that is secured to housing 502 by a hinge 503. In one
embodiment, actuator lever 504 includes pivotal contact elements
505, 506 that contact pistons 602 and 850 respectively to activate
the pump 520 and air compressor 550. Pump 520 includes a dispensing
nozzle 522 which extends below the bottom of housing 502. In
addition, a refill retaining bracket 580 is secured to housing 502.
Refill retaining bracket 580 releasably retains the refill unit 510
in foam dispenser 501. Refill unit 510, including the liquid pump
520 and outlet nozzle 522, may be readily inserted by lowering
refill unit 510 into dispenser 501 and removed from foam dispenser
501 by lifting upward without removing the air compressor 550 from
the foam dispenser.
[0049] FIG. 6 illustrates a cross-section of the exemplary
embodiment of foam dispenser 501 without a refill unit. Foam
dispenser 501 includes housing 502, actuator lever 504, liquid
piston pivotal contact element 505, air piston pivotal contact
element 506 and air compressor 550 as discussed above. Air
compressor 550 is secured to housing 502. Air compressor 550 is
best understood with respect to FIGS. 6 and 7. Air compressor 550
includes a pair of a cylindrical housings 604. Pistons 602 move
reciprocally within piston housings 604. Pistons 602 include
sealing members 603 that form a seal between pistons 602 and piston
housings 604. In one embodiment, biasing members 640 such as, for
example, springs are located within cylindrical housings 604 to
urge pistons 602 to their outermost positions. Cylindrical housings
604 include air outlets 620 and air inlets 641. One-way air inlet
valves 643 are included in air inlets 641 to allow air into the
cylindrical housings 604 but prevent air from exiting through air
inlets 641. Air outlets 620 enter into annular receptacle 554.
Annular receptacle 554 has an outside wall 606, an inside wall 608
and a base 609. An opening 702 is provided in base 609 to allow the
outlet nozzle 522 of liquid pump 550 to pass through when the
refill unit 510 is installed in dispenser 501.
[0050] FIG. 8 is a cross-sectional view of the exemplary embodiment
of a refill unit 510. Refill unit 510 includes a container 512 and
liquid pump 520 secured thereto. Container 512 includes a neck
portion 513 with annular projections 806. Liquid pump 520 includes
pump housing connector 808. Pump housing connector 808 includes an
annular projection 811 that mates with the annular projections 806
to connect pump 520 to container 512. Other types of connections
may be used such, for example, as a press-fit connection, a welded
connection, an adhesive connection, a threaded connection or the
like. In addition, a sealing member (not shown) may be included
between pump housing connector 808 and neck 513 to ensure a liquid
tight connection between pump 520 and container 512.
[0051] Pump housing connector 808 is secured to pump housing 809.
Pump housing 809 may be a separate part from pump housing connector
808 or they may be integrally formed. Pump housing 809 includes an
aperture 812 that has a one-way inlet valve 814 secured thereto. In
one embodiment, one or more liquid inlet apertures 813 are provided
to allow liquid to flow from container 512 to liquid chamber 870.
Optionally, the liquid may enter through aperture 812. One-way
liquid inlet valve 814 may be any type of valve, such as for
example, a flapper valve, a conical valve, a plug valve, an
umbrella valve, a duck-bill valve, a slit valve or a mushroom valve
so long as it allows liquid to enter liquid chamber 870 but
prevents liquid from flowing from liquid chamber 870 back into
container 512.
[0052] Pump housing 809 includes an opening 872 through a sidewall.
Opening 872 leads to the interior of piston housing 858. Piston
housing 858 is a cylindrical housing that receives liquid piston
850. Liquid piston 850 reciprocates back and forth in piston
housing 858. Piston 850 includes a seal 856. Seal 856 may be any
type of suitable seal such as, for example, a wiper seal, one or
more o-rings or the like. A biasing member 859 such as, for example
a spring may be included within piston housing 858 to urge piston
850 to its outermost position to expand the volume of liquid
chamber 870.
[0053] Pump housing 809 includes connector 863. Connector 863 mates
with nozzle housing 860 to join the two together with a snap-fit
connection. Other suitable types of connections may be used such
as, for example, a press-fit connection, an adhesive connection or
the like. Nozzle housing 860 includes a projecting member 861 that
extends up into the interior of pump housing 809. The connection
between pump housing 809 and nozzle housing 860 is a liquid tight
connection, which is facilitated by annular groove 869 and sealing
member 871. Nozzle housing 860 includes an aperture 830
therethrough with a one-way outlet valve 832 positioned therein.
One-way outlet valve 832 may be any type of valve such as, for
example, a flapper valve, a conical valve, a plug valve, an
umbrella valve, a duck-bill valve, a slit valve or a mushroom
valve. One or more apertures 833 allow liquid to pass through and
into mixing chamber 880 located in nozzle housing 860. Optionally,
liquid may flow through aperture 830. One-way outlet valve 832
allows liquid to exit liquid chamber 870 and flow into mixing
chamber 880 located in outlet nozzle housing 860 but prevents
liquid, foam or air from moving from the mixing chamber 880 into
liquid chamber 870. Downstream of mixing chamber 880 is a foaming
cartridge 840. Foaming cartridge 840 may be include one or more
screens, a sponge or other obstructions to create a turbulent
pathway through outlet nozzle housing 860 to cause the liquid and
air mixture to form a rich foam. In one embodiment, foaming
cartridge 840 contains two or more screens. Downstream of foaming
cartridge 840 is outlet nozzle 882.
[0054] Nozzle housing 860 includes one or more openings 824 that
lead from outside of the nozzle housing 860 into the mixing chamber
880. One-way valve(s) 825 are located proximate opening(s) 824 to
provide a sanitary seal between liquid pump 520 and air compressor
550 when the refill unit 510 is installed in dispenser 501 (FIG.
9). One-way valve 825 may be any type of valve such as, for
example, a flapper valve, a conical valve, a plug valve, an
umbrella valve, a duck-bill valve, a slit valve, a mushroom valve
or the like. One-way valve 825 prevents liquid and foam from coming
in contact with the air compressor 550 or other components that are
not replaced with refill unit 510.
[0055] Nozzle housing 860 includes a pair of annular grooves 862
and 866. A pair of sealing members, such as, for example, o-rings
864 and 868 are located within grooves 862, 866 respectively. The
o-rings 864, 868 form a seal with annular receptacle 554 when the
refill unit 510 is placed in foam dispenser 501. The o-rings 864,
868 seal against inside wall 608 (FIG. 6) of annular receptacle 554
and form an air passageway 910 that places the liquid pump 520 in
fluid communication with air compressor 550 when the refill unit
510 is inserted into foam dispenser 501. Optionally, o-rings 864,
868 may be another type of sealing member, such as, for example, a
wiper seal, foam strip or the like.
[0056] Foam dispenser 501 may be permanently or semi-permanently
installed in a desired location. Refill unit 510 is placed inside
of dispenser 501 so that nozzle housing 860 fits within annular
receptacle 554 so that sealing members 864, 868 form a sealed air
passageway 910 to place the mixing chamber 880 of nozzle housing
860 in fluid communication with air compressor 550. One or more
brackets 580 may be used to retain refill unit 510 in dispenser
501. The refill unit 510 is removed from dispenser 501 by releasing
bracket 580, or by lifting refill unit 510 upward.
[0057] During operation, the foam dispensing system 500 is
activated by pushing actuator lever 504 which moves liquid piston
850 and air pistons 602 horizontally toward the back of the
dispenser. Movement of liquid piston 850 horizontally reduces the
volume of liquid chamber 870. Once the pressure is sufficient to
overcome the cracking pressure of liquid outlet valve 832, the
liquid flows out of the liquid chamber 870 and travels into mixing
chamber 880. Movement of air piston 602 reduces the volume of air
chamber 642 and pressurizes the air in the air chamber 642. The
pressurized air passes through air compressor outlet 620 into
passageway 910 and into liquid pump air inlet 824 past sanitary
valve 825 and mixes with the liquid in mixing chamber 880 to form a
liquid/air mixture. The liquid air mixture is forced through
foaming cartridge 840 and is dispensed through nozzle 522 as a
foam.
[0058] Upon release of actuator lever 404, the biasing member 840
in the air compressor 550 urges air pistons 602 away from the rear
of dispenser system 500 and expands the volume of air chamber 642.
Sanitary valve 825 prevents air from entering the air chamber 642
through the air compressor outlet 620, and air is drawn into air
chamber 642 through air inlet 641 past one-way air inlet valve 643.
In addition, liquid piston 850 is urged outward away from the rear
of the dispenser system 500. As liquid piston 850 moves outward,
liquid chamber 870 expands creating a vacuum. The vacuum pressure
seals liquid outlet valve 832 and once the vacuum pressure is
sufficient to overcome the cracking pressure of liquid inlet valve
814, liquid flows from container 512 past liquid inlet valve 814
into liquid chamber 870. The pump 520 and air compressor 550 are
now primed and ready for the next dispense cycle.
[0059] FIGS. 10 and 11 are a cross-sectional view of an exemplary
embodiment of a pump 1000 suitable for use in foam dispensers and
refill units for foam dispensers. Pump 1000 includes a housing
1002. Housing 1002 receives inlet plate 1008. Inlet plate 1008
includes a annular projection 1006. A neck of a container (not
shown) is received within an annular groove 1004 formed between
annular projection 1006 and housing 1002. Housing 1002 may be
connected to the container by any means such as, for example, a
threaded connection, a welded connection, an adhesive connection or
the like. Optionally, a gasket may fit in annular groove 1004 to
help form a liquid tight seal with the container. Inlet plate 1008
may be integrally formed with housing 1002. Inlet plate 1008
includes one or more inlet apertures 1009 located therethrough. In
addition one-way inlet valve 1010 is secured to inlet plate 1008.
One-way inlet valve 1010 may be any type of one-way valve such as,
for example, a ball and spring, a poppet valve, a flapper valve, an
umbrella valve, a slit valve or the like.
[0060] Pump housing 1002 includes a liquid chamber 1012. In one
embodiment, liquid chamber 1012 is cylindrical. Located within
liquid chamber 1012 is a sleeve 1020. Housing 1002 includes an
annular projection 1003 at one end of the liquid chamber 1012.
Sleeve 1020 is secured to annular projection 1003 by collar 1023.
Collar 1023 includes an aperture 1025. Piston 1027 includes a shaft
1030 that projects through aperture 1025. Piston 1027 is slideable
in a reciprocating manner within sleeve 1020. Piston 1027 includes
a double wiper seal 1032 located at one end. Movement of piston
1027 causes the volume of liquid chamber 1012 to expand and
contract. Double wiper seal 1032 may be replaced with any type of
sealing member such as, for example, an o-ring, a single wiper seal
or the like. Housing 1002 includes a projecting member 1034 that
contacts an end 1033 of piston 1027 to stop movement of piston 1027
when it reaches the end of its stroke.
[0061] An inlet passageway 1022 is formed between sleeve 1020 and
the wall of liquid chamber 1012. The inlet passageway 1022 may
extend entirely around sleeve 1020 or may be enclosed by one or
more rib projections (not shown) that cause liquid in inlet
passageway 1022 to flow through passage 1024 into the interior of
sleeve 1020. An outlet passageway 1026 also exists between sleeve
1020 and liquid chamber 1012. The outlet passageway 1026 may extend
entirely around sleeve 1020 or may be enclosed by one or more rib
projections that cause liquid to flow through passage 1028 from the
interior of sleeve 1020. Passageway 1022 and passageway 1026 may be
a common passageway.
[0062] Housing 1002 includes valve seat 1037. Connected to housing
1002 is lower housing 1035. Lower housing 1035 may be connected to
housing 1002 by any means such as, for example, a threaded
connection, a snap-fit connection, a welded connection, an adhesive
connection or the like. Lower housing 1035 has an interior cavity
1039. Lower housing 1035 also includes a first annular projection
1040 that forms an air inlet 1042. An aperture 1044 connects air
inlet to cavity 1039. Annular projection 1040 may be releasably
connected to an air source that is permanently connected to a foam
dispenser (not shown). The releasable connection may be made by any
means such as, for example, a snap-fit, friction fit, a tube (not
shown) that slides over or into annular projection 1040.
[0063] Lower housing 1035 also includes a second annular projection
1050 that has a passageway 1052 connecting to cavity 1039. A
compressible chamber such as, for example, air bellows 1054 is
connected to annular projection 1050 by any means such as, for
example, a friction fit, a snap fit, a welded connection, an
adhesive connection or the like. Lower housing 1002 includes a
floor 1071. A tapered section 1072 extends from floor 1071 to
annular outlet 1074.
[0064] Located within cavity 1039 is an insert 1073. Insert 1073
may be made of one or more components. Insert 1073 includes an
interior cavity 1046 formed by annular member 1075. Interior cavity
1046 retains one-way outlet valve 1036 and biasing member 1038.
One-way outlet valve seals against valve seat 1037. One-way outlet
valve 1036 may be any type of one-way valve such as, for example, a
ball and spring valve, a poppet valve, a flap valve, an umbrella
valve, a slit valve or the like. In addition, insert 1073 contains
a sanitary seal 1060. Sanitary seal 1060 is a flexible member that
forms a one-way valve that allows air to enter from passageway 1042
and into the upper portion of cavity 1039 but prevents liquid or
foam from flowing back into passageway 1042. In one embodiment,
sanitary valve 1060 is integrally formed with insert 1073. Sanitary
valve 1060 is a sanitary valve because it prevents liquid and foam
from traveling into components of the foam dispenser that are not
discarded with the refill unit that includes pump 1000. Insert 1073
includes foaming media 1070 secured therein. Foaming media 1070 may
be one or more screens, porous members, baffles, a sponge, a
foaming cartridge, or the like. Foaming media 1070 may be an
integral part with insert 1073 or may be a separate part.
[0065] An exemplary benefit to using sleeve 1020 is that the liquid
inlet and/or inlet valve 1010 may be positioned over any portion of
the sleeve without affecting the volume of liquid chamber 1012 or
reducing the efficiency of pump 1000. Similarly, the liquid outlet
and/or liquid outlet valve 1036 may be located along any portion of
the sleeve without reducing the volume of liquid chamber 1012 or
reducing the efficiency of pump 1000. In some embodiments, the
liquid inlet and the liquid outlet are offset from one another. In
some embodiments, the liquid outlet is located closer to the front
of a dispenser than the liquid inlet when the pump 1000 is
installed in the foam pump. In some embodiments, the liquid inlet
and liquid outlet are along a common axis. The liquid piston 1027
may moved along a pump axis that is substantially horizontal. In
some embodiments, the liquid inlet valve 1010 moves along an axis
that is substantially normal to the pump axis. In some embodiments,
a portion of the liquid inlet valve 1010 moves along a substantial
vertical axis, such as the inlet valve 1010 illustrated in FIGS. 10
and 11, which may collapse both horizontally and vertically.
[0066] In addition, although the pump 1000 has been described as
being made of selected sub-parts, pump 1000, as well as the other
embodiments of pumps disclosed herein, may be made from more
sub-parts or fewer sub-parts.
[0067] FIG. 10 illustrates pump 1000 in a fully discharged
position. FIG. 11 illustrates pump 1000 in a charged or primed
state. During operation, as piston 1027 of pump 1000 moves from the
discharged position illustrated in FIG. 10 to the charged or primed
state illustrated in FIG. 11, liquid flows in through liquid inlets
1009 into liquid chamber 1012 and through passageways 1022, 1024
into the interior of sleeve 1020. Simultaneously, bellows 1054
moves from a contracted position to an expanded position. Movement
of bellows 1054 to an expanded position draws air in through the
outlet 1074 and sucks back any residual fluid and foam to prevent
fluid from leaking out of the outlet 1074 after the dispense
cycle.
[0068] Movement of piston 1074 from the charged position
illustrated in FIG. 11 to the discharged position illustrated in
FIG. 10 causes fluid to flow out of the liquid chamber 1012
(including the center of the sleeve 1020) through passageways 1028,
1026 past liquid outlet valve 1036 into mixing chamber 1046.
Simultaneously, bellows 1054 is collapsed forcing any liquid drawn
in during the "suck back" operation into cavity 1039. In addition,
air from an air source (not shown) flows through air passage 1042,
through aperture 1044, past sanitary valve 1060, up around the top
of member 1075 and into mixing chamber 1046 where it mixes with the
incoming liquid. The air and liquid mixture is forced through
aperture 1062 and through foam media 1070 to create a rich foam.
The rich foam travels through tapered section 1072 where it
accelerates due to the reduced volume and exits foam pump 1000
through outlet 1074.
[0069] FIG. 12 illustrates yet another exemplary embodiment of a
horizontal pump 1200. As with all the exemplary pumps disclosed
herein, pump 1200 may be used with many different types of the
containers or dispensers including the ones disclosed herein. Pump
1200 includes a housing 1202. Housing 1202 includes annular
projection 1203 that together with the upper portion of housing
1202 forms an annular groove 1203A that receives a container (not
shown). Pump 1200 may be connected to the container by any means
such as, for example, a threaded connection, an adhesive
connection, a friction fit, a welded connection or the like. In
addition, a gasket (not shown) may be used to create a liquid tight
seal between a container and pump 1200.
[0070] Housing 1202 includes an aperture 1204 through the housing
1202 into pump chamber 1220. In addition, one or more liquid inlet
apertures 1208 are included through housing 1202. A one-way check
valve 1206 allows fluid to enter pump chamber 1220 from a container
(not shown) and prevents fluid from exiting pump chamber 1220 and
flowing back into the container. One-way check valve 1206 includes
a stem 1207. Stem 1207 has a projecting member 1209 located at one
end. Projecting member 1209 may be a spherical projection as shown,
or may be a projection with a lower profile. Projection 1209 is
pushed through aperture 1204 and expands once it passes through the
aperture 1204 to retain one-way valve 1206 in place. Optionally, a
second projecting member 1210 is also located along the stem 1207.
Second projecting member 1210 contacts a surface of housing 1202
and also helps to keep one-way valve 1206 in place. One-way valve
1206 includes sealing member 1211. Sealing member 1211 has a
conical shape and is resilient. In one embodiment, one-way valve
1206 is formed of a unitary resilient piece. During operation,
sealing member 1211 is configured to deflect to allow liquid under
pressure to pass from a container into the pump chamber 1220. When
liquid chamber 1220 is pressurized, sealing member 1211 contacts
surface 1205 of annular projection 1203 and forms a seal preventing
liquid from flowing from pump chamber 1220 past sealing member
1211.
[0071] A unique feature about one-way liquid inlet valve 1206 is
that one-way liquid inlet valve 1206 may be secured to pump housing
1202 from outside of the pump. Current liquid inlet valves are
connected to the pump housing from the inside the pump housing. In
addition, the arrangement shown and described herein of having the
sealing member 1211 of the one-way liquid inlet valve located above
the liquid inlet apertures 1208 and outside of the pump chamber
1220 is advantageous in that the portion of one-way valve 1206
located inside of the pump chamber 1220 may be reduced.
[0072] Optionally, other types of one-way check valves may be used
such as, for example, a flap valve, a poppet valve, an umbrella
valve, a spring and ball valve or any other valve that allows fluid
to flow into pump chamber 1220 and prevents fluid from flowing from
the pump chamber 1220 back into the container (not shown). However,
these valves would be secured to the pump housing from inside the
pump housing.
[0073] Located at least partially within pump chamber 1220 is a
sleeve 1230. Sleeve 1230 fits within pump chamber 1220 and creates
one or more passageways between the outside wall of the sleeve 1230
and one or more walls of the pump chamber 1220. The passageways may
be similar to those described with respect to the pumps disclosed
in FIGS. 3, 4, 10 and 11. Sleeve 1230 is secured to housing 1202 by
a collar or end cap 1231. Collar 1231 may be press-fit into housing
1202, secured with an adhesive, connected by a threaded connection,
or the like.
[0074] A piston head 1236 is secured to piston rod 1234 and is
movable in a reciprocating fashion within sleeve 1230 to expand and
contract the pump chamber 1220. As discussed above in more detail,
benefits to having the sleeve 1230 is that the inlet to the pump
chamber 1220 and the outlet from the pump chamber 1220 may be
located anywhere along the length of the pump chamber 1220, or
sleeve 1230. For example, in some embodiments, the liquid inlet and
liquid outlet are offset from one another. In one embodiment, the
liquid outlet is located farther away from the back of a dispenser
when the pump 1220 is used in a dispenser. Although they are only
off-set slightly in the embodiment illustrated in FIG. 12, the
center of the liquid inlet valve being off-sett from the center of
the liquid outlet valve. In some embodiments, the center of the
valves are well off-set.
[0075] Housing 1202 includes a cavity 1270. A portion of cavity
1270 forms mixing chamber 1214. An air inlet 1212 is located in a
side wall of the cavity 1270. An annular projection 1262 extends
outward and surrounds air inlet 1212. Annular projection 1262 forms
a means for connecting pump 1200 with an air source (not shown) for
providing air to pump 1200 to mix with the liquid to form a foam.
The air source may be an air compressor permanently attached to the
pump 1200 or may be an air source that is releasably connected to
pump 1200. The air source may be a positive displacement air pump,
a bellows pump, a piston pump, a fan, an air compressor, or the
like.
[0076] Located within cavity 1270 is dual action valve 1240. Dual
action valve 1240 has a first wiper seal 1242 and a second wiper
seal 1244, both of which are flexible. The first and second wiper
seals 1242, 1244 also form part of the mixing chamber 1214, which
is located between them. First wiper seal 1242 is a one-way liquid
inlet valve which allows liquid under pressure to enter mixing
chamber 1214. Second wiper seal 1244 is a one-way air inlet valve
that allows air to enter mixing chamber 1214 and prevents liquid or
air from traveling from the mixing chamber 1214 back toward the air
source (not shown). Dual action valve 1240 includes an internal
passage 1241. An aperture 1246 through the wall of the dual action
valve 1240 allows the mixture of liquid and air to travel from the
mixing chamber into passage 1241. The lower end of dual action
valve 1240 has a flared portion 1245 proximate the outlet 1256. In
addition, dual action valve 1240 includes an annular projection
member 1260. Annular projection member 1260 is secured to the
surface 1248 of housing 1202. Annular projection member 1260 may be
secured to surface 1248 with an adhesive, a friction fit, a welded
connection or the like. In one embodiment, dual action valve 1240
is a single piece construction. In some embodiments, one or more of
the components of the dual action valve 1240 may be separate
parts.
[0077] A foaming cartridge 1250 fits within the flared portion 1245
of dual action valve 1240. In one embodiment, foaming cartridge
1250 includes screens 1252. Screens 1252 may be individually
secured in the flared portion 1245 without being connected to a
cartridge. Optionally, foaming cartridge 1250 may simply be a
porous member or a series of baffles.
[0078] During operation, piston head 1234 is moved outward toward
the front of pump chamber 1220 which expands pump chamber 1220
creating a vacuum which causes one-way liquid outlet valve 1242 to
seal against surface 1243. Liquid flows from the container (not
shown) and into pump chamber 1220 past one-way liquid inlet valve
1206. The fluid flows around sleeve 1230 along channels 1221 and
1222 and into the interior of the sleeve 1230.
[0079] As the piston head 1234 moves inward toward the back of pump
chamber 1220, the volume of pump chamber 1220 is reduced. The
pressure created by the contracting pump chamber 1220 forces
one-way liquid inlet valve 1206 to close by sealing off against
surface 1205. Liquid travels past wiper seal 1242 into mixing
chamber 1214. Air travels from an air source (not shown) that
connects to member 1262 through aperture 1212 into cavity 1270 past
wiper seal 1244 and into mixing chamber 1214 where the air mixes
with the liquid to form an air/liquid mixture. The liquid and air
may simultaneously enter mixing chamber 1214. Optionally, the
timing may be slightly offset, wherein liquid starts entering the
chamber slightly prior to the air, or in one embodiment, the liquid
enters mixing chamber prior to the air entering the mixing chamber.
The liquid/air mixture is forced by the air pressure through
aperture 1246 into passage 1241, through foaming cartridge 1250 and
is dispensed out of outlet nozzle 1256 as a foam.
[0080] The air compressors and liquid pumps described herein may
include biasing members to return them to a first state, or a
charged state. Optionally, a biasing member in one or more of the
air compressors or liquid pumps may return other air compressors
and/or liquid pumps to a first state. In some embodiments, a
biasing member in the actuator mechanism returns the air compressor
and/or liquid pumps to a first state. Still yet, if the air
compressor and or liquid pump are electrically operated, they may
be moved to the first state electrically.
[0081] In addition, parts described with respect to one embodiment
may be combined with parts described with respect to other
embodiments. For example, the "suck back" feature described with
respect to pump 1000 may be incorporated into any of the other
pumps, refill units or dispensers.
[0082] While the present invention has been illustrated by the
description of embodiments thereof and while the embodiments have
been described in considerable detail, it is not the intention of
the applicants to restrict or in any way limit the scope of the
appended claims to such detail. Additional advantages and
modifications will readily appear to those skilled in the art.
Moreover, elements described with one embodiment may be readily
adapted for use with other embodiments. Therefore, the invention,
in its broader aspects, is not limited to the specific details, the
representative apparatus and/or illustrative examples shown and
described. Accordingly, departures may be made from such details
without departing from the spirit or scope of the applicants'
general inventive concept.
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