Note: Descriptions are shown in the official language in which they were submitted.
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UNDER-COUNTER MOUNT FOAM DISPENSING SYSTEMS WITH PERMANENT
AIR COMPRESSORS AND REFILL UNITS FOR SAME
RELATED APPLICATIONS
[0001] This application claims priority to Non-Provisional Patent Application
Serial No.
13792,024 filed on March 9, 2013 and entitled UNDER-COUNTER MOUNT FOAM
DISPENSING SYSTEMS WITH PERMANENT AIR COMPRESSORS AND REFILL
UNITS FOR SAME, which claims priority to and the benefits of U.S. Provisional
Patent
Application Serial No. 61/723,468 filed on November 7, 2012, and entitled
UNDER-
COUNTER MOUNT FOAM DISPENSING SYSTEMS WITH PERMANENT AIR
COMPRESSORS AND REFILL UNITS FOR SAME. These applications are incorporated
herein by reference in their entirety.
TECHNICAL FIELD
[0002] The present invention relates generally to under-counter mount foam
dispensing
systems, and more particularly to under-counter mount foam dispensing systems
with
permanently affixed air compressors, and refill units for such foam dispensing
systems
having an air connection manifold for placing the refill unit in fluid
communication with the
air compressor.
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. Some foam
dispensing
systems are mounted to a counter top and have a spout on top of the counter
and a liquid
pump, an air pump and a container that are located under the counter. These
types of systems
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are commonly referred to as under-counter mount dispensing systems. There are
two basic
types of under-counter mount systems. The first has a refillable container
that a user
removes, refills with foamable liquid and reinstalls. These types of
dispensers are not
desirable because bacteria can grow in the container and contaminate the
liquid. The second
type has a refill unit that includes an air compressor, a liquid pump and a
container. When
the container is empty, the air compressor, liquid pump and container are
removed and
thrown away. A new refill unit including the air compressor, liquid pump and
container
(filled with foamable liquid) is reinstalled. Although these types of refills
are more sanitary
than refilling the container, these types of refill units are expensive
because they contain an
air pump and a liquid pump.
SUMMARY
[0004] Under-counter foam dispenser systems and refill units for an under-
counter mount
foam dispensing system are disclosed herein. An exemplary refill unit includes
a container
for holding a liquid, at least a portion of a liquid pump, a quick-connect air
manifold for
releasably connecting to a pressurized air source, an air passage to a mixing
chamber and a
liquid passage to the mixing chamber. The air inlet is in fluid communication
with the source
for pressurized air when the refill unit is mounted in the dispensing system
and disengages
from the pressurized air source when the refill unit is removed from the under-
counter mount
foam dispensing system.
[0005] Refill units for an under-counter mount foam dispensing system are
disclosed
herein. Exemplary refill units include a container for holding a liquid, the
container adapted
to mount below a countertop, and a dip tube that extends to the bottom of the
container. The
refill units include at least a portion of a liquid pump in fluid
communication with the dip
tube. A first tube is in fluid communication with the portion of the liquid
pump for
communicating liquid from the container to a mixing chamber. A manifold is
secured to the
container. The manifold includes an air inlet and an air outlet. A second tube
extends from
the air outlet of the manifold to the mixing chamber. The air inlet is engaged
with a source of
pressurized air when the refill unit is mounted in the foam dispensing system
and the air inlet
is disengaged from the pressurized air source when the refill unit is not
mounted in the
dispensing system.
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[0006] In addition, methods of installing a refill unit in an under-counter
foam dispensing
system are disclosed herein. Exemplary methods include obtaining a refill unit
that includes
a manifold having an air inlet located on the top of the manifold. The method
includes
aligning the refill unit so that the air inlet is aligned with a source of
pressurized air; and
moving the refill unit upward to engage the air inlet with the source of
pressurized air.
[0007] Foam dispensing systems are also disclosed herein. An exemplary foam
dispensing
system includes a spout located above a countertop and an air compressor
having an air
outlet. The system also includes a refill unit having a container for holding
a foamable liquid,
a liquid outlet tube and a manifold for releasably engaging the air outlet.
The system also
includes a liquid pump for pumping liquid from the container to through the
liquid outlet tube
and the liquid pump located below the countertop. In some embodiments, the air
compressor
is located above the countertop and in some embodiments the air compressor is
located below
the countertop. Similarly, in some embodiments, the manifold is located above
the
countertop and in some embodiments the manifold is located below the
countertop.
[0008] Another exemplary method of installing a refill unit in an under-
counter foam
dispensing system includes obtaining a refill unit that includes a manifold
having an air inlet
located on a side of the manifold and moving the refill unit into position and
then connecting
an air source to the side of the manifold.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] 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:
[0010] Figure 1 is a cross-section of an exemplary under-counter mount foam
dispenser
system 100 with a refill unit 140 installed;
[0011] Figure 2 is a cross-section of the exemplary under-counter mount foam
dispenser
100 system without a refill unit installed;
[0012] Figure 3 is a cross-section of an exemplary refill unit 140 for use in
an under-counter
mount foam dispensing system 100;
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[0013] Figure 4 is a cross-section of the exemplary under-counter mount foam
dispenser
system 100 with a refill unit 140 installed with the liquid pumping mechanism
130 rotated
out for removal of the refill unit 140;
[0014] Figure 5 is a cross-section of an exemplary air connection manifold 500
for use in an
under-counter mount foam dispenser system;
[0015] Figure 6 is a cross-section of another exemplary air connection
manifold 600 for use
in an under-counter mount foam dispenser system;
[0016] Figure 7 is a cross-section of another exemplary air connection
manifold 700 for use
in an under-counter mount foam dispenser system;
[0017] Figure 8 is a cross-section of another exemplary air connection
manifold 800 for use
in an under-counter mount foam dispenser system;
[0018] Figure 9 is a cross-section of yet another exemplary air connection
manifold 900 for
use in an under-counter mount foam dispenser system;
[0019] Figures 10 and 11 illustrate additional cross-sections of another
exemplary manifold
for connecting an air compressor 1020 to a manifold 1026 of a refill unit of
an under-counter
foam dispensing system; and
[0020] Figure 12 is a cross-section of an exemplary under-counter mount foam
dispenser
system 1200 with a refill unit 1240 installed.
DETAILED DESCRIPTION
[0021] An exemplary embodiment of a foam dispensing system 100 is best
described with
respect to Figures 1-4. Figure 1 is a cross-section of an exemplary embodiment
of a foam
dispenser system 100 with a refill unit 140 installed therein. Figure 2 is a
cross-section of the
foam dispenser system 100 with refill unit 140 removed. Foam dispenser system
100
includes a spout 106. Spout 106 has a hollow interior 107. Spout 106 is
secured to counter
104 by any means such as, for example, a threaded connector (not shown) that
extends from
spout 106 to below the counter, and the threaded connector is connected to a
lower bracket
110. An air pump or air compressor 120 is secured to lower bracket 110 by a
mounting
member, which is not shown for purposes of clarity. Air compressor 120 is
permanently
mounted below the countertop 104 and is not removed with refill unit 140. Air
compressor
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120 includes an actuator 121 (Fig. 2). Actuator 121 is an electric actuator.
Actuator 121 may
include a direct current motor and gearing (not shown) that is preferably
powered by one or
more batteries, but may be powered by other means and may optionally be an
alternating
current motor and gearing. Optionally, actuator 121 may be a manually-operated
actuator.
[0022] Air compressor 120 includes an air tube 122. Air tube 122 terminates at
air tube
outlet 124 inside the interior of lower bracket 110. Air tube outlet 124 of
air tube 122 points
in a downward position. Air tube outlet 124 of air tube 122 mates with a
manifold 126 when
the refill unit 140 is installed in foam dispenser system 100, which is
described in detail
below with respect to the additional embodiments of exemplary manifolds shown
and
described with respect to Figures 6-11 below.
[0023] In addition, secured to lower bracket 110 is a liquid pump 128. Liquid
pump 128 is
a peristaltic pump and contains a plurality of rollers 132. Rollers 132 are
rotated by a motor
(not shown). In one embodiment, a single motor drives the liquid pump 128 and
the air
compressor 121. The housing of liquid pump 128 is secured to lower bracket 110
by a hinge
131. Liquid pump 128 may be rotated out of the way (see Fig. 4) to insert and
remove the
refill unit 140 from the under-counter foam dispenser system 100 and rotated
back into place
(see Fig. 5) for operation of the foam dispensing system 100. The motor that
drives rollers
132 may be powered from the same source as air compressor 120, such as, for
example
batteries, a 120-VAC source, or the like.
[0024] In addition, although a peristaltic pump is shown in the figures and
described in the
specification, any type of liquid pump may be used such as, for example, a
piston pump, a
dome pump, a rotary pump, a diaphragm pump or the like. An aspect of
embodiments of the
present invention is that all of the parts that contact the liquid are
disposed of when the refill
unit 140 is replaced. Parts that do not contact the liquid such as, for
example, the air
compressor 120, air tube 122 and lower bracket 110 may remain secured in
position when the
refill unit 140 is replaced.
[0025] Lower bracket 110 includes a collar 137. Collar 137 is configured to
receive the top
portion of container 142. Collar 137 is keyed, or shaped, so that it mates
with container 142
in a selected orientation so that the refill unit 140 is properly orientated
with lower bracket
110 when refill unit 140 is installed in the foam dispensing system 100. In
addition, lower
bracket 110 includes a rotatable release ring 136. Rotatable release ring 136
engages with
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one or more tabs 308 (Fig. 3) on the refill unit 140 when refill unit 140 is
inserted in foam
dispensing system 100. Rotatable release ring 136 may include a biasing member
(not
shown), such as a spring, to bias the rotatable release ring 136 into a
position that retains
refill unit 140 in place. In addition, in one embodiment, rotatable release
ring 136 has a cam
surface (not shown) so that when refill unit 140 is inserted into foam
dispensing system 100,
the rotatable release ring 136 rotates automatically and allows the refill
unit 140 to move into
place. After the tabs 308 of the refill unit 140 move into place, the biasing
member moves
rotatable release ring 136 into position to secure the refill unit 140. This
may be
accomplished by, for example, mating tabs (not shown) on rotatable release
ring 136.
[0026] Figure 3 illustrates an exemplary refill unit 140. Refill unit 140
includes a container
142 that forms a liquid reservoir for supply of a foamable liquid within the
disposable refill
unit 140. 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 140, the container 142 is a rigid housing member, but
can be any type of
container having a suitable configuration for containing the foamable liquid
without leaking.
In other embodiments, the container 142 may be formed by a collapsible
container and can be
made of thin plastic or a flexible bag-like container.
[0027] Secured to container 142 is a cap 310. Cap 310 includes a plurality of
tabs 308
described above for securing the refill unit 140 to the foam dispensing system
100. In
addition, a bracket 314 is secured to cap 310. Bracket 314 includes a curved
backing plate
316. Bracket 314 and curved backing plate 316 serves to hold liquid tube 146
in place.
Curved backing plate 316 is curved with a slightly larger diameter than the
outside diameter
that rollers 132 travel. When the refill unit 140 is installed in foam
dispensing system 100,
and the rollers 132 rotate counterclockwise they compress liquid tube 146
against curved
backing plate 316 and push liquid up liquid tube 146 toward foaming chamber
152. Foaming
chamber 152 is where the liquid and air are combined and pushed through a
foaming media,
such as, for example, a screen. An exemplary foaming chamber 152 is shown and
described
in U.S. Patent No. 7,819,289, entitled "Foam Soap Generator," which is
incorporated herein
by reference. In one embodiment, rollers 132 rotate clockwise for a brief
period at the end of
a dispense cycle to draw back, or suck back, residual liquid and/or foam to
prevent dripping.
[0028] In addition, refill unit 140 includes a quick-connect air manifold 126.
Liquid tube
146 extends through a wall 330 of manifold 126. The lower portion of liquid
tube 146 is
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sealed to the wall 330 to prevent leakage. Also secured to manifold 126 is air
conduit 150.
Air conduit 150 is located coaxial with liquid tube 146. Air conduit 150
terminates
proximate foaming chamber 152. An air passage is formed between the inside of
air conduit
150 and the outside of liquid tube 149. In addition, quick-connect air
manifold 126 includes
an inlet aperture 325. Air inlet aperture 325 releasably connects to air tube
outlet 124. Air
tube outlet 124 preferably has a tapered end, and when refill unit 140 is
moved upward, air
tube outlet 124 engages air inlet aperture 325. In one embodiment, air tube
outlet 124
extends into air inlet aperture 325. The air outlet tube may be tapered and
seal against the
walls of inlet aperture 325 to form an airtight seal. Optionally, a sealing
member may be
used to ensure a substantially airtight seal. Figures 5 through 11 illustrate
a number of
exemplary embodiments of quick-connect air manifolds suitable for use in under-
counter
mount foam dispensing systems.
[0029] Figure 5 is an enlarged cross-section of an air tube to air manifold
connection 500
for an exemplary quick-connect manifold 526 installed in a foam dispensing
system.
Manifold 526 is similar to manifold 126. Lower bracket 503 may be similar to
lower bracket
110 and is secured to the spout (not shown) and provides support for the
refill unit. Manifold
526 includes coaxial dispensing tubes 550, which are formed by air conduit 502
and liquid
tube 547 arranged coaxially. In this exemplary embodiment, as the refill unit
is installed, the
coaxial tubes 550 are inserted so that they travel up the interior of the
spout (not shown). As
the refill unit, including manifold 526, is moved upward into position, air
tube end 524 passes
through aperture 525 and a sealing member 510 forms a seal between air tube
end 524 and
manifold 526. The refill unit may be secured in place by, for example, a
rotatable
engagement ring (not shown), as described above.
[0030] Figure 6 is an enlarged cross-section of another exemplary
embodiment of an air
tube to air manifold connection 600 for a quick-connect manifold 626 installed
in a foam
dispensing system. Manifold 626 is similar to manifold 526. Lower bracket 603
may be
similar to lower bracket 503 and is secured to the spout (not shown) and
provides support for
the refill unit. Manifold 626 includes coaxial dispensing tubes 650, which are
formed by air
conduit 602 and liquid tube 647 arranged coaxially. In addition, a sealing
member 610 is
located around aperture 625. Sealing member 610 may be an elastomeric element.
In this
exemplary embodiment, as manifold 626 is moved upward into position, air tube
end 624
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contacts and fits around sealing member 610, which is secured to aperture 625.
This
connection forms a seal between air tube end 624 and manifold 626.
[0031] Figure 7 is an enlarged cross-section of another exemplary embodiment
of an air
tube to air manifold connection 700 for a quick-connect manifold 726 installed
in a foam
dispensing system. Manifold 726 is similar to manifold 626. Lower bracket 703
may be
similar to lower bracket 603 and is secured to the spout (not shown) and
provides support for
the refill unit. Manifold 726 includes coaxial dispensing tubes 750, which is
formed by air
conduit 702 and liquid tube 747 arranged coaxially and fit within the spout.
Air tube end 724
is preferably rounded. Sealing member 710 is located around aperture 725 and
may be an
elastomeric element. In this exemplary embodiment, as manifold 726 is moved
upward into
position, air tube end 724 contacts sealing member 710, which is secured to
aperture 725.
This connection forms a seal between air tube end 724 and manifold 726.
[0032] Figure 8 is an enlarged cross-section of another exemplary
embodiment of an air
tube to air manifold connection 800 for a quick-connect manifold 826 installed
in a foam
dispensing system. Manifold 826 is similar to manifold 526. Lower bracket 803
may be
similar to lower bracket 503 and is secured to the spout (not shown) and
provides support for
the refill unit. Manifold 826 includes coaxial dispensing tubes 850, which is
formed by air
conduit 802 and liquid tube 847 arranged coaxially and fit within the spout.
Manifold 826
includes an annular notch 809 that retains an o-ring 810. In this exemplary
embodiment, as
manifold 826 is moved upward into position, air tube end passes into aperture
825 and
contacts sealing member 810. This connection forms a seal between air tube end
824 and
manifold 826.
[0033] In addition, manifold 826 includes a sanitary sealing member 852.
Sanitary sealing
member 852 is a one-way valve that allows air to flow into the air passage
located between
liquid tube 847 and air conduit 802. Sanitary sealing member 852 prevents
liquid or foam
from traveling down the air passage and into manifold 826. Any of the above
embodiments,
may include a sanitary seal.
[0034] Figure 9 is an enlarged cross-section of another exemplary embodiment
of an air
tube to air manifold connection 900 for a quick-connect manifold 926 installed
in a foam
dispensing system. Manifold 926 is similar to manifold 526. Lower bracket 903
may be
similar to lower bracket 503 and is secured to the spout (not shown) and
provides support for
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the refill unit. Manifold 926 includes coaxial dispensing tubes 950, which is
formed by air
conduit 902 and liquid tube 947 arranged coaxially and may be inserted into
the spout. Air
tube end 924 has a tapered end. Sealing member 910 projects above and around
aperture 925
and may be an elastomeric element. In this exemplary embodiment, as manifold
926 is
moved upward into position, air tube end 924 contacts sealing member 910. This
connection
forms a seal between air tube end 924 and manifold 926.
[0035] Figures 10 and 11 are an enlarged cross-section of yet another
exemplary
embodiment of an air tube to air manifold connection 1000 for a quick-connect
manifold
1026 installed in a foam dispensing system. Manifold 1026 is secured to a
refill unit. Lower
bracket 1010 may be similar to lower bracket 110 and is secured to the spout
(not shown) and
provides support for the refill unit. Manifold 1026 includes coaxial
dispensing tubes 1050,
which is formed by an air conduit and liquid tube arranged coaxially. In this
exemplary
embodiment, air manifold 1026 includes an aperture 1003 located on a side
wall. A sealing
member 1104 is located around aperture 1003 and may be an elastomeric element.
In this
exemplary embodiment, the refill unit is removed by unlatching latch 1033 and
rotating
pumping mechanism 1030 and rollers 1032 outward about hinge 1031. A rotatable
release
ring (not shown) is rotated, and the refill unit may be removed downward. To
install a new
refill unit, the coaxial tubes are inserted into the opening and the refill
unit is pushed upward.
The rotatable release ring rotates out of the way until the tabs (not shown)
clear the mating
tabs (not shown) and the rotatable release ring rotates back into position to
hold the refill unit
in place. The user then rotates the pumping mechanism 1030 back and it is
sealed into place
by latch 1033. Air tube end 1102 mates with manifold 1026 and the connection
is sealed by
sealing member 1104. Thus, the new refill unit is installed and the foam
dispensing system is
ready to operate.
[0036] In some embodiments, a membrane (not shown) is located over the air
inlet to the
manifold prior to shipping. The membrane prevents contaminates from entering
the air
manifold prior to installation in a foam dispenser system. In one embodiment,
the membrane
is piercable by the end of the air tube. In one embodiment, the membrane is
removed prior to
installation in a foam dispensing system. In yet another embodiment, air
pressure from the
pressurized air source ruptures the membrane.
[0037] Figure 12 is a cross-section of an exemplary embodiment of a foam
dispenser
system 1200 with a refill unit 1240 installed therein. The dispenser is
similar to the dispenser
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in Figure 2, which is a cross-section of the foam dispenser system with refill
unit removed.
Foam dispenser system 1200 includes a spout 1206. Spout 1206 has a hollow
interior 1207.
Spout 1206 is secured to counter 1204 by any means such as, for example, a
threaded
connector (not shown) that extends from spout 1206 to below the counter, and
the threaded
connector is connected to a lower bracket 1210. An air pump or air compressor
1220 is
located within spout 1206. Air compressor 1220 is permanently mounted in the
spout above
the countertop 1204 and is not removed with refill unit 1240. Air compressor
1220 includes
an electronic actuator, similar to actuator 121 illustrated in Figure 2.
Optionally, actuator
1221 may be a manually-operated actuator.
[0038] Air compressor 1220 includes an air tube 1222. Air tube 1222 terminates
at air tube
outlet 1224 inside the interior of lower bracket 1210. Air tube outlet 1224 of
air tube 1222
points in a downward position. Air tube outlet 1224 of air tube 1222 mates
with a manifold
1226 when the refill unit 1240 is installed in foam dispenser system 1200.
Such mating
connections are described in detail above with respect to Figure 1 and Figures
6-11.
[0039] In addition, secured to lower bracket 1210 is a liquid pump 1228.
Liquid pump
1228 is a peristaltic pump and contains a plurality of rollers 1232. Rollers
1232 are rotated
by a motor (not shown). In one embodiment, a single motor drives the liquid
pump 1228 and
the air compressor 1221. The housing of liquid pump 1228 is secured to lower
bracket 1228
by a hinge 1231. Liquid pump 1228 may be rotated out of the way (see e.g. Fig.
4) to insert
and remove the refill unit 1240 from the under-counter foam dispenser system
1200 and
rotated back into place (see e.g. Fig. 5) for operation of the foam dispensing
system 1200.
The motor that drives rollers 1232 may be powered from the same source as air
compressor
1220, such as, for example batteries, a 120-VAC source, or the like.
[0040] In addition, although a peristaltic pump is shown in the figures and
described in the
specification, any type of liquid pump may be used such as, for example, a
piston pump, a
dome pump, a rotary pump, a diaphragm pump or the like. An aspect of
embodiments of the
present invention is that all of the parts that contact the liquid are
disposed of when the refill
unit 1240 is replaced. Parts that do not contact the liquid such as, for
example, the air
compressor 1220, air tube 1222 and lower bracket 1210 may remain secured in
position when
the refill unit 1240 is replaced.
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[0041] Lower bracket 1210 includes a collar 1237. Collar 1237 is configured to
receive the
top portion of container 1242. Collar 1237 is keyed, or shaped, so that it
mates with
container 1242 in a selected orientation so that the refill unit 1240 is
properly orientated with
lower bracket 1210 when refill unit 1240 is installed in the foam dispensing
system 1200. In
addition, lower bracket 1210 includes a rotatable release ring 1236. Rotatable
release ring
1236 engages with one or more tabs 308 (Fig. 3) on the refill unit 1240 when
refill unit 1240
is inserted in foam dispensing system 1200. Rotatable release ring 1236 may
include a
biasing member (not shown), such as a spring, to bias the rotatable release
ring 1236 into a
position that retains refill unit 1240 in place. In addition, in one
embodiment, rotatable
release ring 1236 has a cam surface (not shown) so that when refill unit 1240
is inserted into
foam dispensing system 1200, the rotatable release ring 1236 rotates
automatically and
allows the refill unit 1240 to move into place. After the tabs 308 of the
refill unit 1240 move
into place, the biasing member moves rotatable release ring 1236 into position
to secure the
refill unit 1240. This may be accomplished by, for example, mating tabs (not
shown) on
rotatable release ring 1236.
[0042] 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 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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