Note: Descriptions are shown in the official language in which they were submitted.
SEQUENTIALLY ACTIVATED MULTI-DIAPHRAGM FOAM PUMPS, REFILL
UNITS AND DISPENSER SYSTEMS
RELATED APPLICATIONS
[0001]
The present invention claims priority to, and the benefits of: U.S.
Provisional
Application serial No. 62/319,061 filed on April 6, 2016 and titled
SEQUENTIALLY
ACTIVATED MULTI-DIAPHRAGM FOAM PUMPS, REFILL UNITS AND DISPENSER
SYSTEMS; U.S. Non-Provisional Application serial No. 15/429,389 filed on
February 10, 2017
and titled HIGH QUALITY NON-AEROSOL HAND SANITIZING FOAM; U.S. Non-
Provisional Application serial No. 15/369,007 filed on December 5, 2016 and
titled
SEQUENTIALLY ACTIVATED MULTI-DIAPHRAGM FOAM PUMPS, REFILL UNITS
AND DISPENSER SYSTEMS; U.S. Non-Provisional Patent Application Serial No.
15/355,112
filed on November 18, 2016 and titled SEQUENTIALLY ACTIVATED MULTI-DIAPHRAGM
FOAM PUMPS, REFILL UNITS AND DISPENSER SYSTEMS; U.S. Non-Provisional
Application serial No. 15/350,190 filed on November 14, 2016 and titled
IMPROVED
FOAMING CARTRIDGE; and U.S. Non-Provisional Application serial No. 15/356,795
filed on
November 21, 2016 and titled FOAM DISPENSING SYSTEMS, PUMPS AND REFILL UNITS
HAVING HIGH AIR TO LIQUID RATIOS.
TECHNICAL FIELD
[0002] The present invention relates generally to pumps, refill units for
dispenser systems, and
more particularly to pumps, refill units, and dispensers having sequentially
activated multi-
diaphragm foam pumps for mixing liquid soap, sanitizer, or lotion with air to
create and dispense
a foam product.
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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.
SUMMARY
[0004] The present application discloses exemplary embodiments of sequentially
activated
multi-diaphragm foam pumps, refill units and dispenser systems and refill
units sequentially
activated multi-diaphragm foam pumps.
[0005] An exemplary foam dispenser includes a housing, a drive motor and a
foam pump
operatively coupled to the drive motor. The foam pump is secured to the
housing and the foam
pump includes a housing and a molded multi-chamber diaphragm. The molded multi-
chamber
diaphragm includes a liquid pump chamber, two or more air pump chambers; and
an outlet
valve. A mixing chamber is included and located downstream of the outlet valve
for mixing
foamable liquid from the liquid pump diaphragm with air from each of the two
or more air pump
chambers. In addition, a foam cartridge and an outlet for dispensing foam are
also included.
[0006] An exemplary refill unit for a foam dispenser includes a container for
holding foamable
liquid, a foam pump secured to the container. The foam pump includes a
housing, a molded
multi-chamber diaphragm. The molded multi-chamber diaphragm includes a liquid
pump
chamber and three air pump chambers. The foam pump also includes an inlet
valve, an outlet
valve, and a mixing chamber downstream of the outlet valve for mixing foamable
liquid from the
liquid pump chamber with air from each of the three air pump chambers. The
refill unit further
includes a foam cartridge in fluid communication with the mixing chamber and
an outlet for
dispensing foam wherein the outlet is in fluid communication with the foam
cartridge.
[0007] Another exemplary foam dispenser includes a dispenser housing and a
foam pump
secured to the housing. The foam pump includes a pump housing and a molded
multi-chamber
diaphragm. The molded multi-chamber diaphragm includes a liquid pump chamber
and three air
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pump chambers. A rotatable drive mechanism for sequentially compressing the
liquid pump
chamber and two or more air pump chambers is also included. The rotatable
drive mechanism is
coupled to a drive motor. A mixing chamber is located downstream of the liquid
and air pump
chambers for mixing foamable liquid from the liquid pump chamber with air from
each of the
three air pump chambers. A foam cartridge is included and is in fluid
communication with the
mixing chamber. In addition, the dispenser includes an outlet for dispensing
foam wherein the
outlet is in fluid communication with the foam cartridge.
[0008] An exemplary refill unit for a foam dispenser includes a container for
holding foamable
liquid, a foam pump secured to the container, a foam cartridge, an outlet and
an actuation
mechanism. The foam pump includes a housing, a liquid pump diaphragm, a
plurality of air
pump diaphragms, and a mixing chamber. Liquid from the liquid pump diaphragm
and air from
the air pump diaphragms mix in the mixing chamber to form a foamy mixture. The
foam
cartridge is in fluid communication with the mixing chamber, and the foamy
mixture travels
through the foam cartridge. A dose of foam exits the foam cartridge, and the
dose of foam is
dispensed out of the outlet of the refill unit. An actuation mechanism
releasably connects to a
drive system that is permanently attached to a dispenser. The actuation
mechanism sequentially
activates the liquid pump diaphragm and the air pump diaphragms when the
refill unit is
connected to the dispenser and the drive system is activated. The sequential
activation of the
liquid pump diaphragm and air pump diaphragms causes the liquid pump diaphragm
to pump at
least a partial dose of liquid into the mixing chamber and the air pump
diaphragms to pump at
least a partial dose of air into the mixing chamber.
[0009] Another exemplary refill unit for a foam dispenser includes a container
for holding
foamable liquid, a foam pump connected to the container, a mixing chamber, a
foam cartridge,
an outlet, and a plate. The foam pump has a plurality of diaphragm pumping
chambers. At least
one diaphragm pumping chamber pumps liquid, and at least two diaphragm pumping
chambers
pump air. The mixing chamber is located downstream of the plurality of
diaphragm pumping
chambers for mixing liquid and air to form a foamy mixture. The foam cartridge
is located
downstream of the mixing chamber, and the foamy mixture travels through the
foam cartridge
and exits the foam cartridge as an enriched foam. The foam is dispensed
through the outlet of
the refill unit. The plate is connected to the plurality of diaphragm pumping
chambers. The
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plate is configured to engage with a drive system that is permanently secured
to the foam
dispenser when the refill unit is installed in the foam dispenser and
disengage with the drive
system when the refill unit is removed from the foam dispenser. Movement of
the plate about an
axis causes at least a partial dose of liquid to be pumped into the mixing
chamber, followed by at
least a partial dose of a first dose of air being pumped into the mixing
chamber, followed by at
least a partial dose of a second dose of air being pumped into the mixing
chamber.
100101 Another exemplary refill unit for a foam dispenser includes a container
for holding
foamable liquid, a sequentially activated multi-diaphragm foam pump secured to
the container, a
wobble plate, a pin, a foam cartridge, and a foam outlet. The sequentially
activated multi-
diaphragm foam pump has a liquid pump diaphragm for pumping liquid into a
mixing chamber,
a first air pump diaphragm for pumping air into the mixing chamber, and a
second air pump
diaphragm for pumping air into the mixing chamber. The wobble plate is secured
to the liquid
pump diaphragm, the first air pump diaphragm, and the second air pump
diaphragm. The pin has
a first end that is connected to the wobble plate and a second end that is
free. Movement of the
second end of the pin in a circular path causes a sequential compression of
the liquid pump
diaphragm, the first air pump diaphragm, and the second air pump diaphragm.
The second end
of the pin is releasably connected to an eccentric drive system that is
permanently connected to
the foam dispenser. The foam cartridge is downstream from the mixing chamber,
and the foam
outlet is downstream of the foam cartridge. Foam is dispensed from the foam
outlet.
100111 Another exemplary refill unit for a foam dispenser includes a container
for holding
foamable liquid, a sequentially activated multi-diaphragm foam pump, a plate,
a foam cartridge,
and an outlet. The sequentially activated multi-diaphragm foam pump includes a
housing, a
liquid pump portion secured to the housing, an air pump portion secured to the
housing, a mixing
chamber, and a pump outlet. The liquid pump portion has a liquid inlet, a
liquid inlet valve, a
liquid pump diaphragm, a liquid outlet valve, and a liquid outlet. The air
pump portion has a
first and second air inlet, a first and second air inlet valve, a first and
second air pump
diaphragm, a first and second air outlet valve, and a first and second air
outlet. The mixing
chamber is in fluid communication with the liquid outlet, the first air
outlet, and the second air
outlet. The liquid pump diaphragm pumps a shot of liquid into the mixing
chamber. The first air
pump diaphragm pumps a shot of air into the mixing chamber to mix with the
liquid to form a
4
liquid air mixture. The second air pump diaphragm pumps a shot of air into the
mixing chamber
to mix with the liquid air mixture to form a foamy mixture. The foamy mixture
is dispensed
from the pump outlet. The plate is connected to the liquid pump diaphragm, the
first air pump
diaphragm, and the second air pump diaphragm. The plate is configured to
engage with a drive
system that is permanently secured to the foam dispenser when the refill unit
is installed in the
foam dispenser and disengage with the drive system when the refill unit is
removed from the
foam dispenser. Movement of the plate about an axis causes the shot of liquid
to be pumped
from the liquid pump diaphragm into the mixing chamber, followed by the shot
of air to be
pumped from the first air pump diaphragm into the mixing chamber, followed by
the shot of air
to be pumped from the second air pump diaphragm into the mixing chamber. The
foam cartridge
is in fluid communication with the pump outlet, and the outlet of the refill
unit is in fluid
communication with the foam cartridge. Foam is dispensed from the outlet of
the refill unit. In
addition, some exemplary refill units do not contain a plate and the drive
mechanism on the foam
dispenser is configured to sequentially compress the diaphragms without the
need for the plate.
[0011a] Another exemplary foam dispenser comprises: a housing; a drive motor;
a foam pump
operatively coupled to the drive motor; the foam pump is secured to the
housing and the foam
pump includes: a pump housing; a molded multi-chamber diaphragm; the molded
multi-chamber
diaphragm comprising: a liquid pump chamber; two or more air pump chambers;
and one or
more outlet valves; a mixing chamber downstream of the one or more outlet
valves for mixing
foamable liquid from the liquid pump chamber with air from each of the two or
more air pump
chambers; a foam cartridge in fluid communication with the mixing chamber; and
an outlet for
dispensing foam wherein the outlet is in fluid communication with the foam
cartridge.
[0011b] Another exemplary refill unit for a foam dispenser comprises: a
container for holding
foamable liquid; a foam pump secured to the container wherein the foam pump
includes: a
housing; a molded multi-chamber diaphragm; the molded multi-chamber diaphragm
comprising:
a liquid pump chamber; and three air pump chambers; an inlet valve; and an
outlet valve a
mixing chamber downstream of the outlet valve for mixing foamable liquid from
the liquid pump
chamber with air from each of the three air pump chambers; a foam cartridge in
fluid
communication with the mixing chamber; and an outlet for dispensing foam
wherein the outlet is
in fluid communication with the foam cartridge.
Date recue/Date received 2023-02-17
[0011c1 Another exemplary foam dispenser comprises: a dispenser housing; a
foam pump
secured to the housing wherein the foam pump includes: a pump housing; a
molded multi-
chamber diaphragm; the molded multi-chamber diaphragm comprising: a liquid
pump chamber;
and two or more air pump chambers; a rotatable drive mechanism for
sequentially compressing
the liquid pump chamber and the two or more air pump chambers; the rotatable
drive mechanism
coupled to a drive motor; a mixing chamber downstream of the liquid pump
chamber and the air
pump chambers for mixing foamable liquid from the liquid pump chamber with air
from each of
the air pump chambers; a foam cartridge in fluid communication with the mixing
chamber; and
an outlet for dispensing foam wherein the outlet is in fluid communication
with the foam
cartridge.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is an exemplary embodiment of a refill unit for a foam
dispenser;
[0013] FIG. 2 is an exemplary embodiment of a foam dispenser;
[0014] FIG. 2A is the exemplary foam dispenser of FIG. 2 with the exemplary
refill unit of
FIG. 1 installed;
[0015] FIG. 3 is an exploded view of an exemplary embodiment of a sequentially
activated
multi-diaphragm foam pump and motor taken from a first perspective;
[0016] FIG. 4 is an exploded view of the exemplary embodiment of the
sequentially activated
multi-diaphragm foam pump and motor of FIG. 3 taken from a second perspective;
[0017]
FIG. 5 is a top view of an exemplary diaphragm assembly for the exemplary
embodiment of the sequentially activated multi-diaphragm foam pump of FIG. 3;
[0018]
FIG. 6 is a bottom view of the exemplary diaphragm assembly of FIG. 5;
5a
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[0019] FIG. 7 is a top view of an exemplary valve seat for the exemplary
embodiment of the
sequentially activated multi-diaphragm foam pump of FIG. 3;
[0020] FIG. 8 is a bottom view of the exemplary valve seat of FIG. 7;
[0021] FIG. 9 is a top view of an exemplary diaphragm assembly seat for the
exemplary
embodiment of the sequentially activated multi-diaphragm foam pump of FIG. 3;
[0022] FIG. 10A is a cross-sectional view taken along the lines A-A of FIGs. 5-
9 of a liquid
pump portion of the sequentially activated multi-diaphragm foam pump of FIG.
3;
[0023] FIG. 10B is a cross-sectional view taken along the lines B-B of FIGs. 5-
9 of a first air
pump portion of the sequentially activated multi-diaphragm foam pump of FIG.
3;
[0024] FIG. 10C is a cross-sectional view taken along the lines C-C of FIGs. 5-
9 of a second
air pump portion of the sequentially activated multi-diaphragm foam pump of
FIG. 3;
[0025] FIG. 11 is a cross-sectional view of another exemplary embodiment of a
sequentially
activated multi-diaphragm foam pump;
[0026] FIG. 12 is a perspective view of an exemplary embodiment of a refill
unit having a
sequentially activated multi-diaphragm foam pump;
[0027] FIG. 13 is a rear view of the exemplary embodiment of the refill unit
having a
sequentially-activated multi-diaphragm foam pump of FIG. 12 with a back cover;
[0028] FIG. 14 is a perspective view of the exemplary embodiment of the refill
unit having a
sequentially-activated multi-diaphragm foam pump of FIG. 12 without the back
cover;
[0029] FIG. 15 is a back view of the exemplary embodiment of the refill unit
having a
sequentially-activated multi-diaphragm foam pump of FIG. 12 without the back
cover;
[0030] FIG. 16 is an exemplary foam dispenser with the refill unit having a
sequentially-
activated multi-diaphragm foam pump installed therein;
[0031] FIG. 17 is the exemplary foam dispenser with the refill unit removed;
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[0032] FIG. 18 is an exemplary motor and drive system for the exemplary foam
dispenser of
FIG. 16;
[0033] FIG. 19A is a perspective view of another exemplary embodiment of a
sequentially-
activated multi-diaphragm foam pump;
[0034] FIG. 19B is an exploded perspective view of the sequentially-activated
multi-diaphragm
foam pump of FIG. 19A;
[0035] FIG. 20A is an exploded side view of the exemplary embodiment of the
sequentially-
activated multi-diaphragm foam pump of FIG. 19A;
[0036] FIG. 20B is a cross-sectional exploded side view of the exemplary
embodiment of the
sequentially-activated multi-diaphragm foam pump of FIG. 19A;
[0037] FIG. 21A is a top view of the exemplary embodiment of the sequentially-
activated
multi-diaphragm foam pump of FIG. 19A;
[0038] FIG. 21B is a front view of the exemplary embodiment of the
sequentially-activated
multi-diaphragm foam pump of FIG. 19A;
[0039] FIG. 21C is a side view of the exemplary embodiment of the sequentially-
activated
multi-diaphragm foam pump of FIG. 19A;
[0040] FIG. 21D is a cross-sectional side view taken along the lines A-A of
FIG. 21A of the
exemplary embodiment of the sequentially-activated multi-diaphragm foam pump
of FIG. 19A;
[0041] FIG. 21E is a cross-sectional view taken along the lines C-C of FIG.
21B of the
exemplary embodiment of the sequentially-activated multi-diaphragm foam pump
of FIG. 19A;
[0042] FIG. 22 is a cross-sectional view another exemplary embodiment of a
sequentially-
activated multi-diaphragm foam pump;
[0043] FIG. 23 is an exploded view of another exemplary embodiment of a
sequentially-
activated multi-diaphragm foam pump;
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[0044] FIG. 24 is a prospective view of an exemplary embodiment of a
sequentially operated
four diaphragm foam pump;
[0045] FIG. 25 is a cross-section of an exemplary embodiment of a sequentially
operated four
diaphragm foam pump.
[0046] FIG. 26 is a prospective view of an exemplary outlet nozzle; and
[0047] FIG. 27 is a cross-sectional view of the exemplary outlet nozzle of
FIG. 26.
DETAILED DESCRIPTION
[0048] The present application discloses exemplary embodiments of foam
dispensers, and refill
units that having sequentially activated multi-diaphragm foam pumps. Some
exemplary
embodiments include a wobble plate and three or more pump diaphragms. The
three or more
pump diaphragms include at least one liquid pump diaphragm and at least two
air pump
diaphragms. Each liquid pump diaphragm has a liquid inlet for receiving
liquid, such as, for
example, a soap, a sanitizer, or a lotion, and each air pump diaphragm has an
air inlet for
receiving air. The three or more pump diaphragms operate sequentially, and
each pump
diaphragm operates once in an operating cycle. An operating cycle begins with
the operation of
a liquid pump diaphragm. Additionally, the sequentially activated multi-
diaphragm foam pump
includes a mixing chamber. Each liquid pump diaphragm pumps liquid into the
mixing chamber,
and each air pump diaphragm pumps air into the mixing chamber. The liquid
mixes with the air
in the mixing chamber to create a foam mixture that is dispensed out of the
pump outlet. In some
embodiments of the present invention, the foam mixture has an air to liquid
ratio of between
about 7 to 1 and about 10 to 1. In some embodiments, the air to liquid ratio
is greater than 10 to
1, and in some embodiments is less than 7 to 1.
[0049] The sequentially activated multi-diaphragm foam pumps may be used in
foam
dispensers. An exemplary foam dispenser comprises a housing, a motor, a refill
unit, a
sequentially activated multi-diaphragm foam pump, and a foam cartridge. The
pump receives a
foamable liquid from the refill unit, mixes the foamable liquid with air to
create a foam mixture,
forces the foam mixture through the foam cartridge to enrich the foam, and
dispenses the foam to
a user.
8
100501 FIG. 1 illustrates a refill unit 100 for a foam dispenser. The refill
unit 100 includes a
collapsible container 102. Collapsible container 102 includes a neck 103 and a
drip-free quick
connector 104. Exemplary drip-free quick connectors are disclosed in U.S.
Patent No. 6,871,679
titled Bag and Dispensing System Comprising Such A Bag, and U.S. Pat. No.
7,647,954 titled
Connector Apparatus And Method For Connecting The Same For Controlling Fluid
Dispensing.
Refill units contain a supply of a foamable liquid. In various embodiments,
the contained
foamable liquid could be for example a soap, a sanitizer, a cleanser, a
disinfectant, a lotion or the
like. The container is a collapsible container and can be made of thin plastic
or a flexible bag-
like material. In other embodiments, the container may be a non-collapsing
container formed by
a rigid housing member, or any other suitable configuration for containing the
foamable liquid
without leaking. In the case of a non-collapsing container, a vent system may
be included.
Exemplary venting systems are disclosed in U.S. Patent Applications
Publication No.
2015/0266657 titled Closed system for venting a dispenser reservoir;
Publication No.
2015/025184 titled Pumps With Container Vents and Application No. 14/811,995,
titled Vented
Refill Units And Dispensers Having Vented Refill Units.
100511 FIG. 2 illustrates an exemplary embodiment of a touch-free foam
dispenser 200. The
touch-free foam dispenser 200 includes a housing 202, a motor 204, a foam pump
206, a refill
unit connector 208, a foam cartridge 210, and a nozzle 212. Exemplary
embodiments of foam
cartridges 210 are shown and described in U.S. Publication No. 20140367419. A
refill unit 100
may be connected to the refill unit connector 208 as shown in FIG. 2A. The
refill unit 100
contains a foamable liquid, such as a soap, a sanitizer, a lotion, a cleanser,
a disinfectant or the
like. The touch-free foam dispenser 200 is activated when sensor 214 detects
the presence of a
user or object. Upon detection of an object or user, the sensor 214 provides a
signal to the
processor (not shown) in the electronic control board 216. The electronic
control board 216
provides an output signal that causes the motor 204 to rotate an eccentric
wobble plate actuator
drive mechanism 301. The sensor 214 and the electronic control board 216
receive power from a
power source 218. In some embodiments, the motor 204 receives power from the
power source
218, and, in other embodiments, the refill unit includes a power source (not
shown) that provides
power to a rechargeable power source (not shown). Exemplary embodiments of
refill units with
power supplies that provide power to the wobble plate actuator drive mechanism
301 (FIG. 3)
are shown and described in U.S. Publication No. 2014/0234140 titled Power
Systems For Touch
9
Date recue/Date received 2023-02-17
Free Dispensers And Refill Units Containing A Power Source. Providing power to
the motor
204 causes wobble plate actuator drive mechanism 301 to rotate. Rotation of
eccentric wobble
plate actuator drive mechanism 301 sequentially compresses and expands the
diaphragms of
foam pump 206 and pumps liquid and air into mixing chamber 325. The liquid and
air mix
together and form a foamy mixture. The foamy mixture is forced through the
foam cartridge
210, which enhances the foam into a rich foam. The rich foam is dispensed from
the foam
dispenser 200 through the nozzle 212.
[0052]
The refill unit 100 and the foam dispenser 200 illustrated in FIGs. 1 and 2,
respectively, are drawn generically because a variety of different components
may be used for
many of the refill unit 100 and the foam dispenser 200. Although foam pump 206
is illustrated
generically above, it is described in detail below. Some exemplary dispenser
components that
may be used in accordance with the present invention are shown and described
in U.S. Patent
No, 8,960,498 titled Touch-Free Dispenser With Single Cell Operation And
Battery Banking;
U.S. Pat. Pub. No. 2014/00543.22 titled Off-Axis Inverted Foam Dispensers And
Refill Units
and Pub. No. 2014/0234140 titled Power Systems For Touch Free Dispensers And
Refill Units
Containing a Power Source.
[0053]
FIG. 3 is an exploded view of an exemplary embodiment of foam pump 206. Foam
pump 206 is driven by motor 204. Foam pump 206 includes a pump base 324, a
wobble plate
314, a diaphragm assembly seat 312, a diaphragm assembly 310, a valve seat
308, outlet valves
323A, 323B, 323C, screws 302, and a cover 348. The valve seat 308, diaphragm
assembly seat
312, and pump base 324 are secured together by screws 302 in screw holes 308A,
312A, 324A.
The cover 348 is attached to the valve seat 308. Outlet valves 323A, 323B 323C
are secured to
and seated in the valve seat 308.
[0054] The diaphragm assembly 310 includes three pump diaphragms 310A, 310B,
310C, and
each pump diaphragm 310A, 310B, 310C has a connector 311A, 311B, 311C. The
diaphragm
assembly 310 is located in the diaphragm assembly seat 312. The pump
diaphragms 310A,
310B, 310C are disposed in the receiving holes 313A, 313B, 313C of the
diaphragm assembly
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seat 312, and the three connectors 311A, 311B, 311C connect to the wobble
plate 314 by
inserting the three connectors 311A, 311B, 311C in the three wobble plate
links 314A, 314B,
314C.
[0055] Air enters the foam pump 206 through pump air inlet 424B (FIG. 4), and
liquid, such as
for example, foamable soap or sanitizer enters the foam pump 206 through
liquid inlet 352. Two
of the pump diaphragms 310B, 310C receive air, and the other pump diaphragm
310A receives
foamable liquid, such as, for example soap or sanitizer.
[0056] FIG. 4 is another exploded view of the exemplary foam pump 206 from a
different
perspective. As described above, the diaphragm assembly 310 includes three
pump diaphragms
310A, 310B, 310C. Each pump diaphragm 310A, 310B, 310C has a corresponding
inlet valve
316A, 316B, 316C (better seen in FIGs. 5 and 6). FIG. 4 also provides a view
of the bottom of
the valve seat 308. The bottom of valve seat 308 has three areas that
correspond to the three
pump diaphragms 310A, 310B, 310C. Each area has three fluid outlet apertures
309A, 309B,
309C that extend through valve seat 308, a valve stem retention aperture 329A,
329B, 329C
(FIG. 7), and a fluid inlet groove 319A, 319B, 319C. The fluid inlet grooves
319A, 319B, 319C
do not extend through valve seat 308.
[0057] FIGs. 5 and 6 illustrate a top view and a bottom view, respectively, of
the exemplary
diaphragm assembly 310 for foam pump 206. In some embodiments, the diaphragm
assembly is
made of natural rubber, EPDM, Silicone, Silicone rubber TPE, TPU, TPV, vinyl,
or the like.
The diaphragm assembly 310 includes three molded pump diaphragms 310A, 310B,
310C and
three corresponding inlet valves 316A, 316B, 316C. The top of the diaphragm
assembly 310
acts as a sealing gasket. The top of the diaphragm assembly 310 has a flat
section 310F, and
each pump diaphragm 310A, 310B, 310C has gasket walls 327A, 327B, 327C that
surround the
respective valves 316A, 316B, 316C and pump diaphragms 310A, 310B, 310C. The
gasket
walls 327A, 327B, 327C seal against the bottom of the valve seat 308 (FIG. 4
and FIG. 8) to
prevent fluid, such as, air and liquid soap or sanitizer from leaking out of
the foam pump 206 at a
location other than the pump outlet 350 (FIG. 3). One-way inlet valves 316A,
316B, 316C allow
air, liquid soap, or sanitizer to enter the pump diaphragms 310A, 310B, 310C
when the pump
diaphragms 310A, 310B, 310C have a negative pressure (i.e., when the pump
diaphragms 310A,
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310B, 310C are expanding), and seal against inlet apertures 321A, 321B, 321C
when the pump
diaphragms 310A, 310B, 310C have a positive pressure (e.g. when the pump
diaphragms 310A,
310B, 310C are compressing). The one-way inlet valves 316A, 316B, 316C are
formed by
flexible tabs and are made of the same material as the diaphragm assembly 310.
[0058] FIG. 7 is a top view of an exemplary valve seat 308 for the foam pump
206. One-way
liquid outlet valve 323A is shown transparently to more clearly illustrate the
flow of liquid 331A
through liquid outlet apertures 309A and into mixing chamber 325. One-way
liquid outlet valve
323A includes a valve stem 357A (FIG. 3) that is inserted into aperture 329A
to secure one-way
liquid outlet valve 323A to valve seat 308. One-way liquid outlet valve 323A
is normally closed
and prevents air or liquid from flowing from the mixing chamber 325, back
through air outlet
apertures 309A, and into liquid pump diaphragm 310A. One-way liquid outlet
valve 323 opens
when liquid pump diaphragm 310A is being compressed to pump fluid.
[0059] Simalarly, one-way air outlet valves 323B, 323C are shown transparently
to more
clearly illustrate the flow of air 331B, 331C through air outlet apertures
309B, 309C and into
mixing chamber 325. One-way air outlet valves 323B, 323C each include a valve
stem 357B,
357C (FIG. 3) that are inserted into corresponding apertures 329B, 329C to
secure the one-way
air outlet valves to valve seat 308. One-way air outlet valves 323B, 323C are
normally closed
and prevent air or liquid from flowing from the mixing chamber 325, back
through air outlet
apertures 323B, 323C, and into air pump diaphragms 310B, 310C. One-way air
outlet valves
323B, 323C open when corresponding air pump diaphragms 310B, 310C are being
compressed
to pump air.
[0060] The valve seat 308 also includes flow directional control walls 308E.
The flow
directional control walls 308E provide flow paths that aid in the mixing of
liquid and air. In this
embodiment the flow directional control walls 308E are curved and cause the
liquid and air to
intersect in a tangential relationship. In some embodiments, flow directional
control walls 308E
are designed and arranged to cause the liquid an air to intersect at a desired
angle, such as, for
example, each flow path may intersect at a 120 degree angle. In some
embodiments, the flow
directional control walls 308E are arranged so that the two air paths
intersect the liquid flow path
at about 180 degrees. The design of the flow path intersection may be
different for different
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types of liquids, for example, a higher quality of foam may be obtained by
causing the liquid
soap to be intersected head on (180 degrees) by the two air flow paths, while
a higher quality
foam may be obtained for foamable sanitizer by having the air paths
tangentially intersect with
the liquid path.
[0061] FIG. 8 is a bottom view of the exemplary valve seat 308 for the foam
pump 206. The
valve seat 308 includes three liquid outlet apertures 309A that pass through
valve seat 308 and a
liquid outlet valve aperture 329A for retaining one-way liquid outlet valve
323A. Valve seat 308
also includes a liquid inlet groove 319A that extends partially into valve
seat 308 to provide a
liquid path from one-way liquid inlet valve 316A to the interior of liquid
pump diaphragm 310A.
In addition, the valve seat 308 includes a first set of three air outlet
apertures 309B that pass
through valve seat 308, and a second set of three air outlet apertures 309C
that pass through
valve seat 308. Also, valve seat 308 includes air outlet valve apertures 329B,
329C for retaining
one-way air outlet valves 323B, 323C, and air inlet grooves 319B, 319C that
extend partially into
valve seat 308 to provide an air path from one-way air inlet valves 316B, 316C
to the interior of
air pump diaphragms 310B, 310C.
[0062] FIG. 9 is a top view of an exemplary diaphragm assembly seat 312 for
the exemplary
embodiment of a foam pump 206. The diaphragm assembly seat 312 includes three
receiving
holes 313A, 313B, 313C and three inlet apertures 321A, 321B, 321C. In fluid
communication
with inlet aperture 321A is fluid inlet 352 which may be coupled to the liquid
outlet of container
102. Each receiving hole 313A, 313B, 313C is sized to receive a diaphragm
310A, 310B, 310C.
Each inlet aperture 321A, 321B, 321C extends through diaphragm assembly seat
312 and allows
either air, liquid soap, or sanitizer to enter one of the diaphragms 310A,
310B, 310C.
[0063] In some embodiments, the foam mixture has an air to liquid ratio of
between about 7 to
1 and about 10 to 1. In some embodiments, the air to liquid ratio is greater
than 10 to 1, and in
some embodiments is less than 7 to 1.
[0064] In some exemplary embodiments, a flow control valve (not shown) is
located between
the container 102 of foamable liquid and pump 206. The flow control valve may
be used to
adjust the liquid to air ratio. If a higher liquid to air ratio is desired,
the flow control valve is set
at a lower flow rate that starves the liquid pump diaphragm 310A. Conversely,
to increase the
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liquid to air ratio, the flow control valve may be opened wider allowing more
liquid to flow into
pump 206. In some embodiments, the liquid pump diaphragm 310A may have a
different
volume than the air pump diaphragms 310B, 310C to adjust the ratio of liquid
to air. In some
embodiments, the volume of the liquid pump diaphragm 310A is reduced by
inserting a sponge
(not shown) in the liquid pump diaphragm 310A. Not only does the sponge (not
shown) reduce
the volume, but in some embodiments, the sponge slows the flow of liquid
through the liquid
pump diaphragm 310A. In some embodiments, a restrictor comprising an orifice
that has a
smaller diameter than the liquid inlet may be used to restrict the fluid flow.
[0065] FIG. 10A is a cross-sectional view taken along the lines A-A of FIGs. 5-
9 showing the
liquid pump portion of foam pump 206. In operation, liquid pump diaphragm 310A
is moved
downward, as shown by reference number 350B, to expand pump chamber 1002,
which causes
liquid inlet valve 316A to open allowing liquid to be drawn into pump chamber
1002 through
liquid inlet 352, inlet aperture 321A, and liquid inlet groove 319A. Once the
pump chamber
1002 is expanded it is primed with liquid, such as, for example, liquid soap
or sanitizer. When
the liquid pump diaphragm 310A is compressed (i.e. the liquid pump diaphragm
310A moves in
the direction shown by reference number 350A), the liquid is pumped in the
direction shown by
reference number 340A. The liquid travels through liquid outlet apertures
309A, past one-way
liquid outlet valve 323A and into mixing chamber 325. One-way liquid outlet
valve 323A is
normally closed, but one-way liquid outlet valve 323A opens due to pressure
caused by
compressing liquid pump chamber 1002. One-way liquid outlet valve 323A
prevents air or
liquid from flowing back through liquid outlet apertures 309A and into liquid
pump diaphragm
310A. Subsequently, the liquid pump diaphragm 310A begins to expand, which
starts the
process again by causing liquid inlet valve 316A to open, and liquid is drawn
into liquid pump
chamber 1002 through liquid inlet aperture 321A and liquid inlet groove 319A.
A operating
cycle of foam pump 206 includes one pump of liquid from liquid pump diaphragm
310A through
liquid outlet apertures 309A, past liquid outlet valve 323A, and into mixing
chamber 325 (FIG.
7) (followed by two pumps of air as described below).
[0066] FIGs. 10B and 10C are a cross-sectional view taken along the lines B-B
and C-C,
respectively, of FIGs. 5-9 showing the air pump portions of foam pump 206. In
operation, air
pump diaphragms 310B, 310C are moved downward, as shown by reference number
350B, to
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expand air pump chambers 1004, 1006, which causes air inlet valves 316B, 316C
to open
allowing air to be drawn into pump chambers 1004, 1006 through air inlet
apertures 321B, 321C
and air inlet grooves 319B, 319C. Once the pump chambers 1004, 1006 are primed
with air, the
air pump diaphragms 310B, 310C may be compressed (moved in the direction shown
by
reference number 350A). Compression of air pump diaphragms 310B, 310C pump the
air in the
direction shown by reference number 340A. The air travels through air outlet
apertures 309B,
309C, past one-way air outlet valves 323B, 323C, and into mixing chamber 325
to mix with the
foamable liquid. One-way air outlet valves 323B, 323C are normally closed, but
one-way air
outlet valves 323B, 323C open due to pressure caused by compressing air pump
chambers 1004,
1006. One-way air inlet valves 323B, 323C prevent air or liquid from flowing
back through air
outlet apertures 309B, 309C and into air pump diaphragms 310B, 310C.
Subsequently, the air
pump diaphragms 310B, 310C begin to expand, which starts the process again by
causing air
inlet valves 316B, 316C to open, and air is drawn into air pump chambers 1004,
1006 through air
inlet apertures 321B, 321C and air inlet grooves 319B, 319C. An operating
cycle of foam pump
206 includes one pump of liquid (as described above) followed by one pump of
air from air
pump diaphragm 310B through air outlet apertures 309B, past air outlet valve
323B, and into
mixing chamber 325 (FIG. 7). In addition, an operating cycle of foam pump 206
includes one
pump of air from air pump diaphragm 310C through air outlet apertures 309C,
past air outlet
valve 323C, and into mixing chamber 325 (FIG. 7).
[0067] The diaphragms 310A, 310B, 310C operate sequentially, in which one
sequence of
operation includes one pump of liquid, such as, for example, soap or
sanitizer, or air by each of
the three pump diaphragms 310A, 310B, 310C. The order of operation of the pump
diaphragms
310A, 310B, 310C is dependent upon the configuration of the wobble plate 314
(FIG. 3). As
shown in FIG. 3, each pump diaphragm 310A, 310B, 310C has a connector 311A,
311B, 311C,
and the three pump diaphragms 310A, 310B, 310C connect to the wobble plate 314
by inserting
the three connectors 311A, 311B, 311C in the three wobble plate links 314A,
314B, 314C.
Wobble plate 314 connects to an eccentric wobble plate actuator that causes
the wobble plate
314 to undulate. As the wobble plate 314 undulates, the wobble plate links
314A, 314B, 314C
move in upward and downward motions. The upward motion causes the pump
diaphragms
310A, 310B, 310C to compress, and the downward motion causes the pump
diaphragms 310A,
310B, 310C to expand. The configuration of the wobble plate 314 causes one
pump diaphragm
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310A, 310B, 310C to compress at a time, which causes the pump diaphragms 310A,
310B, 310C
to pump sequentially. The configuration of the wobble plate 314 also causes
one pump
diaphragm 310A, 310B, 310C to expand at a time, which causes the pump
diaphragms 310A,
310B, 310C to prime sequentially. In the exemplary sequence of operation, the
liquid pump
diaphragm 310A pumps a shot of fluid, followed by air pump diaphragm 310B
pumping a shot
of air, and the sequence of operation ends with air pump diaphragm 310C
pumping a second shot
of air. The sequence may be repeated any number of times depending on the
desired output dose
of foam. The air from the air pump diaphragms 310B, 310C mixes with either the
liquid or
sanitizer from the liquid pump diaphragm 310A in the mixing chamber 325 (FIG.
7), which
creates a foam mixture. The foam mixture exits the foam pump 206 through the
pump outlet
350.
[0068] FIG. 4 illustrates the flow path of the liquid soap or sanitizer
through the exploded
view. When the liquid pump diaphragm 310A expands, liquid enters the foam pump
206
through liquid inlet 352, which is shown by reference number 330A. The liquid
travels through
aperture 321A in the diaphragm assembly seat 312, and past liquid one-way
inlet valve 316A, as
shown by reference number 330B. Inlet valve 316A opens, the liquid travels
through groove
319A and into liquid pump diaphragm 310A, which is shown by reference numbers
330D and
330E.
[0069] The liquid pump diaphragm 310A compresses and pumps the liquid through
liquid
outlet aperture 309A, past one-way liquid outlet valve 323A, and into the
mixing chamber 325
(FIG. 7), which is shown by reference number 340A. Air follows a similar path
for air pump
diaphragms 310B, 310C. When air pump diaphragms 310B, 310C expand, air is
drawn into air
inlet 424B, travels through apertures 321B, 321C (FIG. 9) in diaphragm seat
assembly 312,
travels through one-way air inlet valves 316B, 316C (FIGs. 5 and 6), travels
into grooves 319B,
319C, in the bottom of valve seat 308, and travels into air pump diaphragms
310B, 310C. When
air pump diaphragms 310B, 310C compress, air is forced through apertures 309B,
309C, past
one-way air outlet valves 323B, 323C (FIG. 7), and into mixing chamber 325
where it mixes
with the liquid to form a foam mixture. The foam mixture is dispensed through
outlet 350,
which is shown by reference number 304B.
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[0070] FIG. 11 is a cross-sectional view of another exemplary embodiment of a
sequentially
activated multi-diaphragm foam pump 1100. The sequentially activated multi-
diaphragm foam
pump 1100 includes a motor 1112, a motor shaft 1113, a wobble plate 1110, a
wobble plate pin
1127 an eccentric wobble plate drive 1120, a liquid pump diaphragm 1106, two
air pump
diaphragms 1108 (only one is shown), mixing chamber 1130, and pump outlet
1114. The motor
1112 drives the motor shaft 1113, which causes the motor shaft 1113 to rotate.
The rotation of
the motor shaft 1113 causes the eccentric wobble plate drive 1120 to rotate,
and rotation of the
eccentric wobble plate drive 1120 causes the wobble plate pin 1127 to move
along a circular
path, which causes the wobble plate 1110 to undulate. In some embodiments,
wobble plate 1110
includes a ball (not shown) that rides in a socket (not shown) on the pump
housing and wobble
plate pin 1127 extends outward and connects to an eccentric wobble plate
actuator 1120 that
causes the pin to move along a circular path which causes the wobble plate
1110 to undulate. As
the wobble plate 1110 undulates, the ends connected to the three pump
diaphragms 1106, 1108
move in upward and downward motions, and the three pump diaphragms 1106, 1108
are
compressed sequentially. One sequence of operation of the mixing pump 1100
includes one
pump by each of the three pump diaphragms 1106, 1108. The liquid pump
diaphragm 1106
operates first in the cycle of operation, followed by sequential distributions
by the two air pump
diaphragms 1108.
[0071] Similar to the embodiments described above, during operation, the
liquid pump
diaphragm 1106 expands and contracts to pump liquid, and the air pump
diaphragms 1108 (only
one is shown) expand and contract to pump air. The expansion of the liquid
pump diaphragm
1106 opens the liquid inlet valve 1105 and allows liquid, such as, for
example, soap or sanitizer
to enter liquid pump chamber 1124 through liquid inlet 1102. The expansion of
the air pump
diaphragms 1108 opens the air inlet valves 1107 (only one is shown) and allows
air to enter air
pump chambers 1126 (only one is shown) through air inlets 1104. Circular
movement of the
wobble plate pin 1127 causes the ends of the wobble plate 1110 to sequentially
undulate. The
undulation causes liquid pump diaphragm to compress, which causes liquid
outlet valve 1116 to
open, and liquid to flow into the mixing chamber 1130 through liquid outlet
apertures 1122.
Subsequently, one of the air pump diaphragms 1108 is compressed by the
undulating wobble
plate 1110, which causes air outlet valve 1118 to open, and air to flow the
mixing chamber 1130
through air outlet apertures 1123. Then, the other air pump diaphragm (not
shown) will
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compress and pump air into mixing chamber 1130. The air and liquid soap or
sanitizer mix in
the mixing chamber 1130 to create a foam mixture. The foam mixture exits the
mixing pump
1100 through pump outlet 1114.
100721 Figures 12-15 illustrate and exemplary embodiment of a refill unit
1200. Figure 12 is a
perspective view of an exemplary embodiment of a refill unit 1200 having a
sequentially
activated multi-diaphragm foam pump 1206, and FIG. 13 is another perspective
view of the
exemplary refill unit 1200, having a back plate 1214 removed to illustrate the
plurality of
diaphragms 1510A, 1510B and 1510C. Figure 13 is a rear elevational view of the
refill unit
1200 and FIG 15 is a rear elevational view of the refill unit 1200 with the
back plate 1214
removed to illustrate the plurality of diaphragms 1510A, 1510B and 1510C. The
refill unit 1200
connects to a foam dispenser 1600 (FIGS 16, 17). The refill unit 1200 includes
a container 1202,
a foam pump 1206, a actuation mechanism 1304 (FIG. 13), a foam cartridge 1210,
and a nozzle
1212. Refill unit 1200 contains a supply of a foamable liquid. In various
embodiments, the
contained foamable liquid could be for example a soap, a sanitizer, a
cleanser, a disinfectant, a
lotion or the like. The container 1202 is a collapsible container and can be
made of thin plastic
or a flexible bag-like material. In some embodiments, the container 1202 is a
non-collapsing
container formed by a rigid, or semi-rigid housing member, or any other
suitable configuration
for containing the foamable liquid without leaking. In the case of a non-
collapsing container, a
vent system may be included, such as, for example, any of the venting systems
in the
patents/application incorporated above.
100731 Foam pump 1206, is similar to the pumps described above, and includes a
housing
1208, a liquid pump diaphragm 1510A (FIG. 15), air pump diaphragms 1510B,
1510C, and a
mixing chamber (not shown). The liquid pump diaphragm 1510A and the air pump
diaphragms
1510B, 1510C are disposed in housing 1208. The liquid pump diaphragm 1510A
receives liquid
from the container 1202 through liquid inlet 1552 and liquid inlet apertures
1509A, and liquid
pump diaphragm 1510A pumps the liquid into the mixing chamber. The air pump
diaphragms
1510B, 1501C receive air through at least one air inlet (not shown) and air
inlet apertures 1509B,
1509C, and air pump diaphragms 1510B, 1510C pump the air into the mixing
chamber. The
liquid pump diaphragm 1510A and the air pump diaphragm 1510B are sequentially
activated by
actuation mechanism 1304 (FIG. 13). An operating cycle of the foam pump 1206
includes one
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pump of liquid from liquid pump diaphragm 1510A into mixing chamber 325 and
one pump of
air from air pump diaphragms 1510B, 1510C into the mixing chamber. The
operating cycle
begins with the one shot of liquid from liquid pump diaphragm 1510A, which is
followed by the
one shot of air form air pump diaphragm 1510B and one shot of air from air
pump diaphragm
1510C. The liquid and air mix in mixing chamber (not shown) to form a foamy
mixture, and the
foamy mixture passes through foam cartridge 1210 and exits the foam pump 1206
through the
outlet 1212. A dispense of foam typically requires one or more operating
cycles or revolutions.
In some embodiments of the present invention, the foam mixture has an air to
liquid ratio of
between about 7 to 1 and about 10 to 1. In some embodiments, the air to liquid
ratio is greater
than 10 to 1, and in some embodiments is less than 7 to 1.
[0074] In some exemplary embodiments, a flow control valve (not shown) is
located between
the container 1202 of foamable liquid and pump 1206. The flow control valve
may be used to
adjust the liquid to air ratio. If a higher liquid to air ratio is desired,
the flow control valve is set
at a lower flow rate that starves the liquid pump diaphragm 1510A. Conversely,
to increase the
liquid to air ratio, the flow control valve may be opened wider allowing more
liquid to flow into
pump 1206. In some embodiments, the liquid pump diaphragm 1510A may have a
different
volume than the air pump diaphragms 1510B, 1510C to adjust the ratio of liquid
to air. In some
embodiments, the volume of the liquid pump diaphragm 1510A is reduced by
inserting a sponge
(not shown) in the liquid pump diaphragm 1510A. Not only does the sponge (not
shown) reduce
the volume, but in some embodiments, the sponge slows the flow of liquid
through the liquid
pump diaphragm 1510A.
[0075] The foam pump 1206 may include some or all of any of the embodiments
described
herein. Moreover, the foam pump 1206 may have more than one liquid pump
diaphragm and
one or more air pump diaphragms.
[0076] The actuation mechanism 1304 (FIG. 13) releasably connects to a drive
system of motor
1706 (FIG. 17) that is permanently attached to a foam dispenser 1600.
Actuation mechanism
1304 is covered by back plate 1214.
[0077] In some embodiments, the actuation mechanism 1304 does not include a
wobble plate
1405, but may include a circular plate (not shown) and one or more springs
(not shown). The
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circular plate is connected to the liquid pump diaphragm 1510A and the air
pump diaphragms
1510B, 1510C. The one or more springs bias the circular plate outward thereby
urging the liquid
pump diaphragm 1510A and the air pump diaphragms 1510B, 1510C to their
extended position.
The drive system (not shown) on the dispenser includes a wheel that travels
around the perimeter
of the circular plate. The point of contact between the wheel and the circular
plate pushes that
portion of the circular plate downward. As the wheel rotates around the
perimeter it sequentially
compresses the liquid pump diaphragm 1510A and the air pump diaphragms 1510B,
1510C. As
the wheel moves past the diaphragms 1510A, 1510B, 1510C, the diaphragms 1510A,
1510B,
1510C expand to draw in fluid, as they are biased toward the expanded position
by the
diaphragm material as well as the one or more springs. In some embodiments,
the springs are
not needed and the diaphragm material is sufficient to bias the diaphragms
1510A, 1510B,
1510C to their expanded positions.
[0078] The above-mentioned embodiments are only exemplary, and the actuation
mechanism
1304 may be configured in any manner that causes sequential operation of the
liquid pump
diaphragm 1510A and air pump diaphragms 1510B, 1510C of foam pump 1206.
[0079] FIG. 13 is a back view of the exemplary embodiment of the refill unit
1200 having a
sequentially-activated multi-diaphragm foam pump 1206 of FIG. 12 with back
plate 1214. Back
plate 1214 has an aperture 1301. The refill unit 1200 attaches to a foam
dispenser 1600 (FIG.
16) by connecting the attachment mechanism 1304 to the drive system of motor
1706 through
the aperture 1301 of back plate 1214.
[0080] FIGs. 14 and 15 are views of the exemplary embodiment of the refill
unit 1200 having
the sequentially-activated multi-diaphragm foam pump 1206 with the back plate
1214 removed.
The actuation mechanism 1304 includes a wobble plate 1405, wobble plate
connection links
1407, and pin 1409. Each wobble plate link 1407 connects to pump diaphragms
1510A, 1510B,
1510C. In this exemplary embodiment, the pin 1409 of actuation mechanism 1304
releasably
connects the actuation mechanism 1304 to an eccentric drive system 1707 (FIGs.
17 and 18) of
motor 1706. Referring to FIGs. 17 and 18, a portion of pump 1206 of refill
unit 1200 is received
in socket 1701 of foam dispenser 1600, and the actuation mechanism 1304
releasably connects to
the eccentric drive system 1707. Eccentric drive system 1707 is attached to
shaft 1809 of motor
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1706. The pin 1409 of actuation mechanism 1304 releasably engages with
eccentric drive
system 1707 pin 1409 engaging notch 1811. In some embodiments, the eccentric
drive system
1707 is connected to actuation mechanism 1304 and is part of the refill unit
1200 and releasably
connects to the shaft 1809 of motor 1706.
The above-mentioned embodiments are only
exemplary. The refill unit 1200 and motor 1706 may be configured in any manner
that allows
the refill unit 1200 to releasably attach to motor 1706 and allows motor 1706
to operate foam
pump 1206.
[0081] Referring to FIGs. 14 and 15, the eccentric drive system 1707 (FIGs. 17
and 18) causes
the wobble plate 1405 to undulate, which causes sequential operation of the
liquid pump
diaphragm 1510A and air pump diaphragms 1510B, 1510C. As the liquid pump
diaphragm
1510A expands, liquid travels from container 1202, through liquid inlet 1552
and liquid inlet
aperture 1509A, and into liquid pump diaphragm 1510A. The liquid pump
diaphragm 1510A is
in a primed position when it is filled with liquid. As air pump diaphragms
1510B, 1510C
expand, air travels through at least one air inlet (not shown), through air
inlet apertures 1509B,
1509C, and into respective air pump diaphragms 1510B, 1510C. The air pump
diaphragms
1510B, 1510C are in primed positions when they are filled with air. An
exemplary operating
cycle includes one pump of liquid from liquid pump diaphragm 1510A, followed
by one pump of
air from air pump diaphragm 1510B, followed by one pump of air from air pump
diaphragm
1510C.
[0082] In some embodiments, each pump diaphragm 1510A, 1510B, 1510C has a
volume
between about 0.1 and 1.0 ml. The pump diaphragms 1510A, 1510B, 1510C pump
liquid and air
into a mixing chamber (not shown), and the liquid and air mix to form a foamy
mixture. The
foamy mixture goes through a foam cartridge 1210 to form a rich foam, and the
rich foam exits
the refill unit 1200 through nozzle 1212. In some embodiments the liquid pump
diaphragm
1510A has a volume of between about 0.1 and 1.0 ml.
[0083] In some embodiments the dose of foam dispensed by the foam dispenser
contains
between about .3 ml and about 7.0 ml of liquid of liquid. In some embodiments,
the dose of
foam comprises between about 3 and 10 revolutions per dispense, including
between about 3 and
7 revolutions, including between about 5 and 10 revolutions. In some
embodiment, the dose of
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foam is about 0.3 ml for a highly concentrated light duty soap. In some
embodiments, the dose
of foam is about 7.0 ml of liquid for heavy duty soaps, such as grease
cleaning soaps.
[0084] In some embodiments, the dispenser operates at a voltage of between
about 3 volts and
volts, including between about 3 volts and about 5 volts, including between
about 4 and about
6 volts, including between about 4 volts and 8 volts, including between about
6 volts and about
9.5 volts.
[0085] In some embodiments, the pump sequences for between about .3 and 2
seconds to
dispense a dose of foam, including between about .5 seconds and 1.5 seconds,
including between
about .5 and 1 seconds. In some embodiments, such as, for example, dispensing
of foam
sanitizer having about 1.2 ml of liquid, the dispense time is about .6 sec. In
some embodiments,
such as, for example, light duty and heavy duty soap having between about 0.3
ml liquid to
about 7.0 ml liquid, the dispense time in less than 1.50 sec.
[0086] In some embodiments, the wobble plate drive actuator rotates at between
about 120 and
about 480 revolutions per minute.
[0087] In some embodiments, there are multiple liquid pump diaphragms, such as
for example,
two liquid pump diaphragms, three liquid pump diaphragms, four liquid pump
diaphragms. In
some embodiments there are multiple air pump diaphragms, for example, two air
pump
diaphragms, three air pump diaphragms, four air pump diaphragms, five air pump
diaphragms,
six air pump diaphragms, seven air pump diaphragms and eight. air pump
diaphragms. In some
embodiments, the number of air pump diaphragms to liquid pump diaphragms is
1:1, 2:1, 3:1,
4:1, 5:1, 6:1, 7:1, and 8:1.
[0088] FIGs. 19A-19B, 20A-20B, and 21A-21E illustrate various views of another
exemplary
embodiment of a sequentially-activated multi-diaphragm foam pump 1900. The
foam pump
1900 is coupled to foam cartridge housing 1902 and container receiver 1904,
and the foam
cartridge housing 1902 is coupled to a nozzle 1906. The foam pump 1900
includes housing
1908, diaphragm assembly 1910, pump outlet 1912, and pump cover 1914. The
diaphragm
assembly 1910 includes three pump diaphragms 1916a, 1916b, 1916c. The three
pump
diaphragms 1916a, 1916b, 1916c include one liquid pump diaphragm 1916a and two
air pump
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diaphragms 1916b, 1916c. The diaphragm assembly 1910 is only exemplary, and a
diaphragm
assembly 1910 may include more than three pump diaphragms. Additionally, the
diaphragm
assembly may include one or more liquid pump diaphragms and/or one or more air
pump
diaphragms.
[0089] A container (not shown) is connected to container with closure 1904 in
a manner that
allows liquid to enter liquid inlet 1918. During operation, when liquid pump
diaphragm 1916a
expands, liquid is drawn through liquid channel 1920, past liquid inlet valve
1922a, and into the
liquid pump diaphragm 1916a. Similarly, when air pump diaphragms 1916b, 1916c
expand, air
is drawn through an opening, past air inlet valves 1922b, 1916c, and into the
air pump
diaphragms 1916b, 1916 c respectively. When the liquid pump diaphragm 1916a
compresses,
liquid is forced out of liquid pump diaphragm 1916a and causes the wall of
liquid outlet valve
1923, which is normally closed due to the natural resiliency of the member, to
deflect away from
side wall 1927 and the liquid flows into mixing chamber 2132 (FIG. 21E).
Similarly, as the air
pump diaphragms compress, air is forced out of air pump diaphragms 1916b,
1916c and causes
the wall of liquid outlet valve 1923 to deflect away from side wall 1927 and
the air flows into
mixing chamber 2132. When pressure from the liquid or air is removed, e.g.
when the liquid
pump diaphragm 1916a or the air pump diaphragms 1916b, 1916c expand, liquid
outlet valve
1923 seals against side wall 1927 and seals off the diaphragms 1916a, 1916b,
1916c from the
outlet nozzle 1906.
[0090] The liquid and air mix in a mixing chamber 2132 to create a foam
mixture, and the
foam mixture exits pump outlet 1912. After the foam mixture exits pump outlet
1912, the foam
mixture travels through foam cartridge 1924. In this particular embodiment,
foam cartridge 1924
includes screens 1926a, 1926b and sponge 1928. The foam cartridge 1924 may
include various
members, for example, foam cartridge 1924 members may include one or more
screens 1926
and/or one or more sponges 1928. The foam exits the foam cartridge 1924 and is
dispensed out
of outlet nozzle 1906 as rich foam.
[0091] The pump diaphragms 1916a, 1916b, 1916c operate sequentially, and the
operation of
the pump diaphragms 1916a, 1916b, 1916c may take any form as described for the
various
embodiments of foam pumps described herein. In one embodiment, the liquid pump
diaphragm
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1916a operates first in an operating cycle, followed by sequential operation
by the two air pump
diaphragms 1916b, 1916c.
[0092] FIG. 22 is a cross-sectional view of another exemplary embodiment of a
sequentially-
activated multi-diaphragm foam pump 2200. The sequentially activated multi-
diaphragm foam
pump 2200 is driven by a motor 2212 that has a motor shaft 2213. The foam pump
2200
includes a wobble plate 2210, a wobble plate pin 2227 an eccentric wobble
plate drive 2220, a
liquid pump diaphragm 2206, two air pump diaphragms 2208 (only one is shown),
mixing
chamber 2230, liquid inlet 2202, liquid inlet valve 2205, air pump chamber
2226, air inlet 2204,
air inlet valve 2207, outlet valve 2216, mixing chamber 2230 and outlet 2214.
[0093] The motor 2212 drives the motor shaft 2213, which causes the motor
shaft 2213 to
rotate. The rotation of the motor shaft 2213 causes the eccentric wobble plate
drive 2220 to
rotate, and rotation of the eccentric wobble plate drive 2220 causes the
wobble plate pin 2227 to
move along a circular path, which causes the wobble plate 2210 to undulate. In
some
embodiments, wobble plate 2210 includes a ball (not shown) that rides in a
socket (not shown)
on the pump housing and wobble plate pin 2227 extends outward and connects to
an eccentric
wobble plate actuator 2220 that causes the pin to move along a circular path
which causes the
wobble plate 2210 to undulate. As the wobble plate 2210 undulates, the ends
connected to the
three pump diaphragms 2206, 2208, move in upward and downward motions, and the
three
pump diaphragms 2206, 2208 are expanded and compressed sequentially.
[0094] Expansion of the liquid pump diaphragm 2206 causes the liquid inlet
valve 2205 to
open and draws liquid, such as, for example, soap or sanitizer into liquid
pump chamber 2224
through liquid inlet 2202. Expansion of the air pump diaphragms 2208 (only one
is shown)
causes the air inlet valves 2207 to open (only one is shown) and draw air into
air pump chambers
2226 through air inlets 2204 (only one is shown). Compression of the liquid
pump diaphragm
2206 causes liquid pump chamber 2224 to compress, which causes outlet valve
2216 to deflect
and open, and causes liquid to flow into the mixing chamber 2230. Compression
of one of the
air pump diaphragms 2208 causes air pump chamber 2226 to compress, which
causes outlet
valve 2216 to deflect away from the side wall and open to allow air to flow
the mixing chamber
2230. The second air pump diaphragm similarly pumps air into the mixing
chamber. The air
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and liquid soap or sanitizer mix in the mixing chamber 2230 to create a foam
mixture. The foam
mixture travels through foam cartridge 2232 and exits the foam pump 2200
through pump outlet
2214.
[0095] One sequence of operation of the foam pump 2200 includes one pump by
each of the
three pump diaphragms 2206, 2208. The liquid pump diaphragm 2206 operates
first in the cycle
of operation, followed by sequential distributions by the two air pump
diaphragms 2208.
[0096] FIG. 23 is an exploded view of another exemplary embodiment of a
sequentially-
activated multi-diaphragm foam pump 2300. Foam pump 2300 is driven by motor
2304. Foam
pump 2300 includes a pump housing 2324, a wobble plate 2314, a diaphragm
assembly seat
2312, a diaphragm assembly 2310, a valve seat 2308, inlet valves 2323a, 2323b,
2323c a gasket
2306, and a cover 2348. The cover 2348 is attached to the valve seat 2308, and
the gasket 2306
is located between the cover 2348 and gasket 2306 forms a seal around air
inlet apertures 2325,
liquid inlet 2352 and foam outlet 2350 to prevent fluid leaks. Inlet valves
2323a, 2323b, 2323c
are secured to and seated in the valve seat 2308.
[0097] The diaphragm assembly 2310 includes three pump diaphragms 2311a,
2311b, 2311c,
and each pump diaphragm 2311a, 2311b, 2311c has a connector 2315 The diaphragm
assembly
2310 sits in the diaphragm assembly seat 2312. The pump diaphragms 2311a,
2311b, 2311c, are
disposed in the receiving holes 2313a, 2313b, 2313c respectively, of the
diaphragm assembly
seat 2312, and the three connectors 2315 connect to the wobble plate 2314 by
inserting the three
connectors 2315 into three respective wobble plate links 2317.
[0098] The bottom of valve seat 2308 has three cylindrical projections
2351a, 2351b, 2351c
that correspond to the three pump diaphragms 2311a, 2311b, 2311c respectively.
The three
pump diaphragms 2311a, 2311b, 2311c fit snugly over the three cylindrical
projections 2351a,
235 lb, 2351c and perform the function of one-way liquid outlet valves. When
pump diaphragms
2311a, 2311b, 2311c expand and the interior of the pump diaphragms 2311a,
2311b, 2311c are
under negative pressure, the pump diaphragms 2311a, 2311b, 2311c seal against
the wall of
cylindrical projections 2351a, 2351b, 2351c, respectively, and prevent the
flow of fluid into the
pump diaphragms 2311a, 2311b, 2311c from between the pump diaphragms 2311a,
2311b,
2311c and the wall of cylindrical projections 2351a, 2351b, 2351c. When pump
diaphragms
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23 Ha, 2311b, 2311c compress and the interior of the pump diaphragms 23 Ha,
2311b, 2311c are
under positive pressure, the pump diaphragms 2311a, 2311b, 2311c flex away
from the wall of
cylindrical projections 2351a, 2351b, 2351c, respectively, and allow fluid to
flow out of the
pump diaphragms 2311a, 2311b, 2311c. When the positive pressure stops, or is
below the
cracking pressure of the pump diaphragms 2311a, 2311b, 2311c, the pump
diaphragms 2311a,
2311b, 2311c move back to their normal position and form a seal against wall
of cylindrical
projections 2351a, 2351b, 2351c. In addition, each cylindrical projections
2351a, 2351b, 2351c
has one or more fluid inlet apertures 2309a, 2309b, 2309c that extend through
valve seat 2308
and a valve stem retention aperture 2329a, 2329b, 2329c respectively.
[0099] Similar to the embodiments described above, during operation, when
liquid pump
diaphragm 2311a expands, a vacuum is crated and liquid is drawn in through
liquid inlet 2352,
through fluid inlet apertures 2309a, past fluid inlet valve 2323a and into
liquid pump diaphragm
2311a. Similarly, when air pump diaphragms 2311b, 2311c expand, air is drawn
in through air
inlets 2325, through air inlet apertures 2309b, 2309c, past fluid inlet valves
2323b, 2323c and
into air pump diaphragms 2311b, 2311c.
1001001 When liquid pump diaphragm 2311a contracts, a positive pressure is
created in the
diaphragm 2111 and once the positive pressure reaches the selected cracking
pressure, the
diaphragm 2311a flexes away from the cylindrical wall 2351a and flows into
mixing chamber
2372. When air pump diaphragm 2311b, 2311c contract, a positive pressure is
created and once
the positive pressure reaches the selected cracking pressure, diaphragms
2311b, 2311c flex away
from the cylindrical wall 2351b, 2351c respectively and air flows into mixing
chamber 2372.
The air and liquid mix together to form a foamy mixture which is forced out of
outlet 2350. The
foam mixture may be dispensed as is or may be further refined with the use of
foam cartridges,
sponges, screens, baffles, or the like and combinations thereof (not shown).
1001011 In some embodiments, the liquid pump diaphragm 2311a includes a sponge
(not shown)
to limit the amount of liquid that may is drawn in and expanded to create
different air to liquid
mix ratios. In some embodiments, a flow control valve (not shown) is attached
to liquid inlet
2352 so that the flow of liquid can be controlled to adjust the air to liquid
ratio.
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[00102] The pump diaphragms 2311a, 2311b, 2311c are expanded and compressed
by
movement of wobble plate 2314. The shaft 2303 of motor 2304 connects to
eccentric wobble
plate drive 2326. Wobble plate pin 2327 connects to eccentric wobble plate
drive 2326 in an
area that is offset from the centerline of the motor shaft 2303. Having the
wobble plate pin 2327
offset from the motor shaft 2303 causes circular movement of the wobble plate
pin 2327, which
causes the ends of the wobble plate 2314 to sequentially undulate. The
undulation causes the
pump diaphragms 2311a, 2311b, 2311c to sequentially compress and expand to
pump the liquid
and the air.
[00103] FIGS. 24 and 25 illustrate another exemplary embodiment of a
sequentially-activated
multi-diaphragm foam pump 2400. Foam pump 2400 includes a pump housing 2402,
liquid inlet
valve 2528, three air inlet valves 2538 (only one is shown), a wobble plate
2504, a liquid pump
diaphragm 2506, three air pump diaphragms 2508 (only one is shown), mixing
chamber 2510,
and foam pump outlet 2412. The foam pump 2400 is coupled to, and in fluid
communication
with, foam cartridge housing 2514, which houses foam cartridge 2516. Foam
cartridge 2516 is
in fluid communication with outlet nozzle 2518. Foam pump 2400 also includes
liquid inlet
2420 that is in fluid communication with a container (not shown) holding
foamable liquid. The
liquid inlet 2420 is coupled to foam pump 2400 so that the foamable liquid is
directed into liquid
pump diaphragm 2506.
[00104] FIG. 24 is a prospective view of foam pump 2400 and illustrates liquid
inlet housing
2422 that is upstream of the liquid pump diaphragm 2506 and three air inlet
areas 2424A, 2424B,
and 2424C that upstream of and correspond to the three air pump diaphragms
2508. In some
embodiments of the pumps described herein, the plurality of pump chambers,
e.g. a liquid pump
chamber and two or more air pump chambers, are formed by a molded multi-
chamber
diaphragm.
[00105] The liquid pumping portion includes pump diaphragm 2506, liquid pump
diaphragm
inlet 2526, liquid inlet valve 2528, liquid pump diaphragm chamber 2530,
liquid pump
diaphragm outlet 2532, and outlet valve 2534. In this embodiment, outlet valve
2534 is
integrally molded with the liquid pump diaphragm 2506 and the air pump
diaphragms 2508. The
liquid pump diaphragm 2506, the liquid pump diaphragm inlet 2526, liquid inlet
valve 2528,
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liquid pump diaphragm chamber 2530, liquid pump diaphragm outlet 2532, and
liquid outlet
valve 2534 may take any form described herein. Each air pumping portion
includes air pump
diaphragm 2508, air pump diaphragm inlet 2536, air inlet valve 2538, air pump
diaphragm
chamber 2540, air pump diaphragm outlet 2542, and outlet valve 2534. Outlet
valve 2534 is a
cylindrical member that deflects away from the sealing wall when the pump
diaphragm is under
positive pressure to let the air or liquid flow into the mixing chamber. The
air pump diaphragms
2508, air pump diaphragm inlets 2536, air inlet valves 2538, air pump
diaphragm chamber 2540,
air pump diaphragm outlet 2534, outlet valve 2544 may take any form described
herein.
[00106] During operation, the liquid pump diaphragm 2506 expands and contracts
to pump
liquid, and the three air pump diaphragms 2508 expand and contract to pump
air. The expansion
of the liquid pump diaphragm 2506 opens liquid inlet valve 2528 and draws
liquid into the liquid
pump diaphragm chamber 2530 through liquid inlet 2526. The expansion of each
of the air
pump diaphragms 2508 opens the corresponding air inlet valves 2538 and draws
air into the
corresponding air pump diaphragm chambers 2540. The air enters each air pump
diaphragm
2508 through the corresponding air inlets 2536 (only one is shown). Wobble
plate 2504 is
connected to a motor (not shown), which may take any form described herein.
The motor causes
the ends of the wobble plate 2504 to sequentially undulate. The undulation
causes the liquid
pump diaphragm 2506 to compress, which causes outlet valve 2534 to be forced
open by the
liquid, which flows into the mixing chamber 2510. Outlet valve 2534 is made of
a flexible
material, such as the same material as the pump diaphragms 2506, 2508, and in
some cases the
pump diaphragms 2506, 2508 and outlet valve 2534 are formed as one piece. The
flexible
material allows the outlet valve 2534 to remain closed during expansion of the
liquid pump
diaphragm 2506, as well as when the liquid pump diaphragm 2506 is in a primed
stated.
However, during compression of the liquid pump diaphragm 2506, the flexible
material of the
outlet valve 2534 will be forced open to allow liquid to flow into the mixing
chamber 2510.
[00107] Subsequently, one of the air pump diaphragms 2508 is compressed by the
undulating
wobble plate 2504, which causes the outlet valve 2534 to open and air to flow
the mixing
chamber 2510. The flexible material allows the outlet valve 2534 to remain
closed during
expansion of the corresponding air pump diaphragms 2508, as well as when the
air pump
diaphragms 2508 are in a primed stated. However, as with the liquid, during
compression of an
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air pump diaphragm 2508, the flexible material of the outlet valve 2534 will
be forced open to
allow air to enter mixing chamber 2510. Similarly, the remaining air pump
diaphragms 2508
will sequentially compress and pump air into the mixing chamber 2510. The air
and liquid mix
in the mixing chamber 2510 to create a foam mixture. The foam mixture exits
the foam pump
2400 through pump outlet 2412.
[00108] As can be seen, the liquid is pumped directly into the mixing chamber
2510 from liquid
pump diaphragm 2506. In other words, the liquid does not need to travel
through an additional
conduit or channel after leaving the liquid pump diaphragm 2506 and before
entering the mixing
chamber 2510. In some embodiments, the shorter distance between the liquid
pump diaphragm
outlet 2532 and the mixing chamber 2510 improves the efficiency of the foam
pump 2400.
[00109] After the foam mixture exits the foam pump 2400, the foam mixture
travels through
conduit 2546 of foam cartridge housing 2514 and enters foam cartridge 2516.
The foam
cartridge housing 2514 is an elbow component that directs the foam mixture to
flow downward.
The downward flow of the foam mixture improves the output efficiency of the
foam mixture.
However, the foam cartridge housing may take any form that allows the foam
mixture to exit
through outlet nozzle 2518.
[00110] In any of the above-mentioned embodiments, the size of the liquid path
as compared to
an air path may vary. In certain embodiments, the liquid path is between about
20 times greater
and 40 times greater than an air path. Also, in certain embodiments, liquid
inlet and/or outlet
valves have a higher cracking pressure than air inlet and/or outlet valves.
[00111] The exemplary embodiments of foam pumps may be used in a soap or
sanitizer
dispenser. Refill units as described herein include at least a container for
holding a liquid. The
refill units are removable from the dispenser and may be replaced with a new
refill unit. In some
embodiments, the foam pump is a permanent part of the dispenser and the refill
unit includes a
container and a fitting for connecting to a fitting (not shown) on the foam
pump. In some
embodiments, the refill unit includes the foam pump that is secured to the
containers and the
foam pump releasably connects to a drive unit, such as a motor, that is
permanently secured to
the dispenser. In some embodiments, the refill unit includes the container,
the foam pump and
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motor. In some embodiments, the refill unit includes a power source, such as,
for example a
battery.
[00112] In some embodiments, the dispensers include a direct current (DC)
power supply. In
some embodiments, the power supply has a voltage of between 3 and 9, including
between about
and about 9, including between about 6 and about 8, including about 3,
including about 4.5,
including about 6, including about 7.5, including about 8, and including about
9.
[00113] In some embodiments, the dispensers dispense at between about 1 and
about 2.5
milliliters/second of foam, including between about 1.9 and 2.5
milliliters/second of foam,
including about 1.9 milliliters/second of foam, including about 2.0
milliliters/second of foam,
including about 2.1 milliliters/second of foam, including about 2.2
milliliters/second of foam,
including about 2.3 milliliters/second of foam, including about 2.4
milliliters/second of foam and
including about 2.5 milliliters/second of foam.
[00114] A conventional mechanical piston foam pump required 1.8 joules per 12
ml of foam
dispensed resulting in 0.15 joules/milliliter of foam. The volume of liquid
was 0.9 and the air to
liquid ration was 11 to 1. An exemplary pump constructed in accordance with an
embodiment
the present invention required only 0.6 joules per 12 ml of foam dispensed
resulting in 0.05
joules/milliliter of foam. The volume of liquid was 0.5 and the air to liquid
ration was 24 to 1.
[00115] In some exemplary embodiments, the motor used to drive the foam pump
consumes
between about 0.4 and about 1.5 joules/12 milliliters of foam output,
including between about
0.6 and 1.5 joules/12 milliliters of foam output, including between about 0.5
and 1.3 joules/12
milliliters of foam output, including between about 0.0 and 1.3 joules/12
milliliters of foam
output, including between about 0.9 and 1.3 joules/12 milliliters of foam
output, including about
0.5 joules/12 milliliters of foam output, including about 0.6 joules/12
milliliters of foam output,
including about 0.7 joules/12 milliliters of foam output, including about 0.8
joules/12 milliliters
of foam output, including about 0.9 joules/12 milliliters of foam output,
including about 1.0
joules/12 milliliters of foam output, including about 01.1 joules/12
milliliters of foam output,
including about 1.2 joules/12 milliliters of foam output, including about 1.3
joules/12 milliliters
of foam output.
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[00116] In some embodiments the volume of foam output is between about 60-130
milliliters of
foam, including between about 100-120 milliliters of foam, including about 80
milliliters of
foam, including about 90 milliliters of foam, including about 100 milliliters
of foam, including
about 110 milliliters of foam and including about 120 milliliters of foam.
[00117] In some embodiments the volume of foam output has a foam density of
between about
0.08 and about 0.125 grams per milliliter of foam, including a foam density of
about 0.08 grams
per milliliter of foam, including a foam density of about 0.09 grams per
milliliter of foam,
including a foam density of about 0,1 grams per milliliter of foam, including
a foam density of
about 0.11 grams per milliliter of foam and including a foam density of about
0.12 grams per
milliliter of foam.
[00118] In some embodiments, the foam pump is configured to produce a foam
that has an air
ratio of about 10 to 1. In some embodiments, the foam pump is configured to
produce a foam
that has an air ratio of about 9 to 1. In some embodiments, the foam pump is
configured to
produce a foam that has an air ratio of about 8 to 1. In some embodiments, the
foam pump is
configured to produce a foam that has an air ratio of about 7 to 1. In some
embodiments, the
foam pump is configured to produce a foam that has an air ratio of about 6 to
1.
[00119] Although the embodiments described above generally included pumps that
have one
liquid pump chamber and multiple air chambers, in some embodiments the pumps
have more
than one liquid pump chamber. In some embodiments, the pumps have two or more
liquid pump
chambers. In some embodiments, the two or more liquid pump chambers pump two
or more
different liquids.
[00120] FIG. 26 is a prospective view of an exemplary foam outlet nozzle 2600
that provides
ultra high volume foam soap. In this exemplary embodiment, outlet nozzle 2600
is connected to
a four chamber sequentially activated diaphragm foam pump 2602 described
herein, however,
the outlet nozzle 2600 may be used with other pumps. Pump 2602 includes a
liquid inlet 2604
and three air inlets 2624 (only two are visible) and an outwardly flared
outlet nozzle 2650.
[00121] FIG. 27 is a cross-sectional view of the exemplary foam outlet nozzle
2600 of FIG. 26.
Foam outlet nozzle 2600 includes a fluid inlet 2702. Fluid inlet 202 receives
a liquid/air mixture
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from foam pump 2602. The fluid travels through passage and passes through mix
media 2704,
which may be, for example a screen which causes turbulence in the mixture to
create foam. The
foamy mixture passes through a second mix media 2708, which may also be, for
example, a
screen. Although this exemplary embodiment contains two mix media 2704, 2708,
it has been
discovered that only one mix media 2708 provides a high quality foam in the
novel design of the
outlet nozzle 2600. The foamy mixture passes through a passage having an
inside diameter 2720
and into a second passage having an inside diameter 2722. In some embodiments,
the inside
diameter 2720 and 2722 have an inside diameter of between about 0.2 inches and
about 0.35
inches. Foam outlet nozzle 2600 includes a flared tip 2710. In some
embodiments, flared tip
27110 has an inside diameter of between about 0.5 inches and about 0.7 inches.
In addition, it has
been discovered that the length 2730 of the spout 2709 has an effect on the
quality of the foam
output through the foam outlet nozzle 2600. In some embodiments, the length
2730 of the spout
is between about 0.3 inches and about 1.25 inches. Exemplary embodiments of
foam outlet
spout 2600 have produced foam densities as low as 0.04 grams/cubic cm, as low
as 0.04
grams/cubic cm, as low as 0.03 grams/cubic cm and as low as .02 gram/cubic cm.
Without
limiting effect, it is believed that high foam volume is due to the large
diameter spout 2709 and
the flared tip 2710. The hold leading into the tube cannot be too small or
foam will breakdown.
[00122] In some exemplary embodiments the liquid cylinder (not shown) of the
foam pump
2602 utilize a mechanism to throttle the liquid flow entering foam pump 2602,
such as, for
example, lost motion, smaller diameter liquid diaphragm, a restrictor valve, a
restrictor inlet, a
sponge located within the liquid diaphragm, or the like. In some embodiments,
depending on the
soap formulation level of alcohol and surfactant type the nozzle 2600 of the
foam pump 2602
may differ in design. A larger diameter nozzle with a single screen will foam
a soap
formulation that is harder to foam, such as a soap with alcohol or a non-ideal
surfactant and
create a foam with large bubbles. A better foaming formulation will be able to
create a high
volume foam with consistent and small bubbles when mated with a smaller nozzle
diameter and
dual screens.
[00123] 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
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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.
33
