Abstract:
Exemplary simplified outlet valves, pumps and refill units are disclosed herein. An exemplary inverted refill unit for a dispenser includes a container and a pump secured to the bottom of container. The pump has a liquid inlet valve and a liquid outlet having an annular housing. One or more liquid outlet passages are located within the annular housing. A valve seat is located proximate the liquid outlet passages. A liquid outlet valve is also included. The liquid outlet valve includes an annular body and a resilient disc located on the interior of the annular body. The resilient disc has an opening in the center and seals against the valve seat to seal the one or more liquid outlet passages in a normal state. The resilient disc deflects from the valve seat under pressure so that liquid flows through the liquid outlet passages and through the center of the resilient disc.

Description:
TECHNICAL FIELD 
       [0001]    The present invention relates generally to liquid outlet valves, pumps and refill units. 
       BACKGROUND OF THE INVENTION 
       [0002]    Dispensers having inverted refill units, i.e. refill units that have a container full of liquid and a pump located below the container, are generally configured to provide a user with an amount of soap or sanitizer upon actuation of the dispenser. The inverted dispensers may be liquid dispensers or foam dispensers. Inverted foam dispensers generally convert liquid material, such as liquid soap or sanitizer, into foam by aerating the liquid material as it is dispensed. Air is generally injected into the liquid material to form air bubbles in the liquid, causing the formation of foam. Inverted foam dispensers may include a replaceable refill container that is replaced after the liquid material therein is consumed by the user. Liquid outlet valves for inverted dispensers are known. Many prior art liquid outlet valves include springs. 
       SUMMARY 
       [0003]    Exemplary simplified outlet valves, pumps and refill units utilizing such simplified outlet valves are disclosed herein. An exemplary inverted refill unit for a dispenser includes a container and a pump secured to the bottom of container. The pump has a liquid inlet valve and a liquid outlet having an annular housing. One or more liquid outlet passages are located within the annular housing. A valve seat is located proximate the liquid outlet passages. A liquid outlet valve is also included. The liquid outlet valve includes an annular body and a resilient disc located on the interior of the annular body. The resilient disc has an opening in the center and seals against the valve seat to seal the one or more liquid outlet passages in a normal state. The resilient disc deflects from the valve seat under pressure so that liquid flows through the liquid outlet passages and through the center of the resilient disc. 
         [0004]    Another exemplary inverted refill unit for a dispenser includes a container and a pump secured to the bottom of container. The pump has a liquid inlet valve and a liquid outlet having an annular housing with one or more liquid outlet passages therethrough and a liquid outlet valve. The liquid outlet valve has a resilient disc that has an outside located on the interior of the annular body. The resilient disc has an opening in the center. The resilient disc is angled upward. In addition, the liquid outlet valve is normally closed sealing off the liquid passages. 
         [0005]    Another exemplary inverted refill unit for a dispenser includes a container and a pump secured to the bottom of container. The pump has a liquid inlet valve and a liquid outlet having an annular housing that includes one or more liquid outlet passages therethrough, and a liquid outlet valve. The liquid outlet valve includes a resilient disc that has an opening in the center. In addition, the liquid outlet valve has a plurality of feet located below the resilient disc. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]    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: 
           [0007]      FIG. 1  is an cross-section of an exemplary refill unit for a foam pump having a simplified outlet valve; 
           [0008]      FIG. 2  is a plan view of an exemplary simplified liquid outlet valve for a pump used in an inverted refill unit of  FIGS. 1 and 6 ; 
           [0009]      FIG. 3  is a cross-section of the exemplary simplified liquid outlet valve of  FIG. 2 ; 
           [0010]      FIG. 4  is an enlarged cross-section of a portion of the foam pump and the simplified liquid outlet valve of  FIG. 1  with the simplified liquid outlet valve in a open position; 
           [0011]      FIG. 5   FIG. 4  is an enlarged cross-section of a portion of the foam pump and the simplified liquid outlet valve of  FIG. 1  with the simplified liquid outlet valve in a open position; and 
           [0012]      FIG. 6  is a cross-section of an exemplary refill unit having a liquid pump with a simplified outlet valve. 
       
    
    
     DETAILED DESCRIPTION 
       [0013]      FIG. 1  illustrates an exemplary refill unit  110 . Refill unit  110  includes a container  112  and a foam pump  130 . Foam pump  130  includes a pump housing  102  is secured to a neck  101  of container  112  by collar  104 . Collar  104  is secured to container  112  by a snap-fit connection; however, it could be connected by any means, such as, for example a threaded connection, a welded connection, an adhesive connection or the like. 
         [0014]    Located between pump housing  102  and container neck  101  is plate  106 . Plate  106  includes an aperture  107  surrounded above by valve seat  108  which provides a seat for inlet ball valve  111 . Inlet ball valve  111  is retained from below by anchors  109  which are secured to plate  106 . Inlet ball valve  111  is a normally open valve. Accordingly, liquid may flow past the inlet ball valve  111  into liquid inlet channel  113 , past sleeve  114  and into liquid pump chamber  116 . 
         [0015]    When liquid pump chamber  116  is pressurized, as discussed in detail below, inlet ball valve  111  seals against seat  108  to prevent liquid from flowing from pump chamber  116  back into container  112 . In some embodiments, ball valve  111  may be a normally closed valve and in that case may include a biasing member (not shown) to bias the ball valve  111  closed. In addition, although the one-way liquid inlet valve is a ball valve, other types of one-way inlet valves may be used, such as, for example, a mushroom valve, an umbrella valve, a poppet valve, a flapper valve, or the like. 
         [0016]    Pump housing  102  includes a cavity  113 . Located within cavity  113  is a sleeve  114 . A liquid piston  118  moves in a back and forth reciprocating motion within sleeve  114  to increase and decrease the volume of pump chamber  116 . Similarly, located within cavity  113  is an air piston sleeve  153 . Air piston  152  moves in a back and forth reciprocating motion within air piston sleeve  153  to increase and decrease the volume of air chamber  150 . Sleeves  114  and  153  are manufactured with tight tolerances and allow pump housing  102  to be manufactured inexpensively without tight tolerances. 
         [0017]    The liquid piston  118  is connected to liquid piston stem  119 . Liquid piston stem  119  is connected to air piston  152 . Accordingly, movement of air piston  152  also moves liquid piston  118 . Air piston  152  also includes connector  154 . Connector  154  mates with a connector (not shown) on a dispenser (not shown). 
         [0018]    Pump housing  102  also includes one or more liquid outlet passages  127 . Liquid outlet passages  127  are formed in pump housing  102  and extend from cavity  113  to the bottom of pump housing  102 . Pump housing  102  includes annular projection  128  for connecting to lower pump housing  105 . In addition, pump housing  102  includes an annular projection  410  ( FIG. 4 ) which provides a valve seat for one-way liquid outlet valve  190 . 
         [0019]    The lower pump housing  105 , of foam pump  130  that has an annular projection  107  for connecting to an annular outlet  157  of air chamber  150 . In addition, lower pump housing  105  includes an outlet  130  and a seat  109 . Lower pump housing  105  retains foaming cartridge  109  and valve  190 . Seat  109  provides support for foaming cartridge  123  which contains one or more foaming screens  124 . In addition, foaming cartridge  123  supports one-way liquid outlet valve  190 . 
         [0020]      FIGS. 2-3  provide a detailed view of one-way liquid outlet valve  190 . One-way liquid outlet valve  190  is an elastomeric member that includes cylindrical side wall  202 , resilient disc  204 , opening  206  and a plurality of feet  203 . Cylindrical side wall  202  fits over annular projection  402  ( FIG. 4 ) of lower pump housing  102 . In some embodiments, cylindrical wall  202  forms a tight fit with annular projection  402  and is securely held in place by the friction fit. In addition, as described above, feet  203  rest on foaming cartridge  123  to secure one-way outlet valve  190  in place. 
         [0021]    Resilient disc  204  is flexible and is angled upward, or loaded with a deflection. Because one-way liquid outlet valve  190  is used in an inverted refill unit  110  one-way liquid outlet valve  190  needs to prevent static drip. Typically, elastomeric valves that deflect are only used for air and do not need to overcome static drip issues. Static drip occurs when the weight of the fluid in the container either opens the outlet valve or prevents the outlet valve from closing properly. In addition, the cracking pressure is important. If the cracking pressure is too high, the pump requires too much force to operate and would not be suitable for use in dispensers, particularly touch-free dispensers where the pump actuator is operated by battery power. These two designs considerations are in opposition to one another. 
         [0022]    In one embodiment, the static drip consideration has been addressed by loading the resilient disc  204  with about 0.005 inches of deflection. In some embodiments, the resilient disc  204  is loaded with greater than about 0.003 inches of deflection. In some embodiments, the resilient disc  204  is loaded with between about 0.001 and 0.01 inches of deflection. Loading the resilient disc  204  with deflection prevents static drip. In addition, in some embodiments, the one-way liquid outlet valve opens at a pressure that is lower than about 3 psi (pounds per square inch), which is a standard dispenser pump operating pressure. 
         [0023]    In some embodiments, outlet nozzle  130  is funnel shaped and, as foam flows through outlet nozzle  130  the velocity of the foam is increased helping to enrich the foam. 
         [0024]    Located between air compressor chamber  150  and mixing chamber  404  is an air outlet passage  158 . Air outlet passage  158  is elongated and located at the bottom of air chamber  150 . In some embodiments, air outlet passage  158  includes a stepped down portion  159  where the air outlet passage  158  connects to lower pump housing  105 . This stepped down portion may trap and retain residual foam and liquid that is sucked back into air chamber  150  as air piston  152  is moved back to its charged position. 
         [0025]    In some embodiments, a one-way air inlet valve  156  is located in the body of air piston  153 . In some embodiments, a one-way air inlet valve (not shown) is located in a wall of air piston sleeve  153 . One-way air inlet valve  156  has a cracking pressure that is selected so that when air piston  152  is moved from a fully discharged position toward the fully primed or charged position air is drawn in through though the outlet nozzle  130  and sucks back residual foam and liquid up through air passages  128 . As the air piston  152  moves toward its fully charged position, the vacuum pressure in air chamber  150  increases because of the resistance caused by the foaming screens and air passage  124 . Once the vacuum pressure increases to a set point, the one-way air inlet valve  156  opens and allows air to flow into air chamber  150 . In some embodiments, a cracking pressure of about 3 psi is selected. Thus, foam pump  130  provides for a limited suck back of foam and extends battery life because the one-way air inlet valve  156  allows air piston  152  to move back without the increased resistance of the screen(s)  124 . 
         [0026]    During operation, one-way liquid outlet valve  190  is normally closed as shown in  FIG. 4 . Resilient disc  204  seals against annular projection  410  of pump housing  102 . To prime or charge foam pump  130 , the liquid piston  118  and air piston  152  are moved outward, liquid flows from container  112  past one-way inlet ball valve  111  through passage  115  into the area defined by cavity  113  and sleeve  114  and into liquid pump chamber  116 . Air is initially drawn in through outlet  130  and screens  124 , which sucks back fluid and foam left in the foaming cartridge  123  and outlet  130 . Then, air inlet valve  156  opens and allows air to freely flow into air chamber  150 . 
         [0027]    To discharge foam pump  130 , the liquid piston  118  and air piston  152  are moved inward. Liquid is forced out of liquid pump chamber  116  through liquid outlet passages  127  and the pressure forces resilient disc  204  to deflect downward as illustrated in  FIG. 5 . Liquid flows past disk  204  and through opening  206  into mixing chamber  404 . Air from air chamber  150  travels through air outlet  158  (picking up residual fluid sucked into the air chamber during priming) into mixing chamber  404  where the air and liquid mix together. The air/liquid mixture is forced through mixing cartridge  123  and dispensed as a foam. 
         [0028]      FIG. 6  illustrates another exemplary refill unit  610 . Refill unit  610  includes a container  612  and a liquid pump  630 . Liquid pump  630  includes a pump housing  602  is secured to a neck  601  of container  612  by collar  604 . Collar  604  is secured to container  612  by a snap-fit connection; however, it could be connected by any means, such as, for example a threaded connection, a welded connection, an adhesive connection or the like. 
         [0029]    Located between pump housing  602  and container neck  601  is plate  606 . Plate  606  includes an aperture  607  surrounded above by valve seat  608  which provides a seat for inlet ball valve  611 . Inlet ball valve  611  is retained from below by anchors  609  which are secured to plate  606 . Inlet ball valve  611  is a normally open valve. Accordingly, liquid may flow past the inlet ball valve  610  into liquid inlet channel  615 , past sleeve  614  and into liquid pump chamber  616 . 
         [0030]    When liquid pump chamber  616  is pressurized, as discussed in detail below, inlet ball valve  611  seals against seat  608  to prevent liquid from flowing from pump chamber  616  back into container  612 . In some embodiments, ball valve  611  may be a normally closed valve and in that case may include a biasing member (not shown) to bias the ball valve  611  closed. In addition, although the one-way liquid inlet valve  611  is a ball valve, other types of one-way inlet valves may be used, such as, for example, a mushroom valve, an umbrella valve, a poppet valve, a flapper valve or the like. 
         [0031]    Pump housing  602  includes a cavity  613 . Located within cavity  613  is a sleeve  614 . A liquid piston  618  moves in a back and forth reciprocating motion within sleeve  614  to increase and decrease the volume of pump chamber  616 . Sleeve  614  is manufactured with tight tolerances and allows pump housing  602  to be manufactured inexpensively without tight tolerances. 
         [0032]    The liquid piston  118  is connected to liquid piston stem  619  and includes a connector  654  that mates with a connector (not shown) on a dispenser (not shown). Pump housing  602  also includes one or more liquid outlet passages  627 . Liquid outlet passages  627  are formed in pump housing  602  and extend from cavity  613  to the bottom of pump housing  602 . Pump housing  602  includes annular projection  628  for connecting to lower pump housing  605 . In addition, pump housing includes an annular projection  610  ( FIG. 4 ) which provides a valve seat for one-way liquid outlet valve  190 , which is the same liquid outlet valve described above with respect to foam pump  130 . Liquid outlet valve  190  operates in the same manner described above and is not re-described with respect to liquid pump  630 . 
         [0033]    Liquid pump  630  includes a lower pump housing  605  that has a seat  609 . Lower pump housing  105  and seat  109  provides support for one-way liquid outlet valve  190 . 
         [0034]    As described above, during operation, one-way liquid outlet valve  190  is normally closed as shown in  FIG. 4 . Resilient disc  204  seals against annular projection  610  of pump housing  602 . To prime or charge liquid pump  130 , the liquid piston  118  is moved outward, liquid flows from container  112  past one-way inlet ball valve  111  through passage  115  into the area defined by cavity  113  and sleeve  114  and into liquid pump chamber  116 . 
         [0035]    To discharge liquid pump  130 , the liquid piston  118  is moved inward. Liquid is forced out of liquid pump chamber  116  through liquid outlet passages  127  and the pressure forces resilient disc  204  to deflect downward as illustrated in  FIG. 5 . Liquid flows past disk  204  and through opening  206  and out of outlet  630 . 
         [0036]    While various inventive aspects, concepts and features of the inventions may be described and illustrated herein as embodied in combination in the exemplary embodiments, these various aspects, concepts and features may be used in many alternative embodiments, either individually or in various combinations and sub-combinations thereof. It is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Unless expressly excluded herein, all such combinations and sub-combinations are intended to be within the scope of the present inventions. Still further, while various alternative embodiments as to the various aspects, concepts and features of the inventions—such as alternative materials, structures, configurations, methods, circuits, devices and components, software, hardware, control logic, alternatives as to form, fit and function, and so on—may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Those skilled in the art may readily adopt one or more of the inventive aspects, concepts or features into additional embodiments and uses within the scope of the present inventions even if such embodiments are not expressly disclosed herein. Additionally, even though some features, concepts or aspects of the inventions may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative values and ranges may be included to assist in understanding the present disclosure; however, such values and ranges are not to be construed in a limiting sense and are intended to be critical values or ranges only if so expressly stated. Moreover, while various aspects, features and concepts may be expressly identified herein as being inventive or forming part of an invention, such identification is not intended to be exclusive, but rather there may be inventive aspects, concepts and features that are fully described herein without being expressly identified as such or as part of a specific invention. Descriptions of exemplary methods or processes are not limited to inclusion of all steps as being required in all cases, nor is the order in which the steps are presented to be construed as required or necessary unless expressly so stated.