Multi-reservoir liquid dispenser and associated methods

A liquid dispenser includes a housing configured to receive a liquid supply cartridge, and a reservoir disposed in the housing that holds a volume of the product. The reservoir includes an access port for receiving the liquid supply cartridge and placing the liquid supply cartridge and the reservoir in communication. A dosing tank is connected to the reservoir and configured to hold a metered volume of the product. A control valve is movable between an opened position and a closed position, wherein when the control valve is in the opened position, product in the dosing tank is permitted to flow from the liquid dispenser and product flow from the reservoir to the dosing tank is prevented, and when the control valve is in the closed position, product in the dosing tank is prevented from flowing from the liquid dispenser and product flow from the reservoir to the dosing tank is permitted.

TECHNICAL FIELD

This invention generally relates to chemical dispensing, and more particularly to a liquid dispenser having multiple in-line reservoirs for holding a supply of chemical for dispensing into a receptacle.

BACKGROUND

The dispensing of liquid chemical products into a receptacle is a common requirement of many industries. By way of example, in the janitorial industry it is often desirable to dispense one or more chemicals, such as detergents, bleaches, disinfectants, sanitizers, etc., for application to floors, countertops, and other surfaces and areas. Such chemicals may be added to a receptacle, such as a spray bottle or a bucket, and mixed with water or other diluent to form a solution. A number of dispensing systems have been developed for this purpose. By way of example, many systems use a refillable or replaceable chemical supply cartridge and a control valve to deliver chemical directly to the receptacle. The control valve may be manual or configured as an electronic valve. In many applications, the system may include a way to meter the amount of chemical being dispensed into the receptacle.

While these chemical dispensing systems operate for their intended purpose, there are a number of drawbacks for which manufacturers and chemical suppliers seek to improve. By way of example, when the chemical supply cartridge runs out of chemical, the chemical dispenser is no longer operational, and the cartridge must be immediately replaced to restore operation of the chemical dispenser. In many cases, replenishment of the chemical supply cartridges is performed on a regular schedule by outside service technicians that come on-site to maintain the janitorial equipment. Should a chemical supply cartridge run out of product before the scheduled time, janitorial personnel must seek alternative sources for their cleaning supplies. This can be frustrating and inconvenient to janitorial personnel and delay cleaning services.

Additionally, metering the amount of chemical being dispensed into a receptacle is often accomplished using electronic means, including various processors and sensors, that sense fluid flow and determine volumetric data. Such electronic means adds a certain layer of complexity to the chemical dispenser that typically results in an increase in manufacturing, operational, and maintenance costs. Moreover, chemical dispensers of this type require a power source, such as a battery or a power outlet. This requirement, in turn, restricts potential locations for the chemical dispenser on the premises (e.g., near a power outlet) or increases operational and maintenance expenses to keep the power source functional.

Therefore, it is desirable to provide an improved chemical dispenser that addresses the shortcomings of current dispenser. More particularly, there is a need for a chemical dispenser that provides an excess amount of chemical so that the dispenser remains operational subsequent to the chemical supply cartridge running out of product. There is also a need for a chemical dispenser that can meter a dose of chemical for dispensing into a receptacle in a manner that avoids complex electronics and power sources.

SUMMARY

A liquid dispenser for dispensing a product includes a housing configured to receive a liquid supply cartridge containing the product to be dispensed and a reservoir disposed in the housing and configured to hold a volume of the product, wherein the reservoir includes an access port for receiving a portion of the liquid supply cartridge and placing the liquid supply cartridge and the reservoir in communication when the liquid supply cartridge is inserted into the housing. The liquid dispenser further includes a dosing tank operatively connected to the reservoir and configured to hold a metered volume of the product and a control valve movable between an opened position and a closed position. When the control valve is in the opened position, product in the dosing tank is permitted to flow from a dispensing end of the liquid dispenser and product flow from the reservoir to the dosing tank is prevented. When the control valve is in the closed position, product in the dosing tank is prevented from flowing from the dispensing end and product flow from the reservoir to the dosing tank is permitted.

In one embodiment, the liquid supply cartridge and the reservoir are configured to have an in-line arrangement within the housing such that product from the liquid supply cartridge is configured to flow through the reservoir as product is dispensed by the liquid dispenser. The reservoir is configured to supply product to the dosing tank when the liquid supply cartridge is depleted of product and thereby allow continued operation of the liquid dispenser even though the liquid supply cartridge is depleted. In an exemplary embodiment, the reservoir has a volume greater than the dosing tank such that the reservoir is able to refill the dosing tank with product multiple times before the reservoir becomes depleted of product.

In one embodiment, the dosing tank further includes a vent having an opened position and a closed position. Movement of the control valve from the closed position to the opened position moves the vent between the closed position and the opened position. The dosing tank also includes a flow restrictor configured to restrict the flow of product from the reservoir to the dosing tank when the control valve is in the closed position. In one embodiment, the flow restrictor includes a diffuser having a diverging configuration in a direction from the reservoir to the dosing tank. The liquid dispenser includes a bayonet connection between the reservoir and the dosing tank.

In one embodiment, the liquid dispenser may include a locking mechanism having a locked position and an unlocked position. In the locked position the liquid supply cartridge is prevented from being removed from the liquid dispenser housing, and wherein in the unlocked position the liquid supply cartridge is removable from the liquid dispenser housing.

In an exemplary embodiment, the control valve may include a two-part valve element movable between the opened and closed position. For example, the two-part valve element may include a shuttle disposed in an interior of the dosing tank and a spigot coupled to the shuttle and extending outside the dosing tank. The spigot may define the dispensing end of the liquid dispenser. In one embodiment, the shuttle includes a tubular body having a first end and a second end and a plug at the first end thereof for occluding the flow of product from the reservoir to the dosing tank when the valve element is in the closed position. The shuttle may further include a blind bore formed in the tubular body open to the second end and extending toward the first end, and a contact plate for engaging the vent and moving the vent from the closed position to the opened position with movement of the valve element from the closed position to the opened position. The plug may include a Y-shaped tip configured to be received in respective slots in the diffuser flow restrictor when the valve element is in the opened position.

In one embodiment, the spigot may include a tubular body having a first end and a second end, a post at the first end, a blind bore formed in the tubular body open the second end and one or more ports extending through a side wall of the tubular body and in communication with the blind bore. The one or more ports are configured to be disposed in the interior of the dosing tank when the valve element is in the opened position. The spigot further includes an engagement plate adjacent the second end, which in one embodiment may include a vent hole or ridges that provide venting of the receptacle.

In one embodiment, the housing of the liquid dispenser may include an outer housing and an inner frame received within the outer housing. The inner frame is configured to support the dosing tank, reservoir, and liquid supply cartridge. The outer housing has a removable bottom wall for accessing the interior of the housing.

In another embodiment, a method of dispensing from a liquid dispenser having a liquid supply cartridge and a control valve, wherein the liquid supply cartridge contains a product to be dispensed and the control valve has an opened position and a closed position. The method includes directing the product from the liquid supply cartridge to a reservoir in the liquid dispenser, directing the product from the reservoir to a dosing tank in the liquid dispenser, and dispensing a metered dose of product from the dosing tank when the control valve is in the opened position.

In one embodiment, the method further includes preventing the flow of product from the reservoir to the dosing tank when the control valve is in the opened position. Moreover, the method may include subjecting the dosing tank to atmospheric pressure and air when the control valve is in the opened position. In this regard, the dosing tank may include a vent having an opened position and a closed position, and wherein movement of the control valve from the closed position to the opened position moves the vent from the closed position to the opened position. According to the method, subsequent to dispensing a metered dose of product from the dosing tank, the dosing tank may be refilled with product from the reservoir. The method may further include restricting the flow of product from the reservoir to the dosing tank during refilling of the dosing tank with product. For example, restricting the flow of product may further include directing the flow of product through a diffuser to increase the fill time of the dosing tank. The method may further include directing air in the dosing tank through the flow restrictor, into the reservoir, and into the liquid supply cartridge during refilling of the dosing tank with product.

Upon depletion of the product in the liquid supply cartridge, the method may include continuing to dispense product from the liquid dispenser using the product stored in the reservoir. In one embodiment, upon depletion of the product in the liquid supply cartridge, the method may include removing the empty liquid supply cartridge from the liquid dispenser and inserting a new liquid supply cartridge into the liquid dispenser. The removing and inserting steps may be performed prior to the product in the reservoir being depleted.

In a further aspect, the liquid dispenser may include a locking mechanism having a locked position and an unlocked position, and the method may further include moving the locking mechanism to the unlocked position prior to removing the liquid supply cartridge from the liquid dispenser and moving the locking mechanism to the locked position subsequent to inserting the new liquid supply cartridge in the liquid dispenser.

DETAILED DESCRIPTION

With reference toFIGS.1and2, a liquid dispenser10in accordance with an embodiment of the invention is illustrated. The liquid dispenser10is of the type that utilizes a replaceable liquid supply cartridge12with a control valve14for dispensing a metered dose of liquid, such as a chemical agent, into a receptacle (not shown). The liquid dispenser10includes an in-line reservoir16disposed between the liquid supply cartridge12and the control valve14. In this way, the liquid dispenser10remains operational even after the liquid supply cartridge12runs out of product, due to the supply of product that remains in the reservoir16. The liquid supply cartridge12and the reservoir16collectively constitute multiple “reservoirs” for supplying product during operation of the liquid dispenser10. An empty liquid supply cartridge12may then be replaced before the reservoir16runs out of product. This maintains the liquid dispenser10operational at least for a limited time, even though the liquid supply cartridge12is empty. In addition, the liquid dispenser10includes a dosing tank18(FIG.5) that ensures a precise amount of liquid is delivered to the receptacle when the control valve14is opened. The particular arrangement of the liquid dispenser10provides for metering of the liquid without the use of complicated electronics or a power source. Thus, the liquid dispenser10represents an improved dispensing solution that addresses some of the drawbacks of dispensing systems currently in the market. Various features of the liquid dispenser10will not be described in detail.

In an exemplary embodiment and in reference toFIGS.1-3, the liquid dispenser10may include a housing20for holding the elements of the liquid dispenser10, including the liquid supply cartridge12, control valve14, reservoir16, and the dosing tank18. The housing20may be generally rectangular or trapezoidal in various embodiments but is not limited to any particular cross-sectional profile. The housing20includes an outer housing22and an inner frame24. The outer housing22may be generally rectangular or trapezoidal and include a front wall26, rear wall28and opposed side walls30,32extending between the front and rear walls26,28. The outer housing22may be generally open at its upper end but closed off at its lower end by a base wall34. In one embodiment, the outer housing22may be a monolithic body formed, for example, from a suitable plastic though a molding process. Alternatively, the outer housing22may be formed from separate walls or panels that are coupled together, such as by bonding, ultrasonic welding, etc., to form the assembled outer housing22. In one particular embodiment, for example, the front wall26, rear wall28, and side walls30,32may be formed as a monolithic body, such as through a molding process, and the base wall34may be a separate element that is coupled to the lower end of those walls, such as by a spring clip or other reasonable element. This allows the base wall34to be removed from the outer housing22to gain access to an interior36(FIG.5) of the outer housing22defined by its various walls.

In one embodiment illustrated inFIG.4, the base wall34includes a central aperture38configured to receive a portion of the control valve14and a support tube40extending away from the base wall34and having a passageway open to the central aperture38. The central aperture38may include an inlet ring42that facilitates engagement of a receptacle with the control valve14of the liquid dispenser10. In this regard, the inlet ring42may include a chamfered inner surface to guide a receptacle into proper engagement with the control valve14. The base wall34may further include an outer flange44extending from the base wall34to facilitate engagement of the base wall34with the outer housing22. In an exemplary embodiment, the outer flange44may include the spring clip or other reasonable element for releasably securing the base wall34to the outer housing22in a snap-fit manner.

The front wall26of the outer housing22may include a facia plate46. The facia plate46may be integrally formed with the outer housing22or be a separate element which is attached to the outer housing22. For example, in one embodiment, the facia plate46may couple to the outer housing22through a snap fit connection that allows the facia plate46to be attached or removed in a relatively straight forward manner. In one embodiment, the facia plate46may be decorative in nature and include various letters, numbers, symbols, textures, colors, etc. that provide a pleasing appearance to the liquid dispenser10. The facia plate46may be changed out periodically to give the liquid dispenser10a different appearance.

The rear wall28of the outer housing22may include a mounting plate48for mounting the liquid dispenser10to a wall or other support surface within a facility in which the liquid dispenser10is to be used. For example, the liquid dispenser10may be configured to couple to a wall or support surface in a janitorial closet or other cleaning area within the facility. The mounting plate48may be integrally formed with the outer housing or be a separate element which is attached to the outer housing22. For example, in one embodiment, the mounting plate48may be configured to be connected to the wall or support surface through bonding or by other fastening means (e.g., screws, rivets, clips, etc.). The outer housing22may then be configured to be releasably connected to the mounting plate48. This may allow a service technician, for example, to remove the liquid dispenser10from the wall or support surface for maintenance or replacement. In one embodiment, an inner surface of the mounting plate48may include one or more studs and the rear surface28of the outer housing may include a corresponding one or more apertures that receive the studs in a removable manner. In an alternative embodiment, the liquid dispenser10may be configured to connect to the mounting plate48via other connectors as recognized by those of ordinary skill in the art.

The side walls30,32of the outer housing22may be generally arcuate as the walls extend between the front and rear walls26,28. Additionally, the side walls30,32generally converge in a direction from the rear wall28toward the front wall26since the front wall26may have a width that is less than a width of the rear wall28(i.e., the liquid dispenser10may be wider near the rear of the dispenser as compared to the front of the dispenser). At least one of the side walls30,32, and preferably each of the side walls30,32, includes a generally U-shaped slot50centrally located in the side walls30,32and extending longitudinally from the upper end of the outer housing22toward the lower end. The U-shaped slots50stop short of the lower end such that the side walls30,32have a continuous width along a lower region of the outer housing22. As illustrated in these figures, and discussed in more detail below, the purpose of the slots50is to allow a user or service technician to visually observe the amount of product in the liquid supply cartridge12and the reservoir16. The slots50also allow a service technician to grasp the liquid supply cartridge during a replacement or maintenance process.

The inner frame24is configured to be received within the outer housing22and internally support the liquid supply cartridge12, control valve14, reservoir16and dosing tank18within the housing20of the liquid dispenser10. As illustrated in theFIGS.3and5, and in an exemplary embodiment, the inner frame24may be configured as a U-shaped channel or body52and include a front wall54, a rear wall56, and a bottom wall58extending between the front and rear walls54,56. The U-shaped body52is generally open at its upper end and along the sides of the body52(i.e., side walls that extend between the front and rear walls54,56are generally omitted). In one embodiment, the front and rear walls54,56may be generally arcuate and include a support flange60at an upper end of the walls54,56. The support flanges60are configured to engage with lips or ledges62on the front and rear walls26,28of the outer housing22to support the inner frame24within the outer housing22. In one embodiment, the inner frame24may abut the ledges62without a positive connection therebetween (i.e., the flanges60rest on the ledges62but are not otherwise fixed thereto). Alternatively, the inner frame24may be positively connected to the outer housing22. For example, the flanges60and ledges62may be secured with an adhesive or other bonding agent, ultra-sonic welding, or other means for fixedly connecting the inner frame24to the outer housing22.

The bottom wall58includes a central aperture64configured to receive a portion of the reservoir16and support the reservoir within the housing20, as will be explained in more detail below. The central aperture64of the bottom wall58of the inner frame24is configured to generally align with the central aperture38in the base wall34of the outer housing22when the inner frame24is received and seated within the outer housing22. In an exemplary embodiment, the inner frame24may be formed from a suitable engineering plastic through, for example, a molding process. Alternatively, the inner frame24may be formed from a more durable material, such as a metal. Other materials and processes for forming the inner frame24are possible as well.

In an exemplary embodiment, the reservoir16is configured to be received within and supported by the inner frame24of the housing20. In this regard, the reservoir16includes a generally rectangular body70having a front wall72, rear wall74, opposed side walls76, upper wall78, and lower wall80that collectively define an interior82for holding a volume of product. The front and rear walls72,74may be generally arcuate to generally match the arcuate front and rear walls54,56of the inner frame24. For example, the front and rear walls72,74may have a relatively constant radius of curvature. The radius of curvature may be the same or different between the front and rear walls72,74. In an exemplary embodiment, the radius of curvature of the rear wall74is greater than the radius of curvature of the front wall72. Additionally, the width of the side walls76may be substantially equal to the distance between the front and rear walls54,56of the inner frame24such that the reservoir16substantially fills the void between the front and rear walls54,56. Moreover, the width of the front wall72and rear wall74may be substantially equal to the width of the respective front and rear walls54,56of the inner frame24. In one embodiment, the width of the front and rear walls72,74of the reservoir16may be slightly greater than the respective widths of the front and rear walls54,56of the inner frame24.

The lower wall80of the body70of the reservoir16includes a neck84extending therefrom that defines a passageway that is open to the interior82of the reservoir16. The neck84is sized to be received in the central aperture64in the bottom wall58of the inner frame24and extend therethrough such that the lower wall80of the body70engages against the bottom wall58of the inner frame24. In this way, the reservoir16is supported by the inner frame24of the housing20. For purposes discussed in more detail below, the neck84of the body70includes a key feature86(e.g., one or more outwardly extending tabs or protrusions) and a seal, such as an O-ring disposed about the neck84. Moreover, the upper wall78of the body70includes an access port88for accessing the interior82of the body70. In one embodiment, the access port88may include an actuator, such as a cannula or protrusion, capable of engaging with the liquid supply cartridge12, as explained in more detail below. In another embodiment, the access port88may include a valve. In an exemplary embodiment, the reservoir16may be formed from a suitable engineering plastic by a molding process, for example. Other materials and processes, however, are also possible.

In an exemplary embodiment and in a similar manner, the liquid supply cartridge12is configured to be received within and supported by the inner frame24of the housing20. In this regard, the liquid supply cartridge12includes a generally rectangular body90having a front wall92, rear wall94, opposed side walls96, upper wall98, and lower wall100that collectively define an interior102for holding a volume of product. The front and rear walls92,94may be generally arcuate to generally match the arcuate front and rear walls54,56of the inner frame24. For example, the front and rear walls92,94may have a relatively constant radius of curvature. The radius of curvature may be the same or different between the front and rear walls92,94. In an exemplary embodiment, the radius of curvature of the rear wall94is greater than the radius of curvature of the front wall92. Additionally, the width of the side walls96may be substantially equal to the distance between the front and rear walls54,56of the inner frame24such that the liquid supply cartridge12substantially fills the void between the front and rear walls54,56. Moreover, the width of the front wall92and rear wall94may be substantially equal to the width of the respective front and rear walls54,56of the inner frame24. In one embodiment, the width of the front and rear walls92,94of the liquid supply cartridge12may be slightly greater than the respective widths of the front and rear walls54,56of the inner frame24.

The lower wall100of the body90of the liquid supply cartridge12includes a neck104extending therefrom that defines a passageway that is open to the interior102of the liquid supply cartridge12. As illustrated inFIG.5, the neck104is sized to be received in the access port88in the upper wall78of the reservoir16and extend therethrough such that the interior102of the liquid supply cartridge12is in communication with the interior82of the reservoir16and the lower wall100of the body90engages against the upper wall98of the reservoir16. In this way, the liquid supply cartridge12is supported by the inner frame24of the housing20and the reservoir16. The neck104of the body90may include a seal, such as an O-ring, disposed about the neck104for forming a fluid tight seal between the liquid supply cartridge12and the reservoir16when in communication with each other. The neck104of the liquid supply cartridge12may include a seal member or valve (not shown) having an opened and closed position. The seal member is normally in the closed position to prevent unwanted leakage from the liquid supply cartridge12. However, when the liquid supply cartridge12is inserted into the housing20of the liquid dispenser10, the seal member is moved to the opened position, such as by engagement with the actuator in the access port88of the reservoir16, and the liquid supply cartridge12and reservoir16are in communication with each other. In an exemplary embodiment, the liquid supply cartridge12may be formed from a suitable engineering plastic by a molding process, for example. Other materials and processes, however, are also possible.

Collectively, the reservoir16and the liquid supply cartridge12substantially fill the void between the front and rear walls54,56of the inner frame24and are arranged in an in-line manner with the liquid supply cartridge12positioned generally above the reservoir16and in communication with each other. As a result of the in-line arrangement, the product in the liquid supply cartridge12passes through the reservoir16on its way to being dispensed into the receptacle from the liquid dispenser10. This is in contrast to many reservoir arrangements, which maintain the product in the reservoir completely separate from the flow path from a main product supply vessel to a dispensing end of a liquid dispenser. Thus, as described in more detail below, product from the liquid supply cartridge12being dispensed from the liquid dispenser10flows through the reservoir16. As mentioned above, this arrangement provides the liquid dispenser with multiple sources of the dispensed product.

In one embodiment, the volume of the liquid supply cartridge12may be configured to be greater than the volume of the reservoir16. By way of example, the volume of the liquid supply cartridge12may be between about 200 milliliters and about 500 milliliters. In an exemplary embodiment, the volume of the liquid supply cartridge12may be about 300 milliliters. The reservoir16may be between about 50% and about 90% of the volume of the liquid supply cartridge12in various embodiments. In an exemplary embodiment, the reservoir16may be about 80% of the volume (e.g., about 240 milliliters) of the liquid supply cartridge12. It should be appreciated that these values are exemplary, and aspects of the invention are not limited to these numeric ranges. Nor is it necessary that the volume of the reservoir16be less than that of the liquid supply cartridge12. In an alternative embodiment, for example, the reservoir16may have the same volume or even a greater volume than that of the liquid supply cartridge12. Thus, a great many variations in the relative sizes of the reservoir16and liquid supply cartridge12may exist depending on the particular application.

In one aspect of the invention, and as will be explained in more detail below, the reservoir16is configured to remain part of the liquid dispenser10while the liquid supply cartridge12is configured to be selectively removable from the liquid dispenser10, such as by a service technician or the like. In this way, for example, when product in the liquid supply cartridge12is depleted, the liquid supply cartridge12may be removed from the liquid dispenser10and replaced with a different or replenished liquid supply cartridge12. If the liquid supply cartridge12is replaced prior to the reservoir16running out of product, a continuous supply of product is effectively provided to the liquid dispenser10for dispensing into a receptacle. A customer or other user may establish a regular schedule for monitoring the amount of product in the liquid supply cartridge12and having the cartridge12changed out if necessary. Alternatively, a customer or other user may place a service call as the amount of product in the liquid supply cartridge12is running low on product. Other arrangement, schedules and manners of ensuring that the liquid dispenser10has a supply of product are also possible. In any event, the inclusion of the reservoir16provides additional time to replace an empty liquid supply cartridge12while the liquid dispenser10remains operational by drawing product from the reservoir16.

To prevent unauthorized access to the liquid supply cartridge12within the liquid dispenser10, a locking mechanism106may be provided. In one embodiment, the locking mechanism56may include a locking element or arm movable between a locked position and an unlocked position. For example, a key may be provided for accessing a keyway of the locking mechanism106for moving a locking element108between the locked and unlocked positions. Only service technicians or the like may have the key for accessing the liquid supply cartridge12in the liquid dispenser10. When the locking element108is in the locked position, a portion of the locking element108extends into a groove110formed in the liquid supply cartridge12and prevents the liquid supply cartridge12from being removed from the liquid dispenser10. When the locking element108is in the unlocked position, the liquid supply cartridge12is free to be removed from the liquid dispenser10. By way of example, and as illustrated in the figures, the locking mechanism106may be positioned in the inner frame24, and more particularly in the flange60of the inner frame24adjacent the front wall54. The front wall54of the inner frame24includes a slot112aligned with the groove110in the liquid supply cartridge12to allow the locking element108to extend through the front wall54and into the groove110when the locking mechanism106is in the locked position. While the locking mechanism106is described as being located at the upper end of the liquid dispenser10, this location is merely exemplary and done for convenience in the replacement process. The locking mechanism106may be positioned at different locations on the liquid dispenser10and remain within the scope of the present disclosure.

Turning now to the dosing tank18and in reference toFIGS.3-8, this tank includes a generally cylindrical body118having a base120and a lid122coupled to the base120and collectively enclosing an interior space or cavity124. As explained in more detail below, the volume of the interior cavity124represents the volume of the product that will be dispensed into the receptacle upon movement of the control valve14to the opened position. Thus, the dosing tank18meters the amount of product dispensed from the liquid dispenser10and into the receptacle upon opening the control valve14. The volume of the dosing tank18can be determined with some certainty such that consistent dispensing of a pre-determined amount of product can be achieved in a robust and inexpensive manner. The dosing tank18avoids the complex electronic arrangements typically used to meter a dose of liquid in some conventional dispensers. In one embodiment, the volume of the dosing tank18is configured to be considerably less than the volume of the reservoir16. By way of example and without limitation, the volume of the dosing tank18may be between about 20 milliliters to about 80 milliliters. In an exemplary embodiment, the volume of the dosing tank18may be about 60 milliliters. In various embodiments, the reservoir16may be configured to have a volume between about 3 to about 10 times greater than the volume of the dosing tank18. In this way, should the product in the liquid supply cartridge12run out, the reservoir16can continue to supply product to the dosing tank18for an additional, but limited, number of doses (e.g., between about 3-10 doses) that will, in turn, allow sufficient time for the liquid supply cartridge12to be replenished. It should be recognized that a wide variation in the relative sizes of the dosing tank18and reservoir16are possible depending on the particular application, for example, and aspects of the invention should not be limited to the values provided above.

The base120includes a cylindrical body having a generally circular base wall126and a peripheral wall128extending from an outer edge thereof that primarily defines the interior space124. The base wall126includes a central aperture130for providing an outlet from the interior space124. The peripheral wall128includes a lip132at an upper edge thereof for coupling to the lid122. The base120also includes a double-walled extension or nose depending from the base wall126. The nose includes an inner nose134having a passageway in communication with the central aperture130and an outer nose136coaxially disposed about the inner nose134to define an annular gap therebetween. The base120may be made from an engineering plastic through, for example, a molding process. Other materials and processes, however, are possible.

The lid122includes a generally circular disk-shaped body138having a central aperture140extending therethrough which generally aligns with the central aperture130in the base120. The disk-shaped body138includes an upper surface, a lower surface, and a side surface extending between the upper and lower walls. The upper surface of the lid122includes a cylindrical hub142extending therefrom and disposed about but spaced from the central aperture140to define a radial gap144. The cylindrical hub142is configured to be selectively coupled to the reservoir16, and more particularly to the neck84extending from the lower wall80of the reservoir16. For example, the cylindrical hub142may be configured to couple to the key feature86on the neck84of the reservoir16. In this regard, the cylindrical hub142may include a bayonet-type of keyway146(e.g., insert and rotate) for selectively coupling to the key feature86on the reservoir16and thereby connecting the dosing tank18to the reservoir16(i.e., suspending the dosing tank18from the neck84of the reservoir16). A seal may be disposed in the radial gap144to form a fluid tight seal between the dosing tank18and the reservoir16when coupled together. Moreover, an annular rib148may extend from the upper surface of the lid122adjacent but spaced inwardly of the outer edge thereof.

In accordance with an aspect of the invention, the liquid dispenser10includes a flow restrictor150to restrict the flow of product from the reservoir16to the dosing tank18. The purpose of the flow restrictor150is to prevent users from dispensing more product than is recommended or required for the application. Due to the presence of the flow restrictor150, the flow rate of product from the reservoir16to the dosing tank18is relatively low such that the amount of time to fill the dosing tank18(referred to herein as the fill time), is beyond what most users are willing to wait to add more product to their receptacle. For example, and without limitation, the flow restrictor150may be configured such that the fill time of the dosing tank18is between about 20 seconds to about 90 seconds. Applicant believes that most users are not willing to wait this long to add more product to their receptacle and will move on to performing services without the additional product. Thus, the flow restrictor150is configured to encourage proper dosing of liquid (e.g., a chemical) to the receptacle according to posted instructions and/or guidelines. Costs for the dispensed liquids is also reduced due to the discouragement of unnecessary overdosing of the receptacle.

As illustrated inFIGS.3-8, in an exemplary embodiment, the flow restrictor includes a diffuser152having a frusto-conical wall disposed about the central aperture142and extending from the upper surface of the lid122. The diffuser152defines a passageway in communication with the central aperture142. The passageway includes a diverging portion (i.e., in a direction from the reservoir16to the dosing tank18and a constant diameter cylindrical portion extending from the diverging portion. The diverging portion of the passageway causes the fluid flowing therethrough to decrease in velocity and increase in pressure, i.e., slowing the flow of product into the dosing tank18. The diffuser152further includes one or more (e.g., three) vertical slots154through the wall of the diffuser152that may provide an additional flow path for product from the reservoir16to the dosing tank16. The vertical slots154may also provide a guide and seat function for the control valve14when in the release position, as will be described in more detail below.

To allow the product in the dosing tank18to be dispensed into the receptacle during operation, the dosing tank18may include a vent156that opens the dosing tank18to atmospheric pressure and air. In an exemplary embodiment and as illustrated inFIGS.6and7, the vent156includes a vent housing158extending from the upper surface of the lid122that defines an interior chamber and a removable vent cover160that couples to the upper end of the vent housing158. For example, the vent cover160may be selectively retained to the housing158by fasteners, such as screws, which are received in respective threaded bores in the vent housing158. The valve cover160further includes one or more holes for allowing air to enter the valve chamber of the housing158. The vent156is radially offset from the central aperture140through the disk-shaped body138and generally located outboard of the cylindrical hub142and inboard of the annular rib148.

The vent156further includes a valve element162movable between an opened position and a closed position relative to the valve housing158. The valve element162includes a valve head and a valve stem coupled to and extending from the valve head. The valve head is configured to cooperate with a valve seat defined in the bottom of the valve chamber to prevent air from entering the dosing tank18when the valve element is in the closed position. When the valve head is moved away from the valve seat, air is able to enter the dosing tank18through the vent156. The valve stem extends through an aperture in the base wall126and extends from the lower wall of the lid122. As explained in more detail below, the valve stem is configured to engage with a portion of the control valve14to move the valve head away from the valve seat and to the opened position of the valve element162. The vent156includes a biasing member164, such as a spring, positioned in the vent chamber for biasing the valve element162toward the closed position. Accordingly, when the portion of the control valve14disengages from the valve stem, the valve element162moves to the closed position due to an imposed force from the biasing element164.

The lower surface of the body138of the lid122is generally planar and includes an annular groove166adjacent the outer edge of the body138. The annular groove166is configured to receive the lip132at the upper edge of the base120when the base120and the lid122are connected together. The lip/groove connection between base120and the lid122may provide a snap or friction fit that forms a fluid tight seal for the dosing tank18. The lid122may be made from an engineering plastic through, for example, a molding process. Other materials and processes, however, are possible.

With reference toFIGS.4-8the control valve14includes a valve element172movable between an upper, opened position and a lowered, closed position. When the valve element172is in the opened position, liquid in the dosing tank18is permitted to flow through the dispenser outlet174and into the receptacle positioned generally beneath the liquid dispenser10. When the valve element172is in the closed position, liquid in the dosing tank18is prevented from being dispensed from the dispenser outlet174and into the receptacle. In accordance with an aspect of the invention, in addition to the valve element172interacting with the dosing tank18to prevent or permit the flow of product therefrom, the valve element172is also configured to interact with the reservoir16. More particularly, in an exemplary embodiment of the liquid dispenser10, the valve element172is also configured to prevent or permit the flow of product from the reservoir16to the dosing tank18. This interaction will be explained in more detail below. Furthermore, the valve element172is further configured to interact with the vent156for opening the vent and exposing the dosing tank18to atmospheric air and pressure, thereby permitting the product in the dosing tank18to flow into the receptacle when the valve element172is in the opened position.

In an exemplary embodiment, the valve element172has a two-part design including a lower spigot176and an upper shuttle178removably connected together to form the valve element172. For example, the spigot176and shuttle178may be coupled by a threaded connection. Other types of removable connections may also be possible. The spigot176includes an elongate tubular body180having a first lower end and a second upper end. The lower end of the elongate body180defines the dispenser outlet174. The spigot176includes a blind bore passage182open to the lower end and extending toward the upper end but being closed off prior to the upper end of the spigot176. The upper end of the spigot176includes a post184and an annular abutment ledge186for interfacing with the shuttle178. The spigot176further includes one or more ports188(e.g., four ports) penetrating through the side wall of the spigot176so as to be in communication with the passage182. The ports188are adjacent an upper end of the passage182and beneath the annular ledge186and post184. The spigot176may include one or more seals, such as O-rings. For example, O-rings may be placed both immediately above and below the ports188. Other arrangements of the seals may also be possible. An annular engagement plate190is positioned adjacent the lower end of the spigot176but slightly spaced from the discharge outlet174. The purpose of the engagement plate190will be described below. In an exemplary embodiment, the spigot176may be made from a durable material such as metal, for example. Other materials, however, are also possible.

The shuttle178includes a tubular body192having a first lower end and a second upper end. The shuttle178includes a blind bore passage194open to the lower end and extending toward the upper end but being closed off prior to the upper end of the shuttle178. The passage194is configured to receive the post184of the spigot176in, for example, a threaded connection to connect the spigot176and shuttle178. The upper end of the shuttle178includes a plug196and an annular abutment plate198positioned slightly beneath the plug196. As explained in more detail below, the plug196is configured to be received in the diffuser152to close off the flow of product from reservoir16to the dosing tank18when the valve element172is in the opened position. The plug196includes a generally arcuate head and a Y-shaped tip200projecting from the head. The Y-shaped tip200is configured to be received in the vertical slots154in the diffuser152when the valve element172is in the opened position. The plug196may also include a seal, such as an O-ring for forming a fluid tight seal with the inner wall of the diffuser152. The shuttle178further includes an annular contact plate202along the tubular body192beneath the plug196and adjacent its central or lower region. As explained below, the contact plate202is configured to engage with the valve element162of the vent156for opening the vent156and exposing the dosing tank18to atmospheric pressure and air.

As illustrated inFIGS.4-8, the shuttle178is received in the interior space124of the dosing tank18with the plug196oriented upwardly toward the lid122. The spigot176is coupled to the lower end of the shuttle178and extends through the central aperture130and the inner nose134such that the engagement plate190and the discharge outlet174are outside the dosing tank18and spaced from the end of the inner nose134. As noted above, the valve element172is movable between an opened position and a closed position. In the opened position, the ports188in the spigot176are positioned in the interior space124of the dosing tank18thereby placing the interior space124in communication with the discharge outlet174of the liquid dispenser10. Accordingly, product in the dosing tank18may flow from the dosing tank18through the discharge outlet174and into a receptacle adjacent the outlet174. Additionally, when the valve element172is in the opened position, the plug196of the shuttle178is positioned in the diffuser152to occlude the flow of product from the reservoir16to the dosing tank18. Moreover, in the opened position, the contact plate202moves the valve element162of the vent156to the opened position to expose the dosing tank18to atmospheric pressure and air. This allows the product in the dosing tank18to flow out of the tank and into the receptacle.

In the closed position of the valve element, the ports188in the spigot176are positioned within the inner nose134and the seals adjacent the ports188form a fluid tight seal therewith to prevent product in the dosing tank18to flow from the tank and dispenser outlet174. Additionally, when the valve element172is in the closed position, the plug196of the shuttle178is moved away from the diffuser152to allow product in the reservoir16to flow into the dosing tank18and thereby replenish the product in the dosing tank18. In an exemplary embodiment, the liquid dispenser10may include a biasing element204, such as a spring or the like, for biasing the valve element172toward the closed position. For example, a biasing element204may be disposed between the dosing tank18and the valve element172. More particularly, in an exemplary embodiment, one end of a spring may be disposed in the annular space144between the inner and outer noses134,136and the other end of the spring may engage the engagement plate190of the spigot176.

To arrest the movement of the valve element172due to the biasing element204, the diameter of the shuttle178adjacent its lower end may be larger than the diameter of the central aperture130of the dosing tank18(and the diameter of the spigot176) to define an annular abutment ledge206. In the closed position, the abutment ledge206contacts the lower wall of the base120to prevent any further movement of the valve element172in a closing direction. To arrest the movement of the valve element172in the opened position, the diameter of the abutment plate198on the shuttle178may be larger than the central aperture140of the lid122(and outlet diameter of the diffuser152) such that the abutment plate198contacts the underside of the lid122to prevent any further movement of the valve element172in an opening direction.

With the various parts of the liquid dispenser10outlined above, assembly of the dispenser will now be described. In one embodiment, the assembly process may begin with inserting the inner frame24within the outer housing22such that the flanges60of the inner frame24engage the ledges62of the outer housing22to thereby seat the inner frame24within the outer housing22. At this point, the reservoir16may either be positioned in the inner frame24prior to placement within the outer housing22or subsequent to placement within the outer housing22. The inner frame24may be secured to the outer housing22or simply suspended from the outer housing22by the flange60and ledge62engagement. In any event, the inner frame24is positioned within the outer housing22and the reservoir16is positioned therein such that the neck84(and key feature86) of the reservoir16extends through the central aperture64of the inner frame24.

In a next step, the dosing tank16and control valve14may be assembled. In this regard, the vent156may be assembled by positioning the valve element162in the vent housing158such that the valve head is engaged with the valve seat and the valve stem projects below the lid122. The biasing element164, such as a spring, may be inserted into the valve housing158and the valve cover160coupled to the valve housing158. Next, the shuttle178of the valve element172may be positioned in the interior space124of the base120with the plug196oriented upwardly and the blind passage194aligned with the central aperture130of the base120. The biasing element204, such as a spring, may have one end inserted into the radial space144between the inner and outer noses134,136of the base120. The spigot176may then be inserted into the inner nose134such that the upper end of the spigot176is positioned within the interior space124of the base120. The biasing element204engages the engagement plate190to compress the biasing element204. The spigot176and the shuttle178may then be coupled together, such as by a threaded connection between the post184and the passage194. The lid122of the reservoir16may then be coupled to the base120by inserting the lip132of the base120into the annular groove166of the lid122. With this, the dosing tank18and the control valve14form a subassembly for coupling to the remainder of the liquid dispenser10.

To achieve this coupling and in a next step, the base wall34of the outer housing22may be removed (if it is initially coupled to the outer housing22). For example, the spring clip on the base wall34may be actuated to release the base wall34from the outer housing22and open up the liquid dispenser10at its lower end. The subassembly of the dosing tank18and the control valve14may be inserted through the opening in the outer housing22with the removal of the base wall34. The subassembly may then be orientated such that the keys86on the neck84of the reservoir16engage the keyway146on the cylindrical hub142of the lid122of the dosing tank18. When the keys86so engage the keyway146the subassembly may be rotated (e.g., in a bayonet type of connection) to secure the subassembly to the reservoir16. In essence, the connection between the dosing tank18and the reservoir16clamps the reservoir16and subassembly to the inner frame24.

With the subassembly coupled to the reservoir16, the base wall34may be attached/re-attached to the outer housing22such that the spigot176extends through the support tube40and central aperture38of the base wall34. For purposes described below, the spigot176, support tube40and central aperture38are sized such that there is no seal formed therebetween and the space therebetween may be open to the atmosphere. The lower end of the spigot176, and more particularly the dispenser outlet174, is accessible from the lower end of the liquid dispenser10. But for the liquid supply cartridge12being inserted, the liquid dispenser10is assembled and ready to be placed into operation in the field. For example, the mounting plate48may be attached to a wall or support surface in the field and the liquid dispenser10attached to the mounting plate48.

Operation of the liquid dispenser will now be described. In one embodiment and upon initial use of the liquid dispenser10, the system may be primed by filling the dosing tank18and reservoir16with product, such as a chemical. In this way, when a liquid supply cartridge12is first coupled to the liquid dispenser10, a portion of the liquid supply cartridge12is not used to initially fill the dosing tank18and reservoir16(although this scenario is indeed possible). With the dosing tank18and reservoir16primed, a liquid supply cartridge12may be inserted into the outer housing22. In this regard, the locking mechanism106may be moved to the unlocked position, such as with a key. The liquid supply cartridge12may then be inserted into the liquid dispenser10such that the neck104of the liquid supply cartridge12engages the access port88of the reservoir16to thereby place the interior102of the liquid supply cartridge12into communication with the interior82of the reservoir16. Product in the liquid supply cartridge12may then freely flow into the reservoir16. The locking mechanism106may be moved to the locked position, such as by engaging the locking element108of the locking mechanism106with the groove110in the liquid supply cartridge12.

In one embodiment, janitorial personnel may use the liquid dispenser10to dispense product, such as a chemical, into a receptacle, which in many cases takes the form of a spray bottle, for performing cleaning service. It should be recognized, however, that aspects of the invention are not limited to the receptable being a spray bottle. In this embodiment, janitorial personnel engage the upper end of the spray bottle to the lower end of the spigot176, such as by engaging with the engagement plate190, and pushing upward against the bias of the biasing element204to move the valve element172to the opened position. As noted above, when the valve element172is in the opened position, the ports88of the spigot176are open to the interior space124of the dosing tank18, the plug196is positioned in the diffuser to occlude product flow from the reservoir16to the dosing tank18, and the vent156is opened. This allows the product in the dosing tank18to flow through the spigot176, through the dispenser outlet174and into the spray bottle. As the product flows into the spray bottle, the displaced air from the bottle is able to escape to the atmosphere through a vent hole208in the engagement plate190of the spigot176and therefore prevent any back pressure as a result of the liquid dispensing. Alternatively, the engagement plate190may include one or more ridges (not shown) configured to engage with the end or mouth of the spray bottle in a manner that provides a gap or opening (i.e., nota sealed engagement) for allowing displaced air in the bottle to escape to atmosphere. Since the flow of product from the reservoir16to the dosing tank18is cut off when the valve element172is in the opened position, only the volume of product that is in the dosing tank18may flow into the spray bottle. Accordingly, a precise and repeatable amount of product may be dispensed by liquid dispenser10by controlling the volume of the dosing tank18.

After the flow of product to the spray bottle ceases, the janitorial personnel may move the spray bottle away from the dispenser10. As the spray bottle is moved away, the valve element172is moved from the opened position toward the closed position under the force of the biasing element204. As discussed above, when the valve element172is moved toward the closed position, the ports88in the spigot88engage the walls of the inner nose134and form a fluid tight seal that cuts off the flow of product out of the dosing tank18. Additionally, the contact plate202disengages from the valve element162of the vent156such that the valve element162moves to the closed position, thereby closing off the dosing tank18from atmospheric air and pressure. Moreover, the plug196disengages from diffuser152in the lid122of the dosing tank18, thereby permitting the flow of product from the reservoir16to the dosing tank18.

In this regard, after being evacuated of product due to a dispensing event, the dosing tank18is filled with air (from the vent156). Thus, as product from the reservoir16refills the dosing tank18, the displaced air must escape the dosing tank18. Because the vent156is closed and the lower end of the dosing tank18sealed, the air in the dosing tank100may escape by going through the central aperture140and diffuser152in the lid122. The trapped air then travels through the product in the reservoir16and liquid supply cartridge12(e.g., as bubbles) and collects at the upper end of the liquid supply cartridge12. Channeling the air in the dosing tank18after a dispensing event through the diffuser152may be used in an advantageous manner.

As described above, in many cases users try to increase the dosage of product being added to the receptacle. The diffuser152is configured to minimize this from happening by increasing the fill time of the dosing tank18from the reservoir16. In addition, by forcing the air from the dosing tank18to flow through the diffuser152as the dosing tank18is being refilled, the product entering the dosing tank18and the air escaping the dosing tank18must share the same cross-sectional area of the diffuser152, which at the end of the diffuser152may be quite small (e.g., about 7 millimeter in diameter). Accordingly, not all of the cross-sectional area of the diffuser152can be used for moving product into the dosing tank18. Instead, some of the cross-sectional area is used for the escaping air. This sharing of the cross-sectional space then also decreases the rate at which the dosing tank18can be refilled with product after a dispensing event (i.e., longer fill times).

As product is dispensed from the liquid dispenser10, more and more air is collected in the liquid supply cartridge12until all the product in the liquid supply cartridge12is depleted. It is noted, however, that although the liquid supply cartridge12may be depleted, product remains in the reservoir16which can be used to replenish the dosing tank18during additional dispensing events. When the liquid supply cartridge12is depleted of product, it may be replaced with another cartridge12that has a full supply of product (referred to as a new liquid supply cartridge). The new liquid supply cartridge12may be the same cartridge that is refilled with product or it may be a different cartridge that has a full supply of product. To replace an empty liquid supply cartridge12, a service technician may move the locking mechanism106to the unlocked position and remove the empty liquid supply cartridge12by disengaging the neck104of the cartridge12from the access port88of the reservoir16and then disengaging the cartridge12from the housing20of the liquid dispenser10. The new cartridge12may then be inserted into the housing20such that the neck104of the new cartridge12engages the access port88of the reservoir16. Product in the new liquid supply cartridge12is then free to flow into the reservoir16and be dispensed by the liquid dispenser10. The service technician may then move the locking mechanism106back to the locked position.

When a liquid supply cartridge12is empty, it should be changed out with a new liquid supply cartridge12before the product in the reservoir16is depleted. In this way, dispensing product from the liquid dispenser10is not interrupted by a lack of supply of product to the janitorial personnel. The inclusion of a reservoir16provides some additional time to replace the liquid supply cartridge12after it is depleted of product. In this way, janitorial services will not be interrupted due to a lack of cleaning products.

While the present invention has been illustrated by a description of various preferred embodiments and while these embodiments have been described in some detail, it is not the intention of the Applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The various features of the invention may be used alone or in numerous combinations depending on the needs and preferences of the user.