Electronic soap dispenser

An electronic soap dispenser includes an upper dispensing head supported above a sink deck, and a liquid soap reservoir and a pump assembly supported below the sink deck. A capacitive sensor is operably coupled to the dispensing head. A controller is in electrical communication with the capacitive sensor and activates the pump assembly in response to input from the capacitive sensor.

BACKGROUND AND SUMMARY OF THE INVENTION

The present invention relates generally to a soap dispenser and, more particularly, to a sink deck mounted electronic soap dispenser for simple operation and ease of maintenance.

Electronic soap dispensers including sensors for hand-free operation are known in the art. Such electronic soap dispensers may include infrared or capacitive sensors to detect the presence of a user and dispense soap in response thereto.

The present disclosure relates to an electronic soap dispenser that includes a controller to actuate a pump in response to input from a capacitive sensor. Additionally, the electronic soap dispenser of the present disclosure includes a mounting structure to support a dispensing head above a mounting deck, and to support a reservoir and pump assembly below the mounting deck.

According to an illustrative embodiment of the present disclosure, an electronic soap dispenser includes a dispensing head configured to be supported above a mounting deck and including an outlet. A lower reservoir is operably coupled to the dispensing head and is configured to be supported below the mounting deck. A pump assembly is operably coupled to the lower reservoir. The pump assembly is configured to be supported below the mounting deck and to pump liquid soap from the lower reservoir to the outlet of the dispensing head. A capacitive sensor is operably coupled to the dispensing head. A controller is in electrical communication with the capacitive sensor. The controller is configured to receive an output signal from the capacitive sensor and to distinguish between a proximity output signal from the capacitive sensor when a user is positioned in a detection area near the dispensing head, and a touch output signal from the capacitive sensor when a user touches the dispensing head.

According to a further illustrative embodiment of the present disclosure, an electronic soap dispenser includes a dispensing head configured to be supported above a mounting deck and including a spout body. A dispensing tube is received within the spout body and defines an outlet. A lower reservoir is configured to be supported below the mounting deck. The lower reservoir includes an upper neck operably coupled to the dispensing head. A pump assembly is operably coupled to the lower reservoir and is configured to pump liquid soap from the lower reservoir to the outlet of the dispensing tube. A supply tube extends within the lower reservoir. The supply tube extends from a lower end fluidly coupled to the pump assembly to an upper end extending within the upper neck of the reservoir. A tube retainer secures the lower end of the dispensing tube to the spout body. The tube retainer includes a downwardly facing funnel portion receiving the upper end of the supply tube to define a releasable fluid coupling between the dispensing tube extending above the mounting deck and the supply tube extending below the mounting deck.

According to another illustrative embodiment of the present disclosure, an electronic soap dispenser includes a dispensing head having a spout body. A mounting base is configured to be supported above a mounting deck and releasably coupled to the dispensing head. A lower reservoir is operably coupled to the dispensing head and is configured to be supported below the mounting deck. A pump assembly is operably coupled to the lower reservoir and is configured to pump liquid soap from the lower reservoir to the dispensing head. A controller is in electrical communication with the pump assembly. An electrical connector is positioned between the dispensing head and the controller. The electrical connector includes a first contact supported for movement by the dispensing head, and a second contact in selective electrical communication with the first contact supported on the mounting base wherein the electrical connector is configured to maintain electrical communication as the dispensing head is rotated relative to the mounting base.

According to a further illustrative embodiment of the present disclosure, an electronic soap dispenser includes a dispensing head configured to be supported above a mounting deck and including an outlet. A reservoir is operably coupled to the dispensing head. A pump assembly is operably coupled to the reservoir and is configured to pump liquid soap from the reservoir to the outlet of the dispensing head. A capacitive sensor is operably coupled to the dispensing head. A controller is in electrical communication with the capacitive sensor. The controller is configured to receive a touch output signal from the capacitive sensor when a user touches the dispensing head. The controller is further configured to dispense a liquid soap for a set dispensing duration in response to the touch output signal when operating in a dispensing mode, and to selectively change the set dispensing duration in response to successive touch output signals when operating in a programming mode.

DETAILED DESCRIPTION OF THE DRAWINGS

The embodiments of the invention described herein are not intended to be exhaustive or to limit the invention to precise forms disclosed. Rather, the embodiments elected for description have been chosen to enable one skilled in the art to practice the invention.

Referring initially toFIGS. 1-4, an illustrative electronic soap pump or dispenser10is shown coupled to a mounting deck, illustratively a sink deck12. An upper dispensing spout or head14extends above an upper surface16of the sink deck12, while a lower soap reservoir18and pump assembly20are supported below a lower surface22of the sink deck12. The pump assembly20is configured to propel liquid soap from within the lower soap reservoir18to a dispensing outlet23of the dispensing head14.

A mounting shank24extends downwardly through an opening26in the sink deck12and secures both the dispensing head14and the lower soap reservoir18to the sink deck12. The mounting shank24includes external threads28that engage with internal threads30of a mounting nut32(FIG. 7). The mounting nut32may be of conventional design and formed of a polymer. A mounting spacer31, illustratively a split annular ring formed of a polymer, may be positioned intermediate the mounting nut32and the sink deck12. The sink deck12is clamped between the dispensing head14and the mounting nut32. An open upper neck33of the reservoir18includes internal threads34coupled to the external threads28of the mounting shank24, while a lower bottom wall35of the reservoir18supports the pump assembly20(FIG. 7). A supply tube or straw36extends axially through the soap reservoir18and fluidly couples the pump assembly20and the dispensing head14.

The dispensing head14illustratively includes a hollow spout body40receiving a dispensing tube42. The spout body40is illustratively formed of a metal or polymer, such as a chromed acrylonitrile butadiene styrene (ABS). The dispensing tube42is illustratively formed of a flexible polymer, such as a cross-linked polyethylene (PEX), and extends within a hollow passageway43of the spout body40. A lower end44of the dispensing tube42is in fluid communication with an upper end46of the supply tube36, and an upper end48of the dispensing tube42defines the dispensing outlet23.

With reference toFIGS. 2-4and6, a tip or nozzle50is secured to the outlet23by a retainer52. More particularly, the retainer52includes a barbed fitting54received within the upper end48of the dispensing tube42. A check valve56is illustratively coupled intermediate the tip50and the retainer52to prevent dripping of liquid soap from the outlet23. The check valve56may be of conventional design as including a pair of opposing flaps58defining a dispensing slot60(FIG. 3). The check valve56is illustratively formed of a resilient material, such as an elastomer or polymer, such as a silicone.

With further reference toFIGS. 2-4, a hose or tube retainer62secures the lower end44of the dispensing tube42to the spout body40. The tube retainer62may be formed of a polymer, such as an acetal copolymer, and illustratively includes an upper barbed fitting64and a tapered lower receiving chamber or funnel66. The upper barbed fitting64is secured within the dispensing tube42, while the lower receiving chamber66receives the upper end46of the supply tube36. A pair of mounting bosses68including openings70to receive fasteners, such as screws72, to secure the tube retainer62within retaining bosses73of the spout body40(FIG. 3).

A releasable coupler74couples the spout body40to the mounting shank24to facilitate removal of the dispensing head14from the sink deck12for refilling the reservoir18with liquid soap from above the sink deck12and/or replacing the dispensing head14with different styles or designs. Illustratively, the releasable coupler74includes a structural coupling or connector76between the dispensing head14and the mounting shank24, and an electrical coupling or connector78between the dispensing head14and the pump assembly20.

In one illustrative embodiment, the structural connector76of the releasable coupler74includes a retainer cap80, and a retaining clip82supported by the spout body40. The mounting shank24includes a lower threaded portion84supporting the external threads28, and an upper mounting base86including an arcuate upper wall88and a flange90. Opposing ends92and94of the upper wall88define an opening96. A passageway98within the mounting shank24receives the supply tube36. The flange90separates the upper wall88from the lower threaded portion84of the mounting shank24and rests on the upper surface16of the sink deck12. The mounting shank24is illustratively formed of an electrically non-conductive material, such as a polymer. As such, the mounting base86of the mounting shank24defines an electrical insulator between the dispensing head14and the sink deck12.

With reference toFIGS. 3,6and15, the retainer cap80may be formed of a polymer and illustratively includes openings100to receive screws72for securing to the tube retainer62and the spout body40. The retaining clip82, illustratively a wire snap ring, is received within an annular groove104formed within the retainer cap80. The retaining clip82secures the spout body40to the mounting shank24. More particularly, the retaining clip82extends radially outwardly to be retained by inwardly extending tabs106supported by the arcuate upper wall88of the mounting shank24.

With reference toFIGS. 1-4and13, an input member or electrode110, illustratively an electrically conductive sensing plate or touch pad112, may be coupled to the spout body40. More particularly, the sensing plate112is coupled to a sensing plate insulator114which, in turn, is supported within a recess116formed in the spout body40. The sensing plate112is formed of an electrically conductive material, such as a chromed stainless steel, and is electrically coupled to a capacitive sensor118. The sensing plate insulator114is formed of an electrically insulating material, such as a polymer.

With reference toFIG. 13, the capacitive sensor118is electrically coupled to a controller120, which may be supported by a printed circuit board (PCB). As further detailed herein, an output signal119from the capacitive sensor118is provided by the controller120. The capacitive sensor118is illustratively used for both a touch sensor and a hands free proximity sensor. In the hands free mode of operation, the capacitive sensor118and the controller120detect a user's hands or other object within a detection area121located near the input member110of the dispensing head14(FIGS. 6 and 13).

In certain illustrative embodiments, a light indicator122, such as one of more light emitting diodes (LEDs) may be positioned within the insulator114to provide illumination around the sensing plate112during different operating conditions of the dispenser10, such as when the pump assembly20is dispensing liquid soap. As further detailed herein, while a separate input member110such as sensing plate112may be coupled to the spout body40to provide a capacitive input to the capacitive sensor118, other input members may be substituted therefor. For example, and as further detailed herein, the spout body40itself may define the input member110when at least partially formed of an electrically conductive material.

As noted above, the electrical connector78defines a releasable electrical coupling between the dispensing head14and the pump assembly20for selective electrical communication therebetween. The electrical connector78provides communication between the capacitive input member110above the sink deck12and electronics below the sink deck12. This quick disconnect feature allows a user to remove the spout body40, for example, when refilling the soap reservoir18, without dealing with a wired connection between the mounting base86and the spout body40.

With reference toFIGS. 4,15and17, the electrical connector78illustratively includes a first electrical contact124supported for movement by the dispensing head14, and a second electrical contact126in selective electrical communication with the first electrical contact124supported by the mounting base86of the mounting shank24. The electrical connector78is configured to maintain electrical communication between the contacts124and126as the dispensing head14is rotated within a predetermined angular range relative to the mounting base86.

The second electrical contact126illustratively includes an electrically conductive arcuate strip or band128extending circumferentially outside the wall88of the mounting shank24. Illustratively, the band128is formed of a metal strip, such as copper or brass. Opposing ends130and132of the band128are bent or wrapped around ends92and94of the upper wall88of the mounting shank24. The first electrical contact124illustratively includes a connecting tab134providing electrical communication between the sensing plate112and the capacitive sensor118. Illustratively, the tab134is formed as an integral part of the sensing plate112(FIG. 4) and may be formed of a metal, such as copper or brass. As may be appreciated, the positions of the arcuate band128′ and the tab134′ may be reversed (FIG. 17A). Conventional wires or cables (not shown) may couple the conductive band128to the capacitive sensor118. A channel136may be formed in the mounting shank24to receive the wires or cables extending between the dispensing head14and under deck electrical components (e.g., the pump assembly20).

With reference toFIG. 13, a conventional power supply140illustratively provides power to the controller120. The power supply140may comprise a conventional AC power connection with an AC/DC convertor, or a battery. A power switch142is provided to selectively supply power to the controller120. As shown inFIGS. 14-16, the power switch142may be of conventional design and illustratively includes a lever contact144in a normally open position and supported by a base145. A slide switch housing146is operably coupled to the power switch142. The slide switch housing146is retained on the spout body40for sliding movement between on and off positions. The housing146defines a chamber148receiving the base145and lever contact144. As the housing146is slidably moved, a protrusion150engages the lever contact144of the power switch142to close the lever contact144. As such, sliding the housing146causes the lever contact144to toggle between on and off positions.

With reference toFIGS. 10 and 11, the pump assembly20is supported by the soap reservoir18and illustratively includes a drive mechanism160operably coupled to a pump device162. The soap reservoir18includes a cylindrical side wall164defining a chamber166to store liquid soap. The soap reservoir18generally defines a bottle formed of a polymer. The upper neck33of the reservoir18includes internal threads34to couple with external threads28of the mounting shank24. The bottom wall35of the reservoir18supports the pump assembly20and is secured to bosses168supported by the side wall164through fasteners, such as screws170. An o-ring172provides a radial seal, and a gasket174provides a face seal between the bottom wall35and the side wall164of the reservoir18. In alternative embodiments, the bottom wall35may be secured to the side wall164in other conventional manners, such as adhesives or ultrasonic welding.

With reference toFIGS. 10-13, the drive mechanism160illustratively includes an electric motor176having a rotatable drive shaft178and operably coupled to the controller120. The electric motor176is illustratively supported below the bottom wall35by a motor mount179. The motor mount179includes a pair of receiving bosses180receiving a pair of posts182extending downwardly from the bottom wall35(FIG. 8). The drive mechanism160is retained within a motor cover184which, in turn, is secured to the bottom wall35by fasteners, such as screws186. The motor cover184is illustratively formed of a polymer and protects the drive mechanism160from debris.

The drive mechanism160further includes a first or drive pulley188coupled to drive shaft178of the motor176. A second or driven pulley190is coupled to the first pulley188by a flexible belt192. The second pulley190is supported by a rotatable shaft193. The pump device162illustratively includes a pair of gears194and196operably coupled to the motor176. More particularly, a first or drive gear194is supported on the shaft193driven by the second pulley190. A second or driven gear196is supported by a stud or post198extending upwardly from the bottom wall35of the soap reservoir18. Cooperating teeth202and204of the gears194and196mesh to force liquid soap from the reservoir18up the supply tube36.

With reference toFIG. 12, the gears194and196are received within a recess206formed in the bottom wall35. A gear cover208is positioned above the gears194and196and is secured to the bottom wall35by a plurality of fasteners, such as screws210. The gear cover208includes an inlet port212and an outlet port214on opposite sides of where the gear teeth202and204mesh. The outlet port214is defined by an upwardly extending nipple216received within the lower end218of the supply tube36.

The supply tube36extends upwardly through the reservoir18and into the dispensing head14. More particularly, the lower end218of the supply tube36is fluidly coupled to the outlet port214of the gear cover208, while the upper end46of the supply tube36is received within the receiving chamber66of the tube retainer62. As such, the dispensing tube36extends axially the full length of the soap reservoir18from proximate the bottom wall35through the sink deck12and into the dispensing head14.

With reference toFIGS. 5-10, the dispensing tube36defines a rigid straw that extends from the bottom of the reservoir18upwardly and is releasably coupled to the dispensing tube42. The funnel66of the tube retainer62and a cooperating seal220on the dispensing head14receives upper end48of the dispensing tube42to assist with assembly of the dispensing head14to the mounting base86of the mounting shank24. The retainer cap80also illustratively includes a tapered receiving chamber221to guide the upper end of the dispensing tube42to the tube retainer62.

With reference toFIG. 5, support walls or ribs222support the dispensing tube42below the inlet224of the lower reservoir18in order to facilitate refilling the reservoir18with liquid soap from above the sink deck12. More particularly, the upper end48of the dispensing tube42is concentrically received within the neck33of the reservoir such that when the dispensing head14is removed, liquid soap may be poured into inlet224of the neck33defined around the dispensing tube42. A funnel (not shown) may be used to facilitate refilling the reservoir18with liquid soap. A flange225is illustratively formed on the tube36below the support ribs222to prevent inadvertent removal of the tube36from the reservoir18.

As detailed above, the dispensing head14is illustratively coupled to the mounting shank24via a releasable coupler74for ease of filling the soap reservoir18. More particularly, the dispensing head14may be removed from the mounting shank24for refilling the lower reservoir18from above the sink deck12and/or replacing the dispensing head14with different styles or designs.

In operation, the controller120is powered when the power switch142is moved to the on position. The light indicator122may be illuminated when the soap dispenser10is powered and/or when the pump device162is actively dispensing soap. Flashing patterns or different colors of the light indicator122may provide different indications to the user, such as dispensing mode (proximity vs. touch). The pump assembly20may be touch controlled using a touch sensor, or activated by a proximity sensor when an object (such as a user's hands) are within the detection zone or area121to toggle water flow on and off.

Output signal119from the capacitive sensor118may be supplied to the controller120to control the motor176of the pump assembly20, which thereby controls the flow of liquid soap from the reservoir18to the outlet23of the dispensing head14. By sensing capacitance changes with capacitive sensor118, the controller120can make logical decisions to control different modes of operation of dispenser10. For example, in one illustrative embodiment, the controller120may operate in a proximity mode of operation where the pump assembly20dispenses a predetermined quantity of liquid soap (i.e., for a set dispensing duration), and a touch mode of operation where the pump assembly20continuously dispenses liquid soap as long as contact is maintained. In another illustrative embodiment, the controller120may cause the pump assembly20to dispense a predetermined quantity of liquid soap (i.e., for a set dispensing duration) in the touch mode of operation, and be inactive in proximity mode of operation.

The controller120may include a timer such that dispensing of liquid soap automatically stops after a predetermined amount of time to protect against potential malfunctions or misuse of the dispenser10. In another illustrative embodiment, the pump assembly20dispenses a single quantity (i.e., “shot”) of soap with each tap. For example, the controller120causes one shot of soap in response to a single tap, two shots of soap in response to two taps, etc.

In one illustrated embodiment, the capacitive sensor118is a CapSense capacitive sensor available from Cypress Semiconductor Corporation or other suitable capacitive sensor. In this illustrated embodiment, the capacitive sensor118converts capacitance into a count value. The unprocessed count value is referred to as a raw count. Processing the raw count signal determines whether the dispensing head14is touched or whether a user's hands are in the detection area121. Additional details of an illustrative capacitive sensing system for use in a fluid delivery device are disclosed in U.S. patent application Ser. No. 12/763,690, filed Apr. 20, 2010, the disclosure of which is expressly incorporated herein by reference.

FIG. 18shows an exemplary output signal119from capacitive sensor118. The controller120establishes a hands free threshold level232and a spout touch threshold level234as illustrated inFIG. 18. As the user's hands enter the detection area121, a slope of the capacitive signal119changes gradually as illustrated at location236inFIG. 18. Edge portion236of the capacitive signal119illustrates the effect of the user's hands within the detection area121and the negative slope of capacitive signal119at location238illustrates the user's hands leaving the detection area121. When a change in slope is detected at edge location236and the capacitive signal119rises above the hands free threshold232such as during portion240of the signal119, the controller120determines that the user's hands are within the detection area121. If the hands free mode is active or enabled, controller120will then provide a signal to pump assembly20to pump liquid soap through the outlet23. Illustratively, the controller120maintains the soap flow for a slight delay time (illustratively about 2 seconds) after the capacitive signal119drops below the threshold level at location238. This reduces the likelihood of pulsation if the user's hands are moved slightly or for a very short duration out of the detection area121and then back into the detection area121.

The same output signal119from the capacitive sensor118may also be used to distinguish between whether the input member110is touched by a user. When the input member110coupled to the dispensing head14is touched, a large positive slope is generated in the capacitive signal119as illustrated a location242. The capacitive signal count level exceeds the touch threshold234during the time of the touch which is shown by portion246between the positive slope242and the negative slope at location244. The negative slope at location244as detected by the controller120indicates that the touch has ended. The controller120may also distinguish between a “tap” and a “grab” of the dispensing head14. More particularly, the controller120may make such a distinction based on the amount of time between the positive and negative slopes244and244of the capacitive signal119. A longer duration indicates a “grab”, while a shorter duration indicates a “tap”.

In an illustrated embodiment, hands free threshold232for proximity detection is set at about 30-40 counts. The spout touch detection threshold234is illustratively set at about 300-400 counts. In other words, the amplitude of the capacitive signal119from capacitive sensor118for the spout touch threshold234is about 10 times greater than the amplitude for the hands free threshold232. In certain illustrative embodiments, the proximity or hand free threshold is factory set such that the controller120activates the pump assembly20when a user's hand is within 0.5 inches of the electrode110.

To refill the soap reservoir18, the dispensing head14is removed from the mounting shank, for example by axially pulling the spout body40from the mounting shank24. The dispensing tube42is thereby uncoupled from the supply tube36. Liquid soap may then be poured within the reservoir neck33around the supply tube36to replenish the reservoir18. A funnel may be used to facilitate pouring the liquid soap into the inlet224. After refilling the soap reservoir18, the dispensing head14is replaced. More particularly, the spout body40is placed axially on the mounting shank24and then locked in position. The dispensing tube42is again fluidly coupled to the supply tube36. More particularly, the upper end46of the supply tube36is received within the funnel66of the tube retainer62

With reference now toFIGS. 19-23, the dispensing head314of a further illustrative electronic soap dispenser310is shown. The components below the sink deck12(e.g., the soap reservoir18and the pump assembly20) may be substantially similar to those detailed above in connection with the electronic soap dispenser10ofFIGS. 1-18. As such, in the following description similar components are identified with like reference numbers.

Similar to mounting shank24detailed above, a mounting shank324extends downwardly through opening26in the sink deck12and secures both the dispensing head314and the lower soap reservoir18to the sink deck12. The mounting shank324includes external threads328that engage with internal threads30of mounting nut32. The sink deck12is clamped between the dispensing head314and the mounting nut32.

The dispensing head314illustratively includes a hollow spout body340receiving dispensing tube42. The spout body340is illustratively formed from a material having at least a portion being electrically conductive and thereby defining the input member or electrode110. In one illustrative embodiment, the spout body340is formed of a metal, such as a plated brass. In another illustrative embodiment, the spout body340is formed of a chromed acrylonitrile butadiene styrene (ABS). The dispensing tube42extends within a hollow passageway343of the spout body340. As detailed above, lower end44of the dispensing tube42is in fluid communication with an upper end46of the supply tube36, and an upper end48of the dispensing tube42defines dispensing outlet23.

A hose or tube retainer362secures the lower end44of the dispensing tube42to the spout body340. The tube retainer362may be substantially similar to the tube retainer62detailed above. More particularly, the hose retainer362may be formed of a polymer, such as an acetal copolymer, and illustratively includes an upper barbed fitting364and a tapered lower receiving chamber or funnel366. The upper barbed fitting364is secured within the tube42, while the lower receiving chamber366receives the upper end46of the supply tube36. A pair of mounting bosses368include openings370to receive fasteners, such as screws72, to secure the tube retainer362to retaining bosses373of the spout body340.

A releasable coupler374couples the spout body340to the mounting shank324to facilitate removal of the dispensing head314from the sink deck12for refilling the reservoir18with liquid soap from above the sink deck12and/or replacing the dispensing head314with different styles or designs. Illustratively, the releasable coupler374includes a structural coupling or connector376between the dispensing head314and the mounting shank324, and an electrical coupling or connector378between the dispensing head314and the pump assembly20.

In one illustrative embodiment, the structural connector376of the releasable coupler374includes a spout retainer380coupled to the mounting shank324through a mounting base382. The spout retainer380is secured to openings384formed in the retaining bosses378of the spout body340through fasteners72. The spout retainer380is illustratively formed of a polymer and includes an upper wall386including openings388aligned with the openings370of the hose retainer362and the openings384of the spout body340for receipt of the fasteners72.

A cylindrical sidewall390extends downwardly from the upper wall386, and a flange392extends radially outwardly from the sidewall390proximate the upper wall386. A pair of diametrically opposed snap fingers394extend outwardly from the sidewall390and include tabs or latches396(FIG. 27). Detent tabs398extend downwardly from the flange392and are positioned radially outside of the sidewall390. A receiver400is positioned concentrically within the sidewall390and includes a frusto-conical inner surface402to define a funnel to assist in locating and directing the upper end46of the supply tube36toward the receiving chamber366of the hose retainer362.

The mounting base382includes a cylindrical inner wall406defining a center opening408receiving the mounting shank324such that the upper end of the mounting shank324is captured between the spout retainer380and the mounting base382. A cylindrical outer wall410is connected to the inner wall406by a lower wall412that rests upon upper surface16of the sink deck12. The outer wall410defines an electrically insulating spacer between the sink deck12and the spout body340.

With reference toFIG. 22, a lower surface414of an upper lip416of the mounting shank324rests upon a flange418of the mounting base382, while an upper surface420of the upper lip416of the mounting shank324faces a lower surface422of the spout retainer380. As shown inFIG. 21, a plurality of recesses424in the mounting base382receive tabs426of the mounting shank324to rotationally orient and secure the mounting shank324relative to the mounting base382. The mounting base382is illustratively formed of a non-conductive material, such as a polymer. As such, the mounting base382defines an electrical insulator between the spout body340and the sink deck12.

A light indicator430, such as one or more LEDs, may be coupled to a support432, such as a printed circuit board. The support432is illustratively received within a cavity or slot434defined between the inner and outer walls406and410of the mounting base382. The light indicator430is oriented to provide light visible through a lens436. A cable or wire438electrically couples the light indicator430to the controller120.

The latches396of the snap fingers394are received within an annular slot440formed within the inner wall406of the mounting base382. The snap fingers394axially restrain the spout retainer380and therefore the spout body340, while permitting rotational movement of the spout retainer380and the spout body340relative to the mounting base382. When the spout body340is coupled to the mounting base382, the detent tabs398of the spout retainer380are received within cooperating arcuate notches442formed in the upper end of the inner wall406of the mounting base382. Protrusions444are supported within the notches442and define discrete angular positions of the spout retainer380and spout body340relative to the mounting base382.

As noted above, the electrical connector378defines a releasable electrical coupling between the dispensing head314and the pump assembly20for selective electrical communication therebetween. The electrical connector378provides communication between the capacitive input member110above the sink deck12and electronics below the sink deck12. This quick disconnect feature allows a user to remove the spout body340, for example, when refilling the soap reservoir18, without dealing with a wired connection between the mounting base382and the spout body40.

The electrical connector378includes a first electrical contact446supported for movement by the dispensing head314, and a second electrical contact448in selective electrical communication with the first electrical contact446supported by the mounting base382. The first electrical contact446is illustratively formed of an electrically conductive material, such as copper or brass, and is supported within the passageway343of the spout body340. The first electrical contact446may be secured in place through a fastener, such as a screw450. The second electrical contact448is supported by the wall of the mounting base382and is in selective electrical communication with the first electrical contact446supported by the spout body340. More particularly, the second electrical contact448is illustratively formed of an electrically conductive material, such as copper or brass, and is received within a recess452formed in the inner wall406of the mounting base382.

With reference toFIGS. 24-26, the spout body340may be rotated relative to the mounting base382to activate and deactivate the capacitive sensing input to the controller120. In the position ofFIG. 24, the spout body340is in a centered or home position where the contacts446and448are angularly aligned and thereby in electrical communication. In the position ofFIG. 25, the spout body340has been rotated counter-clockwise by more than a predetermined amount (illustratively more than −28 degrees) to an off or deactivated position. Similarly, the spout body340may be rotated clockwise by more than the predetermined amount (illustratively more than +28 degrees) to an off or deactivated position. In the off positions, the contacts446and448are not angularly aligned and thereby not in electrical communication with each other. The spout body340may also be rotated clockwise or counterclockwise by a predetermined amount (illustratively by +/−28 degrees) to an active intermediate position where the contacts446and448are still angularly overlapping and thereby in electrical communication.FIG. 26illustrates the spout body340rotated clockwise to the +28 degree position. As noted above, the mounting base wall includes arcuate notches to receive tabs398from the spout retainer380. The tabs398and protrusions444act as an indexing member to define different defined angular positions of the spout body340relative to the mounting base382.

In operation, the electronic soap dispenser10may be toggled between on and off conditions by rotating the spout body340about the mounting base382. In the manner detailed above, the controller120may distinguish between a proximity input and a touch or contact input. The controller120may also distinguish between a touch input and a grasp or grab input. A proximity input may be distinguished from a contact input (touch or grab) based upon the intensity of the input signal from the capacitive sensor118. A contact input may be distinguished between a touch (or tap) and a grab based upon the duration of the contact input signal from the capacitive sensor118.

Illustratively, upon detecting a proximity output signal from the capacitive sensor118, the controller120will cause the pump assembly20to dispense soap in a predetermined quantity. Upon detecting a touch (or tap) output signal from the capacitive sensor118, the controller120will cause the pump assembly20to dispense soap continuously for a predetermined time. As such, the quantity of soap dispensed may be different depending upon proximity or touch activation. Alternatively, the quantity of soap dispensed may be the same for both proximity and touch activation. As further detailed herein, this predetermined quantity may be set by a user in certain embodiments.

A timer within the controller120may limit the time for dispensing soap, for example should a sensor malfunction or misuse occur. In another illustrative embodiment, the controller120may dispense a quantity of soap for each touch (or tap). For example, the controller120may dispense a single shot of soap in response to a single tap, two shots of soap in response to two taps, etc. Upon detecting a grab the controller120may cause the pump assembly20to remain inactive, such that no soap will be dispensed. As such, a user may grab and rotate the spout body340without dispensing soap. For example, the user may rotate the spout body340between on and off positions, or may remove the spout body340from the sink deck12without dispensing soap.

The dispensing head314may be removed from the sink deck12by pulling the spout body340upwardly away from the mounting base382. The snap fingers394of the spout retainer380are thereby released from the slot440of the mounting base382. The soap reservoir18may then be refilled in a manner similar to that detailed above with soap dispenser10.

An illustrative electronic soap dispenser510is shown coupled to sink deck12in a stand-alone configuration inFIG. 28, while the electronic soap dispenser510is shown coupled to sink deck12in an integrated configuration inFIG. 29. The electronic soap dispenser510is substantially similar to the illustrative soap dispensers10and310ofFIGS. 1-27as detailed above. As such, in the following description similar components are identified with like reference numbers.

In the stand-alone configuration ofFIG. 28, the electronic soap dispenser510may be operated independently from other devices. More particularly, the electronic soap dispenser510includes its own controller120and power supply140. In the illustrative embodiment, the controller120is supported on a printed circuit board (PCB)512which is electrically coupled to motor176. An electrical cable514illustratively couples the dispensing head314to the controller120. The electrical cable514illustratively includes an electrical connector, such as a mini-USB plug516. The spout body340is illustratively formed from an electrically conductive material, thereby defining the input member or electrode110.

In the illustrative stand-alone configuration of soap dispenser510(FIG. 28), the power supply140comprises a battery pack518. The battery pack518is coupled to the motor176through an electrical cable520. The battery pack518illustratively includes a battery box522having a lower housing or holder524and a cover526. The lower housing524defines an internal chamber sized to receive batteries (not shown), illustratively two 3 cell groups of AA-cell batteries (6 batteries total).

In the integrated configuration ofFIG. 29, the electronic soap dispenser510is operably coupled, or tethered, to another electronic device, illustratively an electronic faucet610. The electronic faucet610may include a spout612supporting a sprayhead614defining a mixed water outlet616. A handle618is connected to a manual valve619, which is fluidly coupled to hot and cold water supply lines620and622to control the flow rate and the temperature of water supplied to the mixed water outlet616.

A control unit624may include a housing626supporting an electrically actuated valve628operated by controller120. In the illustrative embodiment, the controller120is supported by a printed circuit board (PCB) in electrical communication with the electronic faucet610. The controller120is configured to open and close the electrically operably valve628in response to an input sensor of the faucet610. The input sensor may be an infra-red (IR) sensor and/or a capacitive sensor.

Each of the illustrative soap dispensers10,310,510detailed herein may be configured to operate in either the stand-alone mode (without a connection to an external controller), or in the integrated mode (with a connection to an external controller, such as electronic faucet610).

With reference now toFIGS. 30-32, the dispensing head314of illustrative electronic soap dispenser510is shown in greater detail. The components below the sink deck12(e.g., the soap reservoir18and the pump assembly20) may be substantially similar to those detailed above in connection with the electronic soap dispenser10ofFIGS. 1-18and the electronic soap dispenser310ofFIGS. 19-27. One distinction however, is that the motor176is directly coupled to the printed circuit board (PCB)512. More particularly, electrical connections of the motor176are soldered directly to electrical contacts on the PCB512(FIG. 30). This eliminates the need for a separate electrical cable between the motor176and the PCB512, thereby reducing associated component and assembly costs.

As further detailed above, mounting shank324extends downwardly through opening26in the sink deck12and secures both the dispensing head314and the lower soap reservoir18to the sink deck12. The mounting shank324includes external threads328that engage with internal threads30of mounting nut32. The sink deck12is clamped between the dispensing head314and the mounting nut32.

The dispensing head314illustratively includes hollow spout body340receiving dispensing tube42. The spout body340is illustratively formed from a material having at least a portion being electrically conductive and thereby defining the input member or electrode110. As detailed above, lower end44of the dispensing tube42is in fluid communication with an upper end46of the supply tube36, and an upper end48of the dispensing tube42defines dispensing outlet23.

Tip or nozzle50secures the outlet23defined by the upper end48of the dispensing tube42to the dispensing head314. As shown inFIG. 32, the outlet23of the dispensing tube42extends a distance D from the outer face528of the dispensing head314to prevent dripping of soap down the outer surface thereof. In the illustrative embodiment, the distance D is at least 0.063 inches.

Tube retainer362secures the lower end44of the dispensing tube42to the spout body340. Mounting bosses368include openings370to receive fasteners, such as screws72, to secure the tube retainer362to retaining bosses373of the spout body340.

Releasable coupler374couples the spout body340to the mounting shank324to facilitate removal of the dispensing head314from the sink deck12for refilling the reservoir18with liquid soap from above the sink deck12and/or replacing the dispensing head314with different styles or designs. Illustratively, the releasable coupler374includes structural coupling or connector376between the dispensing head314and the mounting shank324, and an electrical coupling or connector378′ between the dispensing head314and the pump assembly20.

In one illustrative embodiment, the structural connector376of the releasable coupler374includes spout retainer380coupled to the mounting shank324through mounting base382. The spout retainer380is secured to openings384formed in the retaining bosses373of the spout body340through fasteners72. The spout retainer380includes upper wall386having openings388aligned with the openings370of the hose retainer362and the openings384of the spout body340for receipt of the fasteners72.

The mounting base382includes cylindrical inner wall406defining center opening408receiving the mounting shank324such that the upper end of the mounting shank324is captured between the spout retainer380and the mounting base382. Cylindrical outer wall410is connected to the inner wall406by lower wall412that rests upon upper surface16of the sink deck12. The outer wall410defines an electrically insulating spacer between the sink deck12and the spout body340.

As noted above, the electrical connector378′ defines a releasable electrical coupling between the dispensing head314and the pump assembly20for selective electrical communication therebetween. The electrical connector378provides communication between the capacitive input member110above the sink deck12and electronics (e.g., PCB512) below the sink deck12. As noted above, this quick disconnect feature allows a user to remove the spout body340, for example, when refilling the soap reservoir18, without dealing with a wired connection between the mounting base382and the spout body40.

The electrical connector378includes a first electrical contact446′ supported for movement by the dispensing head314, and second electrical contact448in selective electrical communication with the first electrical contact446′ supported by the mounting base382. The first electrical contact446′ is illustratively defined by a protrusion or boss integral with the spout body340and extending within the passageway343. The second electrical contact448is supported by the wall of the mounting base382and is in selective electrical communication with the first electrical contact446′ defined by the boss of the spout body340. More particularly, the second electrical contact448is illustratively formed of an electrically conductive material, such as copper or brass, and is received within recess452formed in the inner wall406of the mounting base382.

With reference toFIGS. 30 and 33, the pump assembly20is supported by the soap reservoir18and illustratively includes a drive mechanism160operably coupled to a pump device162. The bottom wall35of the reservoir18supports the pump assembly20and is secured to the side wall164.

The drive mechanism160illustratively includes electric motor176having rotatable drive shaft178and operably coupled to the controller120. The electric motor176is illustratively supported below the bottom wall35by motor mount179′. The motor mount179′ includes a pair of receiving bosses180′ receiving a pair of posts182extending downwardly from the bottom wall35(FIG. 8). The drive mechanism160is retained within a motor cover184′ which, in turn, is secured to the bottom wall35. The motor cover184′ is illustratively formed of a polymer and protects the drive mechanism160from debris.

With reference toFIG. 33, gears194and196are received within a recess206formed in the bottom wall35. A gear cover208is positioned above the gears194and196and is secured to the bottom wall35by a plurality of fasteners, such as screws210. The gear cover208includes an inlet port212and an outlet port214on opposite sides of where the gear teeth202and204mesh. The outlet port214is defined by an upwardly extending nipple216received within a check valve530. The check valve530may be received within a lower end44of the dispensing tube42. The check valve530may be of conventional design similar to check valve56, as detailed above.

The supply tube36extends upwardly through the reservoir18and into the dispensing head14. More particularly, the lower end218of the supply tube36is fluidly coupled to the outlet port214of the gear cover208, while the upper end46of the supply tube36is received within the receiving chamber66of the tube retainer62. As such, the dispensing tube36extends axially the full length of the soap reservoir18from proximate the bottom wall35through the sink deck12and into the dispensing head14.

An illustrative method of operation of electronic soap dispenser510is shown inFIGS. 34A and 34B. Beginning at block710, the capacitive sensor118detects the presence of a user. More particularly, the capacitive sensor118detects proximity to, or touching of, the dispensing head314by a user. If a touch or proximity input is detected at block712, then liquid soap is dispensed at a predetermined quantity at block714. If no proximity or touching is detected by the capacitive sensor118at block712, then the process returns to sensing block710.

If a grasp or grab is detected by the capacitive sensor118, the method continues to decision block716. At decision block716, the controller120determines if the grab lasts at least 5 seconds. If the grab lasts less than 5 seconds, then the method returns to block710. If the grab lasts at least 5 seconds, then the method proceeds to decision block718.

At block718, the controller120determines if the grab lasts at least 10 seconds. If the grab lasts less than 10 seconds (but at least 5 seconds as determined at block716), then the method proceeds to block720where the light indicator430displays a continuous purple light. At block722, a subroutine within the controller120allows the user to set the amount of soap dispensed per activation or shot (i.e., set dispensing duration). More particularly, each tap of the dispensing head314by the user will set the duration of soap dispensed per subsequent activation.

In an illustrative embodiment, the soap dispensing duration may be set per the following table:

Number of TapsSet Dispensing Duration1300milliseconds2600milliseconds31second41.5seconds52seconds

The controller120is illustratively set at the factory to dispense liquid soap at the duration equivalent to 3 taps, in the illustrative embodiment being 1 second. So to reduce the amount of soap delivered per activation, the user taps the dispensing head314one or two times once in the program mode. To increase the amount delivered, the user taps the dispensing head314four or five times once in the program mode.

At block722, the controller120causes the light indicator430to flash a blue light equal to the number of taps, thereby indicating the set dispensing duration. The controller120then causes the pump assembly20to dispense soap for the set dispensing duration. If the setting is correct, at block726the user grabs the dispensing head314for at least 5 seconds to save the setting and exit the subroutine. If a different dispensing duration is desired, then the user again taps the dispensing head314to the desired setting at block728. At block730, the controller120deactivates the light indicator430. The method continues to block732, where the setting is stored by the controller120such that the same amount of soap is dispensed (i.e., set dispensing duration) with both touch and proximity activation. The method then returns to block710.

Returning to decision block718, if the controller120determines that the grab lasts at least 10 seconds, then the method proceeds to block734where the light indicator430displays a continuous or solid red light for 3 seconds. At block734, a subroutine within the controller120allows the user to activate and deactivate proximity sensing. More particularly, at block734, proximity sensing is deactivated. If the user wishes to reactivate proximity sensing, then at block736the user grabs the dispensing head314for at least 10 seconds. The method then continues to block738where the controller120causes the light indicator430to display a continuous or solid blue light for 3 seconds and the proximity sensing is again activated. The method then returns to block710. As detailed herein, proximity sensing allows a user to dispense liquid soap without touching the dispensing head314if the user places his or her hand within 0.5 inches anywhere near the dispensing head314.