# Patent

## Title
Automated cleansing sprayer having separate cleanser and air vent paths from bottle

## Abstract

An automated sprayer for spraying the walls of a shower enclosure with a liquid cleanser dispenses the cleanser using a pump and rotatable spray head. A motor drives the pump and rotates the spray head. The sprayer has a showerhead mountable housing with a hanger. The housing supports a bottle of cleanser in an inverted fashion. Cleanser is delivered from the bottle through a cleanser conduit in the piercing post into a well of the housing. The bottle is vented from the well through an air vent path in the piercing post or from a well vent outlet through the air vent path in the piercing post. An outlet valve in the well permits outflow of cleanser from the well. Various bottle caps and bottle closures are also provided to improve venting and/or limit cleanser leakage from the bottle when the bottle is installed in the housing.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 11/376,867 filed Mar. 16, 2006 now U.S. Pat. No. 7,308,990, which is a divisional application of U.S. application Ser. No. 10/418,761 filed Apr. 18, 2003, now U.S. Pat. No. 7,021,494.


STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
This invention relates to sprayers that are designed to automatically clean enclosures. It appears to be especially well suited for automatically cleaning shower/bathing enclosures of the type typically found in homes.
The walls and doors of shower/bathing enclosures can become mildewed, coated with soap build up or hard water and mineral deposits, or become otherwise soiled, during typical use. Removing these deposits and stains normally requires one to scrub the walls and doors by hand, which is an undesirable task.
To assist in this task, cleaning chemicals may be sprayed, squirted, or otherwise applied on the surfaces to be cleaned. After allowing the active ingredients some time to “work”, the walls are then wiped with a cloth, brush, or scrubbing pad, and then rinsed with water.
In some cases these cleaners are so effective that the amount of scrubbing can be somewhat reduced (particularly if the cleaners are used on a daily basis). See generally, WO 96/22346 and WO 98/02511.
However, for these “no scrub” cleaners to work well they preferably should be applied immediately after the shower has been used. This requires a consumer to keep a pump spray bottle of the cleanser in or near the shower enclosure (further cluttering the shower area), that the consumer remember to do the spraying (which may be problematic if the consumer has just woken up), and that the consumer be willing to spend the time to spray the enclosure (for example they may be running late in the morning).
An alternative approach is to provide an automated cleaning system for a shower. For example, U.S. Pat. No. 4,872,225 discloses a sprayer and conduit system for a bath and shower enclosure. The unit is associated with the showerhead. Supply water can be diverted to the sprayer for cleaning the enclosure. A container of cleanser is mounted in the shower enclosure for introducing cleanser (through an injector assembly) for spraying cleanser on the walls.
A drawback with this system is that the user must manually turn on the supply water (if not already on), adjust the diverter, squeeze cleanser into the sprayer and shut off the water after the walls have been washed. There is also some risk that the consumer will be sprayed with the cleanser.
Other automated enclosure cleaning systems are more elaborate, such as that disclosed in U.S. Pat. No. 4,383,341, which includes multiple pop-out spray nozzles connected by a manifold to a mixing valve where cleaning concentrate is mixed with water. Thus, it is not something that a consumer can easily and inexpensively retrofit to their shower enclosure.
U.S. Pat. No. 5,452,485 discloses an automatic cleaning device for a tub and shower having large, powered tub and shower “gliders” that move in tracks around the tub and shower stall, respectively. The gliders are coupled to the water supply, which is mixed with a cleanser. The gliders have spray heads for spraying the cleaning solution on the tub and shower walls. The gliders also have brushes for scrubbing the walls. A user operates the gliders and cleanser mixing by a central controller. Again, this system is not suitable for easy and inexpensive retrofitting.
It seems particularly desirable to develop a relatively small automated dispenser that can be hung from a showerhead, shower enclosure wall, or the like, yet dispense cleanser without the need for drawing water from the building supply. It would also be desirable for such a system to accept inverted bottles of cleaning fluid.
However, the use inverted bottles in such a dispenser can present problems. For example, negative pressure (i.e., vacuum) effects in the bottle may hinder the flow of fluid from the bottle. While air vents have been proposed to overcome these negative pressure problems, the location of such air venting systems need to be optimized in order to provide for improved fluid flow from the bottle. For instance, too much air flow into the bottle can cause frothing or foaming of the liquid in the bottle, whereas inadequate air flow into the bottle fails to overcome the negative pressure effects. Additionally, mixing of the air flow into the liquid flow must be controlled as certain levels of mixing of the air flow into the liquid flow may prevent appropriate dispensing of the liquid. The present invention addresses the need for an automated dispenser that can accept inverted bottles of cleaning fluid and can deliver the fluid from the bottle with improved fluid flow characteristics.
SUMMARY OF THE INVENTION
In one aspect the invention provides an automated sprayer for spraying an enclosure with a liquid cleanser (for example a cleanser such as that described in WO 96/22346). The sprayer includes a bottle suitable to contain a liquid cleanser, a reservoir tray having an upwardly extending well for supporting the bottle in an inverted orientation, a spray head in fluid communication with the well and having an outlet orifice through which cleanser from the bottle can be expelled if there is such liquid cleanser in the bottle, and a piercing post extending from the reservoir tray into the bottle.
The piercing post includes a cleanser conduit in fluid communication with the well for delivering cleanser to the well, and an air vent path separate from the cleanser conduit for venting the bottle. In one configuration of the sprayer, the air vent path is in fluid communication with a vent outlet of the well. In another configuration of the sprayer, the air vent path is in communication with an air passage between the bottle and an inner surface of the well. In one form, the cleanser conduit terminates at an opening of the piercing post, and the air vent path terminates at another opening of the piercing post such that the opening of the air vent path is at a position further into the bottle than the opening of the cleanser conduit when the bottle is installed in the inverted orientation in the tray. A wall may also extend outward from the piercing post between the opening of the air vent path and the opening of the cleanser conduit. Optionally, a gasket may be used to seal against the piercing post and limit leakage around the piercing post when the bottle is installed in the inverted orientation in the tray.
In one embodiment, the well has a spring-loaded outlet valve that permits outflow of cleanser from the well when a portion of a cap of the bottle abuts against the outlet valve when cleanser is in the bottle. The outlet valve may include a valve stem that moves toward the bottle to permit outflow of cleanser, and the portion of the cap that abuts against the outlet valve may be a section of the cap that projects axially from the cap. In one form, the bottle has a cap having axially projecting segmented ridges, and the well has a spring-loaded outlet valve that permits outflow of cleanser from the well when a portion of at least one of the segmented ridges of the cap of the bottle abuts against the outlet valve.
The well may include a chamber for holding cleanser delivered to the well and a valve for controlling outflow of cleanser from an outlet of the chamber. The valve may include a valve stem that is spring-biased in a normally closed seated position that seals the outlet of the chamber and the valve includes an actuator that unseats the valve stem from the outlet of the chamber when a portion of a cap of the bottle abuts against the actuator of the valve. The actuator may include a plunger in contact with a rocker that unseats the valve stem.
In another aspect, the invention provides a cap for a bottle for an automated sprayer including a reservoir tray having an upwardly extending well for supporting the bottle in an inverted orientation, a spray head in fluid communication with the well and having an outlet orifice through which cleanser from the bottle can be expelled if there is such liquid cleanser in the bottle and a spring-loaded outlet valve that permits outflow of cleanser from the spray head when the bottle is inserted in the tray and cleanser is in the bottle. The cap includes a side wall and a transverse wall extending inwardly from the side wall. The transverse wall has a central piercable surface, and a plurality of segmented ridges project axially from the transverse wall. Preferably, the ridges project to a plane spaced from the side wall, and the ridges are arcuate.
In yet another aspect, the invention provides a closure for an opening of a bottle for an automated sprayer of the type that includes (i) a reservoir tray having an upwardly extending well suitable for supporting the bottle in an inverted orientation when the bottle is inserted in the tray and having a piercing post extending from the reservoir tray into the bottle when the bottle is inserted in the tray, (ii) a spray head having an outlet orifice through which cleanser from the bottle can be expelled if there is such liquid cleanser in the bottle, and (iii) a spring-loaded outlet valve that permits outflow of cleanser from the spray head when the bottle is inserted in the tray and cleanser is in the bottle. The closure includes a cap, and a gasket. The gasket is configured to seal against the piercing post when the bottle is installed in the inverted orientation in the tray.
In one version of the closure, the gasket is arranged between the cap and the opening of the bottle. In another version of the closure, the cap has a piercable area that is punctured by the piercing post when the bottle is installed in the inverted orientation in the tray. In still another version of the closure, the cap has a central hole through which the piercing post passes when the bottle is installed in the inverted orientation in the tray. In yet another version of the closure, at least a portion of an inner surface of the central hole of the cap is sloped. In still another version of the closure, the gasket has a central hole through which the piercing post passes when the bottle is installed in the inverted orientation in the tray. At least a portion of an inner surface of the central hole of the gasket may be sloped. In yet another version of the closure, the gasket is sealed over the opening of the bottle and is punctured when the bottle is installed in the inverted orientation in the tray.
In still another aspect, the invention provides a closure for an opening of a bottle for an automated sprayer of the type that includes (i) a reservoir tray having an upwardly extending well suitable for supporting the bottle in an inverted orientation when the bottle is inserted in the tray and having a piercing post extending from the reservoir tray into the bottle when the bottle is inserted in the tray, (ii) a spray head having an outlet orifice through which cleanser from the bottle can be expelled if there is such liquid cleanser in the bottle, and (iii) a spring-loaded outlet valve that permits outflow of cleanser from the spray head when the bottle is inserted in the tray and cleanser is in the bottle. The closure includes a cap including a side wall, a transverse wall extending inwardly from the side wall, and a central wall extending outwardly from the transverse wall and defining an outlet for the cap. The central wall of the cap has a central piercable surface that seals the outlet for the cap before the bottle is installed in the inverted orientation in the tray and is punctured when the bottle is installed in the inverted orientation in the tray. Preferably, the central wall extends a distance outwardly from the transverse wall such that any portion of the central piercable surface that remains attached to the central wall when the central piercable surface is punctured does not extend inward beyond the transverse wall. The closure may further include a gasket, wherein the gasket is configured to seal against the piercing post when the bottle is installed in the inverted orientation in the tray. The gasket may be arranged between the cap and opening of the bottle. Optionally, the gasket has a central hole through which the piercing post passes when the bottle is installed in the inverted orientation in the tray, and at least a portion of an inner surface of the central hole of the gasket may be sloped. Alternatively, the gasket is sealed over the opening of the bottle and is punctured when the bottle is installed in the inverted orientation in the tray.
The invention facilitates the flow of fluid from the bottle (for example by overcoming any negative pressure effect in the bottle), and does so in a manner that avoids excessive air being added in a way that causes frothing or foaming in the fluid in the bottle. Thus, the problem of negative pressure build-up in the bottle, or uncontrolled air venting, is addressed by the present invention. The invention also provides for improved control of cleaning fluid delivery from the dispenser, by way of, among other things, the cleanser conduit in the piercing post and the valve. Additionally, uncontrolled mixing of the air flow into the liquid flow is avoided, thereby improving dispensing of the cleaning fluid.
These and other advantages of the invention will be apparent from the detailed description which follows and the drawings. It should be appreciated that what follows is merely a description of preferred embodiments. That description is not meant as a limitation of the full scope of the claims. Rather, the claims should be looked to in order to judge the full scope of the invention.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially exploded perspective view of an automated sprayer with a cleanser bottle shown inverted prior to being set into the sprayer, the sprayer being an earlier prototype of the automated sprayer according to the invention shown in FIGS. 17-22 and 30;
FIGS. 2A and 2B are exploded perspective views of the sprayer of FIG. 1;
FIG. 2C is an exploded perspective view of one possible pump used in the sprayer;
FIG. 3 is a side cross-sectional view of the sprayer taken along line 3-3 of FIG. 1;
FIG. 4 is a partial cross-sectional view taken along line 4-4 of FIG. 3 showing the pump and drive mechanism with the pump and a drive motor shown in full;
FIG. 5 is a front cross-sectional view taken along line 5-5 of FIG. 3 showing the spray head drive and junction with the dispenser tube;
FIG. 6 is a cross-sectional view taken along line 6-6 of FIG. 3 showing the gear train for the spray head drive;
FIG. 7 is a schematic diagram showing the control circuit and cleanser flow path;
FIG. 8 is a partial reverse perspective view of the cleanser bottle with its bottle cap;
FIG. 9 is an enlarged view of the bottle-tray interface with the bottle seating in the tray and a discharge valve open;
FIG. 10 is a view similar to FIG. 9 although with the bottle unseated from the tray and the discharge valve closed;
FIG. 11 is a top view of the tray with the bottle removed;
FIG. 12 is an enlarged partial top view showing the discharge valve and piercing post;
FIG. 13 is a cross-sectional view taken along line 13-13 of FIG. 10;
FIG. 14 is a partial reverse perspective view of the cleanser bottle with an alternative embodiment of a bottle cap with an adapter that can be used with the dispenser of FIGS. 1-13;
FIG. 15 is an enlarged view of the bottle-tray interface with the bottle seating in the tray and a discharge valve open, the bottle having the embodiment of the bottle cap with the adapter as shown in FIG. 14;
FIG. 16 is a view similar to FIG. 15, although with the bottle and adapter unseated from the tray and the discharge valve closed;
FIG. 17 is a view similar to FIG. 15, showing the bottle-tray interface of a first embodiment of a dispenser according to the invention;
FIG. 18 is a view similar to FIG. 17 although with the bottle unseated from the tray and the discharge valve closed;
FIG. 19 is a view similar to FIG. 8, but of an embodiment of a bottle and bottle cap for use with the embodiment of the dispenser of the present invention shown in FIGS. 17-18;
FIG. 20 is a view similar to FIG. 14, but of the FIG. 19 embodiment where the cap has been split into a main cap and another adapter;
FIG. 21 is a view similar to FIG. 17, but with the FIG. 20 adapter;
FIG. 22 is a view similar to FIG. 21 although with the bottle and adapter unseated from the tray and the discharge valve closed;
FIG. 23 is a view similar to FIG. 16 although with a bottle having an alternative cap and a cap liner;
FIG. 24 is a view similar to FIG. 22 although with a bottle having an alternative cap and a cap liner;
FIG. 25 is a view similar to FIG. 16 although with a bottle having a removable cap and a closure seal;
FIG. 26 is a view similar to FIG. 22 although with a bottle having a removable cap and a closure seal;
FIG. 27 is a view similar to FIG. 14, but of another adapter that may be used with the present invention;
FIG. 28 is a view similar to FIG. 23 with the adapter of FIG. 27;
FIG. 29 is a view similar to FIG. 25 with the adapter of FIG. 27;
FIG. 30 is a view similar to FIG. 17, showing the bottle-tray interface of another embodiment of a dispenser according to the invention;
FIG. 31 is a view similar to FIG. 10, showing the bottle-tray interface and a cap that may be used with the dispenser of FIG. 30;
FIG. 32 is a view similar to FIG. 10, showing another bottle cap for use with the invention;
FIG. 33 is a view similar to FIG. 32, showing yet another bottle cap for use with the invention;
FIG. 34A is a perspective view of an alternative valve plate suitable for use with the invention of FIG. 30;
FIG. 34B is a perspective view of another alternative valve plate suitable for use with the invention of FIG. 30;
FIG. 34C is a perspective view of yet another alternative valve plate suitable for use with the invention of FIG. 30;
FIG. 34D is a perspective view of still another alternative valve plate suitable for use with the invention of FIG. 30; and
FIG. 34E is a perspective view of yet another alternative valve plate suitable for use with the invention of FIG. 30.



DETAILED DESCRIPTION OF THE INVENTION
As background, we describe an earlier prototype of an automated sprayer generally referred to in the figures by reference number 20. With particular reference to FIGS. 1-2B, the sprayer 20 includes as main components a bottle 22, a housing 24 with an adjustable hanger 26, a pump 28, a drive mechanism 30, a spray head 32 and a control circuit 34. The sprayer is typically suspended via the hanger from a shower spout or the like and then activated via a button 35 at the front of the sprayer to rotate a spray head and pump cleanser from the bottle out of the spray head during a spray cycle of a prescribed time period, after which dispensing is automatically terminated.
The exterior of the sprayer is defined by the housing 24, which can be molded from, for example, plastic by any suitable technique and consists primarily of two pieces, a receptacle 36 and a hanger tower 38 that easily snaps into a pocket in the receptacle. This allows the sprayer to be shipped and stored in a compact package with minimal assembly by the consumer. The hanger tower 38 is an upright member defining a cavity in which the elongated body of the hanger 26 fits through an opening 40 at its upper end. The upper end of the hanger tower 38 has two oval openings 42 vertically spaced apart.
A deflectable tab 44 formed in the lower end of the hanger can snap into one of the openings to lock the hanger at either of two extended positions. The hanger is extended and locked in the lower opening by simply pulling it away from the hanger tower. In this position, the sprayer 20 will hang from standard shower spouts at an appropriate height for spraying down the shower walls. The height can be adjusted by depressing the tab inwardly and sliding the hanger up or down. The hanger itself has two ears 46 at its upper end for mounting a rubber strap 48. The ears can be tapered to ease connection of the strap, which can have a series of holes at one end for adjustment purposes so that the strap fits tightly around a shower spout or the like. The back side of the hanger tower is closed by a back plate 50. The hanger tower connects to the receptacle at its lower end, which fits into a pocket 52 and has two latches 54 (one shown) that snap into two slots in the back of the receptacle.
The receptacle defines an upwardly opening bottle tray 56 above a compartment 58 (see FIG. 4) containing the pump and drive mechanism which is closed at the bottom by a cover 60. The cover has a circular skirted opening 62 for the spray head and a wall stand-off 64 extending backward the distance of the pocket to brace the lower end of the receptacle against the wall and keep it plumb. The back side of the receptacle defines a battery compartment 66 with a lid 68 and the front side has an oval switch opening 70 for the control button 35.
The tray 56 is formed to mate with a specially contoured upper end of the bottle. The bottle and tray are generally oval and have mating seating surfaces 72 and 74 and sloped shoulders 76 and 78 with complementary V-shaped features 80 and 82, respectively. These features and the contour of the shoulders fix the orientation of the bottle in the tray and make conventional cleanser bottles incompatible with proper operation of the sprayer.
Referring next to FIGS. 9-12, the tray defines a circular well 84 at the center of the seating surface 74 accommodating a special cap 86 screwed onto the mouth of the bottle. The well is formed with a shoulder portion 88, a vent nipple 90 and a recess 92 with a discharge nipple 94. The well supports a valve plate 96 (see FIG. 2A) fastened thereto by two screws 97 (see FIG. 3). The valve plate has a piercing post 98 projecting up from the valve plate. The post has a slanted top end defining a sharp point and defines a vent passageway 100 and three radial ribs 102. The vent passageway extends into a recess 104 at the underside of the valve plate accommodating a small o-ring 106 surrounding the vent passageway and the opening in the vent nipple 94. The valve plate also defines a valve recess 108 with a discharge passageway 110 through which a valve stem 112 extends. The upper end of the valve stem has a cross-shaped plunger 114 that is biased away from the well by a coil spring 116 fit into the valve recess.
The lower end of the valve stem mounts a disc-shaped rubber gasket 118 retained by an enlarged end 120 of the valve stem. As shown in FIG. 10, the plunger is biased upward by the spring so that the gasket seals against the underside of the valve plate so as to close off the discharge orifice when the sprayer is not being used. The valve plate also defines arcuate stand-offs 124 spaced in slightly from its periphery. The valve plate and the well are designed to cooperate with the specially designed bottle cap (described below) to discourage use of unaffiliated cleanser and thereby promote proper operation of the sprayer.
Referring next to FIGS. 8-11, the cap is generally circular with a serrated periphery 126 and a tapered sealing flange (or web) 128 that seals against the tray well above its shoulder. The top of the cap has an outer surface 130 with a recessed thinned area 132 at its center around which is a raised ring surface 134 extending to a plane spaced from surface 130. The thinned area 132 is located so that as the bottle is seated in the tray the piercing post will puncture the cap in this area to permit discharge of the cleanser and venting of the bottle. The raised ring is located to contact the plunger of the valve and push the valve downward to unseat the gasket from the plate and open the discharge orifice. The flat surface 130 of the cap rests on the stand-offs 124 to space the punctured area from the floor of the well.
This arrangement thus provides a no-mess means of opening and inserting the bottle, but also further inhibits uses of improper cleanser containers. It does this for several reasons. First, if a conventional bottle and cap were inserted into the tray, the piercing post would not puncture a conventional cap lacking the weakened area. Even if the cap was removed so that the mouth was opened, the sprayer still would not operate because the valve is located radially inward of the place where a conventional thin-walled bottle mouth would normally extend so that the valve would not be opened.
Another feature that serves this purpose is the conforming sloping of the bottle shape and receiving well. A bottle not having a complementary shape would not be received sufficiently low to activate the outlet valve.
Also, while the cap has conventional internal threads 136 at its upper end that mate with threads 138 on the mouth of the bottle, and it also has a ring of one-way ratchet teeth 140 that engage corresponding ratchet teeth 142 on the bottle (see FIG. 13). The ratchets allow the cap to be turned in a tightening direction but resist untightening rotation to prevent non-destructive removal of the cap and thus refilling of the bottle.
FIGS. 2B-6 show the pump, controller, and drive mechanism contained inside the receptacle compartment beneath the bottle tray. These components will now be described working from the bottle-tray interface to the spray head. A short vent tube 144 couples to the vent nipple 90 defining the vent orifice in the tray well. A small check valve 148 fits into the end of the vent tube. The check valve is normally closed so that cleanser does not leak out via that path. The valve opens by negative pressure that develops as cleanser is withdrawn from the bottle. The opened check valve aspirates the air to the bottle to allow the cleanser to flow from the bottle in a consistent manner, without introducing air in a manner that would cause foaming or gurgling. The check valve remains open until the pressure in the bottle has equalized sufficiently to alleviate the negative pressure and then it closes.
From the discharge nipple defining the discharge orifice of the tray well a first tube 152 of a dispenser line 154 extends to an inlet barb 156 of the pump 28, which snaps into a support 158 mounted to the underside of the bottle tray. The pump can be any conventional pump, such as a diaphragm pump, a piston pump, a peristaltic pump, or even a gear pump as shown. The inlet defines a passageway leading between intermeshing drive gear 160 and idler gear 162 (see FIG. 2C). The drive gear is connected to an upper shaft 164 (surrounded by o-ring 165) of a direct current motor 166 mounted through an opening in a gear plate 167 mounted to the lower cover of the receptacle. Operation of the motor rotates the drive gear which meshes with and turns the idler gear as conventional to draw cleanser from the bottle and through to an outlet barb 168. A second tube 170 connects the outlet barb to a filter 172. The filter accumulates cleanser within its housing and aids in priming the pump. A short tube 174 of the dispenser line connects the filter 172 to another check valve 176 which is connected by another short tube 178 continuing a spring 179 for support to an inlet barb 180 of a shaft junction 182.
Referring to FIGS. 2B and 5, the stationary portion of the junction 182 is a chamber formed in part by the gear plate at a circular wall 184 having an inner shoulder 185 and covered at one end by a cap 186. The cap includes the inlet barb 180 and a raised annular ring 188 extending downwardly within the circular wall to press an o-ring 190 against the shoulder. The o-ring seals against the upper end of a rotating spray head drive shaft 192, which forms the rotating portion of the function. The drive shaft is an inverted Y-shaped structure with a cylindrical stem 194 defining a passageway 198 and a forked end 196 extending down through an opening in the receptacle cover and defining a gap 200 accommodating a spray nozzle 202. The forked end has lateral mounting posts 204 onto which snaps a dome-shaped cover 206 concealing the spray nozzle 202.
The spray nozzle is preferably a fluidic oscillator providing oscillating spray (in this case up and down), however, any other suitable nozzle could be used. See e.g. U.S. Pat. No. 4,562,867 which shows examples of known fluidic oscillators. Such a fluid oscillator can be any suitably sized oscillator including a housing 208 with an inlet 210 and an outlet 212 on opposite sides. A barrier member (not shown) in the interior of the housing defines a passage between the inlet and the outlet so that cleanser entering the inlet passes through and around the barrier member to the outlet. The fluidic oscillator operates, as known in the art, by creating areas of low pressure at alternate sides of the passage through the barrier member to convert the straight flow entering the housing to an oscillating pattern.
The nozzle is coupled to an outlet barb 214 extending from the stem by another tube 216. The nozzle is mounted so that its outlet end extends through the opening in the cover pointed downwardly at approximately a 30 degree angle. A drive gear 220 is press fit onto the stem of the drive shaft and meshes with a first reducer gear 222 which is rotated by another smaller diameter reducer gear 224 driven by a pinion 226 at the end of lower motor shaft 228. The gear train couples to the motor to the spray head at a reduced revolution per minute rate than the motor shaft. This arrangement provides a revolving, oscillating spray pattern.
Also mounted to the support within the receptacle compartment is the control circuitry 34 which is electrically coupled to a direct current power supply via battery terminals 230 (see FIGS. 2A and 7) in the battery compartment and to the push-button switch 35, which is mounted through the opening 70 in the front of the receptacle through a lighted watertight, flexible membrane 232. The circuitry includes timing circuitry 234 and a speaker 236 that functions as described below.
The electrical arrangement as well as the dispensing line and bottle venting flow paths are shown in FIG. 7 and the sprayer is operated as follows. When a bottle is loaded into the sprayer (that is, the bottle is inverted and set into the receptacle tray), the thinned area of the bottle cap is punctured by the piercing post, the cap sealing flange seals against the tray well and the annular ring contacts and depresses the plunger of the discharge valve to open the valve. Cleanser pours out of the bottle between and around the ribs of the piercing post and is replaced by an equal volume of air through the vent tube.
Because air is lighter than the cleanser, it is displaced to the top of the bottle where it is trapped. Cleanser pours out of the bottle and drains through the valve plate and into the dispenser line, through the pump, past the filter until it reaches valve 176. Until the sprayer is operated, the sprayer remains in this state of equilibrium in which no cleanser flows from the bottle.
When a user wishes to spray the enclosure walls with cleanser, he or she simply depresses the switch at the front of the sprayer. This signals timing circuitry to begin a countdown delaying spraying for a predetermined time, such as 20 seconds. This affords the user time to exit the shower enclosure and close the doors or curtains. It also may provide the user time to abort the spray cycle by depressing the switch a second time. Initially depressing the switch may also send a pulsed tone to the speaker and flashes the lighted ring around the switch for warning the user of the impending operation of the sprayer.
Unless cancelled by the user, the spray cycle begins automatically at the expiration of the countdown. The motor is then energized which simultaneously rotates the drive gear of the pump and turns the gear train to rotate the drive shaft and the spray head. At the same time, the pump draws cleanser from the bottle through the dispenser line and opens valve 176 so that cleanser can flow through the junction and be expelled through the nozzle as the spray head is rotated, thereby providing a circular, oscillating spray pattern. This reduces the level of cleanser in the bottle, creating a negative pressure in the bottle, which opens the check valve in the vent tube to aspirate the bottle and allow more cleanser to be drawn from the bottle during the spray cycle.
The motor continues to be energized until the expiration of a second countdown performed by the timing circuit, preferably another 20 second interval, automatically initiated by the timer. At that point the motor is deenergized which shuts down the pump causing valve 176 to close. Closing the valve prevents cleanser from leaking out of the dispenser line and also keeps the cleanser in the line upstream from the valve so that the pump remains primed. The sprayer thus returns to stand-by mode without further intervention from the user, ready for another spray cycle at the demand of the user.
FIGS. 14-16 depict a modified bottle cap and an adapter suitable for use with the dispenser of FIGS. 1-13. A flat top cap 86a is provided with a bottle 22. An adapter 300 is employed between the bottle cap and tray 56 to bridge the action of loading the bottle into the tray and the opening of the discharge orifice.
In FIG. 14, bottle cap 86a has a generally flat transverse outer surface 130a with a recessed thinned area 132a at its center. Adapter 300 has a flat ring 302 with an opening in the middle and a ring 134a protruding from the ring 302 but with a smaller outer circle. The ring 302 of the adapter 300 may have the same serrated periphery 306 as the bottle cap 86a, and the outer circles of the ring 302 and the bottle cap 86a, including the serrated peripheries, typically have the same diameter.
When the bottle 22 is seated in the tray 56, piercing post 98 will go through the opening in the middle of the adapter 300 and puncture the cap 86a in the thinned area 132a to permit discharge of the cleanser and venting of the bottle. Meanwhile, the bottle cap 86a presses against the ring 302 of the adapter 300 so that the ring 134a of the adapter, which is located to contact plunger 114, pushes the valve downward to unseat gasket 118 from valve plate 96 and open the discharge orifice. The ring 302 of the adapter 300 rests on the stand-offs 124 to space the punctured area from the floor of the well 84.
What has been described thus far with respect to FIGS. 1-16 provides context for the use of the present invention claimed herein. Turning now to FIGS. 17-19, there are shown embodiments of a cap and the bottle-tray interface according to the invention that may used to deliver cleanser from the bottle 22 to the tube 152 of the dispenser line 154 that extends to the inlet barb 156 of the pump 28 as described above. In FIGS. 17-19, the cap 86b is as described above with references to FIGS. 8-11 except that the cap 86b has four equally spaced segmented ridges 134b extending to a plane spaced from the surface 130. The segmented ridges 134b are separated by slots 434. The segmented ridges 134b are located to contact a valve actuator to deliver cleanser from the bottle 22 to the first tube 152 of the dispenser line 154 that extends to the inlet barb 156 of the pump 28 as described below.
Referring now to FIG. 18, the embodiment of a bottle-tray interface is shown just before the bottle 22 is placed in the reservoir tray. The reservoir tray has a well 480 including a circular upper section 484 with a floor 485 and a circular lower chamber 490 extending downwardly from a portion of the floor 485. A spout 491 extends downwardly from the lower chamber 490 and defines an outlet orifice 492.
A circular piercing post 420 extends upwardly from the floor 485 of the circular upper section 484 of the well 480. The piercing post 420 has an outer wall 421, and an inner wall 427 that defines an air vent path 425 and a cleanser conduit 428 in the piercing post 420. The cleanser conduit 428 provides a fluid flow path to the lower chamber 490 of the well 480. An air hole 426 passes through the outer wall 421 into the air vent path 425, and an opening 429 passes through the outer wall 421 into the cleanser conduit 428. The piercing post terminates in an obliquely truncated upper end 422 to facilitate puncturing the cap 86a in the thinned area 132a to permit discharge of the cleanser.
The lower chamber 490 of the well 480 contains a valve 438 that controls cleanser flow from the bottle 22 as will be described below. The valve 438 includes a valve actuator 440 and a valve stem 448. The valve actuator 440 includes a plunger 441, a valve cover 443 and a rocker 444. The plunger 441 is biased in the upward direction against the valve cover 443 by a spring 442 as shown in FIG. 18. The rocker 444 includes a pivot pin 446, an upper arm 445 and a lower forked arm 447. The forked arm 447 is seated in a groove 450 in the valve stem 448. A spring 449 biases the valve stem 448 against the entry to the outlet orifice 492 as shown by the arrow in FIG. 18. By spring-biasing the valve stem 448 into a normally closed seated position that seals the outlet orifice 492 of the lower chamber 490 of the well 480, any downward pressure exerted on the valve stem 448 (such as sucking by the pump, downward fluid pressure, or gravity) merely keeps the valve stem 448 seated (absent downward movement of the plunger 441 as described below).
Turning now to FIG. 17, the embodiment of a bottle-tray interface is shown after the bottle 22 has been placed in the reservoir tray. When the bottle 22 is placed in the tray, at least a portion of one or more of the segmented ridges 134b of the cap 86b contacts the valve cover 433 thereby moving the plunger 441 downward in the direction shown in FIG. 17. The slots 434 between the segmented ridges 134b of the cap 86b have a width smaller than the diameter of the plunger 441 to insure movement of the plunger 441. When the plunger 441 moves downward, the upper arm 445 of the rocker 444 pivots the lower forked arm 447 in an upward direction thereby moving the valve stem 448 in the upward direction shown in FIG. 17. This unseats the valve stem 448 from the entry to the outlet orifice 492 as shown in FIG. 17. A cleanser flow path is then created from the bottle 22, through the cleanser conduit 428 of the piercing post 420, into the lower chamber 490 of the well 480, through the outlet orifice 492, and into the first tube 152 of the dispenser line 154 that extends to the inlet barb 156 of the pump 28 as described above. Delivery of the cleanser from the spray nozzle 202 then occurs using the mechanisms, circuits, and processes described above.
Still referring to FIG. 17, when the bottle 22 is placed in the tray, an air passage 460 is created between the bottle 22 and an inner surface 482 of the well 480. An air flow path is thereby created from the air passage 460, through the slots 434 (best shown in FIG. 19) between the segmented ridges 134b of the cap 86b, through the air hole 426 in the outer wall 421 of the piecing post 420, through the air vent path 425 of the piercing post 420, and into the bottle 22.
The arrangement of FIGS. 17-19 also provides a no-mess means of opening and inserting the bottle and also further inhibits uses of improper cleanser containers. It does this for several reasons. First, if a conventional bottle and cap were inserted into the tray, the piercing post 420 would not puncture a conventional cap lacking the weakened area. Even if the cap was removed so that the mouth was opened, the sprayer still would not operate because the valve actuator 440 is located radially inward of the place where a conventional thin-walled bottle mouth would normally extend so that the valve would not be opened. In addition, the floor 485 of the well may also include arcuate upwardly extending ribs (such as arcuate stand-offs 124 in FIG. 11) of a thickness or spaced inward sufficiently such that bottles with a narrower neck cannot contact the valve while a cap with narrow segmented ridges can contact the valve by way of thin, high segmented ridges. Also, while the cap 86b has conventional internal threads 136 at its upper end that mate with threads 138 on the mouth of the bottle, and it also has a ring of one-way ratchet teeth 140 that engage corresponding ratchet teeth 142 on the bottle as in FIG. 13. The ratchets allow the cap to be turned in a tightening direction but resist untightening rotation to prevent non-destructive removal of the cap and thus refilling of the bottle.
FIGS. 20-22 depict an embodiment of a modified cap and adapter that may be used with the present invention. A flat top cap 86c is provided for the bottle 22 and an adapter 500 is employed between the bottle cap 86c and tray 56 to bridge the action of loading the bottle into the tray and the opening of the discharge orifice. Other aspects of this embodiment are the same as those described in FIGS. 17-19 above. In this embodiment, bottle cap 86c has a generally flat transverse outer surface 130c with a recessed thinned area 132c at its center. Adapter 500 has a flat ring 502 with an opening in the middle and four segmented annular ridges 134c protruding from the ring 502. The ring 502 of the adapter 500 may have the same serrated periphery 506 as the bottle cap 86c and the outer circles of the adapter ring and the bottle cap, including the serrated peripheries, typically have the same diameter. When the bottle 22 is seated in the tray 56, piercing post 420 will go through the opening in the middle of the adapter 500 and puncture the cap 86c in the thinned area 132c to permit discharge of the cleanser and venting of the bottle. Meanwhile, the bottle cap 86c presses against the ring 502 of the adapter 500 so that at least a portion of one of the segmented ridges 134c, which is located to contact valve cover 443, pushes the valve actuator 440 downward to unseat valve stem 448 from outlet orifice 492 and open the outlet orifice 492.
FIG. 23 depicts a modified bottle cap and an adapter suitable for use with the dispenser of FIGS. 1-13. A flat top cap 86d and a cap liner or gasket 333 are provided with a bottle 22. Other aspects of this embodiment are the same as those described in FIGS. 1-16 above. In this embodiment, bottle cap 86d has a generally flat transverse outer surface 130d with a central hole 132d at its center. The cap liner 333, which may be any piercable material such as a soft closed cell polyethylene foam or foil, seals the opening of the bottle 22 and also seals the central hole 132d of the bottle cap 86d. In one version of the invention, the cap liner 333 is sealed to the bottle 22 by way of conventional methods such as ultrasonic welding, radio frequency welding or heat sealing. In another version of the invention, the cap liner 333 is positioned between the bottle 22 and the bottle cap 86d but is not attached to the bottle 22 or the bottle cap 86d. 
Still referring to FIG. 23, when the bottle 22 is seated in the tray 56 by movement in direction ‘D’, piercing post 98 will go through the opening in the middle of the adapter 300, through the central hole 132d of the bottle cap 86d, and puncture the cap liner 333 to permit discharge of the cleanser and venting of the bottle. The cap liner 333 can provide a compliant seal around the piercing post 98. This prevents leakage down the sides of the piercing post 98. Meanwhile, the bottle cap 86d presses against the ring 302 of the adapter 300 so that the ring 134a of the adapter 300, which is located to contact plunger 114, pushes the valve downward to unseat gasket 118 from valve plate 96 and open the discharge orifice.
FIG. 24 depicts a modified bottle cap and an adapter suitable for use with the dispenser of FIGS. 17-22. A flat top cap 86d and a cap liner or gasket 333 are provided with a bottle 22 as described in FIG. 23 above. Other aspects of this embodiment are the same as those described in FIGS. 17-22 above. In this embodiment, when the bottle 22 is seated in the tray 56 by movement in direction ‘E’, the piercing post 420 will go through the opening in the middle of the adapter 500, through the central hole 132d of the bottle cap 86d, and puncture the cap liner 333 to permit discharge of the cleanser and venting of the bottle. The cap liner 333 can provide a compliant seal around the piercing post 420. This prevents leakage down the sides of the piercing post 420. Meanwhile, the bottle cap 86d presses against the ring 502 of the adapter 500 so that at least a portion of one of the segmented ridges 134c, which is located to contact valve cover 443, pushes the valve actuator 440 downward to unseat valve stem 448 from outlet orifice 492 and open the outlet orifice 492.
FIG. 25 depicts another modified bottle cap and an adapter suitable for use with the dispenser of FIGS. 1-13. A cap closure 833 is provided with a bottle 22. Other aspects of this embodiment are the same as those described in FIGS. 1-16 above. The cap closure 833, which may be any piercable material such as a closed cell polyethylene foam or foil, seals the opening of the bottle 22. The cap closure 833 may be sealed to the bottle 22 by way of conventional methods such as ultrasonic welding, radio frequency welding or heat sealing. Optionally, the bottle 22 may be provided with a removable cap (similar to cap 86d with no central hole 132d) for shipping purposes. When the bottle 22 is seated in the tray 56 by movement in direction ‘F’, piercing post 98 will puncture the cap closure 833 to permit discharge of the cleanser and venting of the bottle. The cap closure 833 can provide a compliant seal around the piercing post 98. This prevents leakage down the sides of the piercing post 98. Meanwhile, the cap closure 833 presses against the ring 302 of the adapter 300 so that the ring 134a of the adapter 300, which is located to contact plunger 114, pushes the valve downward to unseat gasket 118 from valve plate 96 and open the discharge orifice.
FIG. 26 depicts a modified bottle cap and an adapter suitable for use with the dispenser of FIGS. 17-22. A cap closure 833 provided with a bottle 22 as described in FIG. 25 above. Other aspects of this embodiment are the same as those described in FIGS. 17-22 above. The cap closure 833, which may be any piercable material such as a closed cell polyethylene foam or foil, seals the opening of the bottle 22. Optionally, the bottle 22 may be provided with a removable cap (similar to cap 86d with no central hole 132d) for shipping purposes. In this embodiment, when the bottle 22 is seated in the tray 56 by movement in direction ‘G’, the piercing post 420 will puncture the cap closure 833 to permit discharge of the cleanser and venting of the bottle. The cap closure 833 can provide a compliant seal around the piercing post 420. This prevents leakage down the sides of the piercing post 420. Meanwhile, the cap closure 833 presses against the ring 502 of the adapter 500 so that at least a portion of one of the segmented ridges 134c, which is located to contact valve cover 443, pushes the valve actuator 440 downward to unseat valve stem 448 from outlet orifice 492 and open the outlet orifice 492.
What has been described with respect to FIGS. 1-13 also provides context for the use of another modified cap and adapter that may be used with the present invention as depicted in FIGS. 27 and 28. A flat top cap 86d is provided with a bottle 22. An adapter 800 is employed between the bottle cap and tray 56 to bridge the action of loading the bottle into the tray and the opening of the discharge orifice. Other aspects of this embodiment are the same as those described in FIGS. 1-13 and 23 above. In this FIG. 27 embodiment, bottle cap 86d has a generally flat transverse outer surface 130d with a hole 132d at its center. Adapter 800 is a flat annular ring with an opening in the middle and has a square or rectangular vertical cross-section. When the bottle 22 is seated in the tray 56 by movement in direction ‘I’, piercing post 98 will go through the opening in the middle of the adapter 800, through the central hole 132d of the bottle cap 86d, and puncture the cap liner 333 to permit discharge of the cleanser and venting of the bottle. The cap liner 333 can provide a compliant seal around the piercing post 98. This prevents leakage down the sides of the piercing post 98. Meanwhile, the bottle cap 86d presses against the adapter 800 so that the adapter 800, which is located to contact plunger 114, pushes the valve downward to unseat gasket 118 from valve plate 96 and open the discharge orifice. The adapter 800 rests on the floor of the well inward of the stand-offs 124. The vertical height of the adapter 800 is preferably greater than the height of the stand-offs 124 above the floor of the well 84. However, the vertical height of the adapter 800 must not be so great as to prevent the piercing post 98 from puncturing the cap liner 333 to permit discharge of the cleanser and venting of the bottle.
What has been described with respect to FIGS. 1-13 also provides context for the use of another modified cap and adapter that may be used with the present invention as depicted in FIGS. 27 and 29. A cap closure 833 is provided with a bottle 22. An adapter 800 is employed between the bottle cap and tray 56 to bridge the action of loading the bottle into the tray and the opening of the discharge orifice. Other aspects of this embodiment are the same as those described in FIGS. 1-13 and 25 above. The cap closure 833, which may be any piercable material such as a closed cell polyethylene foam or foil, seals the opening of the bottle 22. Optionally, the bottle 22 may be provided with a removable cap (similar to cap 86d with no central hole 132d) for shipping purposes. When the bottle 22 is seated in the tray 56 by movement in direction ‘J’, piercing post 98 will puncture the cap closure 833 to permit discharge of the cleanser and venting of the bottle. The cap closure 833 can provide a compliant seal around the piercing post 98. This prevents leakage down the sides of the piercing post 98. Meanwhile, the cap closure 833 presses against the adapter 800 so that the adapter 800, which is located to contact plunger 114, pushes the valve downward to unseat gasket 118 from valve plate 96 and open the discharge orifice. The adapter 800 rests on the floor of the well inward of the stand-offs 124. The vertical height of the adapter 800 is preferably greater than the height of the stand-offs 124 above the floor of the well 84. However, the vertical height of the adapter 800 must not be so great as to prevent the piercing post 98 from puncturing the cap closure 833 to permit discharge of the cleanser and venting of the bottle.
What has been described with respect to FIGS. 17-19 provides context for the use of another embodiment the present invention claimed herein. Turning now to FIG. 30, there is shown another bottle-tray interface according to the invention that may used to deliver cleanser from the bottle 22 to the tube 152 of the dispenser line 154 that extends to the inlet barb 156 of the pump 28 as described above. In FIG. 30, the cap 86 is as described above with references to FIGS. 8-11.
Referring still to FIG. 30, the embodiment of a bottle-tray interface is shown after the bottle 22 has been placed in the reservoir tray. The reservoir tray has a well 480 including a circular upper section 484 with a floor 485 and a circular lower chamber 490 extending downwardly from a portion of the floor 485. The circular upper section 484 of the well 480 has a downwardly extending vent nipple 90a. A spout 491 extends downwardly from the lower chamber 490 and defines an outlet orifice 492.
A circular piercing post 420a, which is formed as part of a valve plate 496, extends upwardly from the floor 485 of the circular upper section 484 of the well 480. Valve plate 496 is secured to the well 480 with screws as described above with reference to valve plate 96. The piercing post 420a has an outer wall 421a, and an inner wall 427a that defines an air vent path 425a and a cleanser conduit 428a in the piercing post 420a. The air vent path 425a extends from the top end of the piercing post 420a to the vent nipple 90a. The cleanser conduit 428a provides a fluid flow path to the lower chamber 490 of the well 480. Optionally, an air hole may pass through the outer wall 421a into the air vent path 425a, and an opening may pass through the outer wall 421a into the cleanser conduit 428a. The piercing post 420a terminates in an obliquely truncated upper end to facilitate puncturing the cap 86 in the thinned area 132 to permit discharge of the cleanser.
The lower chamber 490 of the well 480 contains a valve 438 that controls cleanser flow from the bottle 22 as will be described below. The valve 438 includes a valve actuator 440 and a valve stem 448. The valve actuator 440 includes a plunger 441, a valve cover 443 and a rocker 444. The plunger 441 is biased in the upward direction against the valve cover 443 by a spring 442 as shown in FIG. 18. The rocker 444 includes a pivot pin 446, an upper arm 445 and a lower forked arm 447. The forked arm 447 is seated in a groove 450 in the valve stem 448. A spring 449 biases the valve stem 448 against the entry to the outlet orifice 492 as shown by the arrow in FIG. 18. By spring-biasing the valve stem 448 into a normally closed seated position that seals the outlet orifice 492 of the lower chamber 490 of the well 480, any downward pressure exerted on the valve stem 448 (such as sucking by the pump, downward fluid pressure, or gravity) merely keeps the valve stem 448 seated (absent downward movement of the plunger 441 as described below).
Still referring to FIG. 30, the bottle-tray interface is shown after the bottle 22 has been placed in the reservoir tray. When the bottle 22 is placed in the tray, circular gasket 577 (which may be formed from suitable conventional gasket materials) provides a seal between the piercing post 420a and the surface 130 of the cap 86. This prevents leakage down the sides of the piercing post 420a. Also, when the bottle 22 is placed in the tray, raised ring surface 134 of the cap 86 contacts the valve cover 433 thereby moving the plunger 441 downward in the direction shown in FIG. 30. When the plunger 441 moves downward, the upper arm 445 of the rocker 444 pivots the lower forked arm 447 in an upward direction thereby moving the valve stem 448 in the upward direction shown in FIG. 30. This unseats the valve stem 448 from the entry to the outlet orifice 492 as shown in FIG. 30. A cleanser flow path is then created from the bottle 22, through the cleanser conduit 428a of the piercing post 420a, into the lower chamber 490 of the well 480, through the outlet orifice 492, and into the first tube 152 of the dispenser line 154 that extends to the inlet barb 156 of the pump 28 as described above. Delivery of the cleanser from the spray nozzle 202 then occurs using the mechanisms, circuits, and processes described above.
Still referring to FIG. 30, the short vent tube 144 described above with reference to FIGS. 2B-6 couples to the vent nipple 90a defining the vent orifice in the tray well. A small check valve 148 fits into the end of the vent tube 144 as described above. The check valve 148 is normally closed so that cleanser does not leak out via the air vent path 425a, the vent nipple 90a and the vent tube 144. The check valve 148 opens by negative pressure that develops as cleanser is withdrawn from the bottle via cleanser conduit 428a. The opened check valve 148 aspirates the air to the bottle through the vent tube 144, the vent nipple 90a and the air vent path 425a to allow the cleanser to flow from the bottle in a consistent manner, without introducing air in a manner that would cause foaming or gurgling. The check valve 148 remains open until the pressure in the bottle has equalized sufficiently to alleviate the negative pressure and then it closes.
FIG. 31 depicts a modified bottle cap 86e suitable for use with the dispenser of FIGS. 1-13 and 30. A bottle cap 86e and a cap liner or gasket 333 are provided with a bottle 22. Other aspects of this embodiment are the same as those described in FIGS. 1-16 above. The top of the bottle cap 86e has an outer surface 130e with a central hole 132e at its center around which is a raised ring surface 134e extending to a plane spaced from surface 130e. The central hole 132e is located so that as the bottle is seated in the tray the piercing post will go through this area to permit discharge of the cleanser and venting of the bottle. The raised ring 134e is located to contact the plunger of the valve and push the valve downward to unseat the gasket from the plate and open the discharge orifice.
Still referring to FIG. 31, the flat surface 130e of the cap rests on the stand-offs 124 to space the punctured area from the floor of the well. The cap liner 333, which may be any piercable material such as a closed cell polyethylene foam or foil, seals the opening of the bottle 22 and also seals the central hole 132e of the bottle cap 86e. In one version of the invention, the cap liner 333 is sealed to the bottle 22 by way of conventional methods such as ultrasonic welding, radio frequency welding or heat sealing. In another version of the invention, the cap liner 333 is positioned between the bottle 22 and the bottle cap 86e but is not attached to the bottle 22 or the bottle cap 86e. 
Still referring to FIG. 31, when the bottle 22 is seated in the tray 56 by movement in direction ‘R’, piercing post 98 will go through the central hole 132e of the bottle cap 86e, and puncture the cap liner 333 to permit discharge of the cleanser and venting of the bottle. The cap liner 333 can provide a compliant seal around the piercing post 98. This prevents leakage down the sides of the piercing post 98. Meanwhile, the raised ring 134e of the bottle cap 86e presses the contact plunger 114, pushes the valve downward to unseat gasket 118 from valve plate 96 and open the discharge orifice.
In order to facilitate movement of the piercing post 98 through the central hole 132e of the bottle cap 86e, the central hole 132e has a chamfered inner surface 133. In this configuration, the central hole 132e is frustoconical with a larger diameter near the surface 130e of the bottle cap 86e as shown in FIG. 31. Accordingly, the central hole 132e has a smaller diameter near the cap liner 333. The larger diameter near the surface 130e of the bottle cap 86e provides a guide means for ensuring that the piercing post 98 will go through the central hole 132e of the bottle cap 86e in the event that the piercing post 98 is off center with respect to the central hole 132e when the bottle 22 is being placed in the tray. This central hole configuration may be used with any bottle cap described herein.
FIG. 32 depicts another modified bottle cap 86f suitable for use with the dispenser of FIGS. 1-13 and 30. A bottle cap 86f and a cap liner or gasket 333 are provided with a bottle 22. Other aspects of this embodiment are the same as those described in FIGS. 1-16 above. The bottle cap 86f has a raised cylindrical inlet conduit 133f having a piercable area 132f at its center around which is a raised ring surface 134f extending to a plane spaced from surface 130f. The piercable area 132f is located so that as the bottle is seated in the tray the piercing post 98 will puncture the cap 96f in this area to permit discharge of the cleanser and venting of the bottle. The raised ring 134f is located to contact the plunger of the valve and push the valve downward to unseat the gasket from the plate and open the discharge orifice.
Still referring to FIG. 32, the flat surface 130f of the cap rests on the stand-offs 124 to space the punctured area from the floor of the well. The cap liner 333, which may be any piercable material such as a closed cell polyethylene foam or foil, seals the opening of the bottle 22 and also seals the cylindrical inlet conduit 133f of the bottle cap 86f. In one version of the invention, the cap liner 333 is sealed to the bottle 22 by way of conventional methods such as ultrasonic welding, radio frequency welding or heat sealing. In another version of the invention, the cap liner 333 is positioned between the bottle 22 and the bottle cap 86e but is not attached to the bottle 22 or the bottle cap 86f. 
Still referring to FIG. 32, when the bottle 22 is seated in the tray 56 by movement in direction ‘S’, piercing post 98 will puncture the piercable area 132f of the bottle cap 86f, and puncture the cap liner 333 to permit discharge of the cleanser and venting of the bottle. The cap liner 333 can provide a compliant seal around the piercing post 98. This prevents leakage down the sides of the piercing post 98. The cylindrical inlet conduit 133f is configured in a raised arrangement from the bottle cap surface 130f as described above in order to provide clearance for the chad 299 (drawn in phantom in FIG. 32) that may remain attached to the cylindrical inlet conduit 133f after puncturing the piercable area 132f. Meanwhile, the raised ring 134f of the bottle cap 86f presses the contact plunger 114, pushes the valve downward to unseat gasket 118 from valve plate 96 and open the discharge orifice.
FIG. 33 depicts another modified bottle cap 86g suitable for use with the dispenser of FIGS. 1-13 and 30. A bottle cap 86g and a cap liner or gasket 333a are provided with a bottle 22. Other aspects of this embodiment are the same as those described in FIGS. 1-16 above. The bottle cap 86g has a raised cylindrical inlet conduit 133g having a piercable area 132g at its center around which is a raised ring surface 134g extending to a plane spaced from surface 130g. The piercable area 132g is located so that as the bottle is seated in the tray the piercing post 98 will puncture the cap 96g in this area to permit discharge of the cleanser and venting of the bottle. The raised ring 134g is located to contact the plunger of the valve and push the valve downward to unseat the gasket from the plate and open the discharge orifice. The flat surface 130g of the cap rests on the stand-offs 124 to space the punctured area from the floor of the well.
Still referring to FIG. 33, the cap liner 333a, which may be any piercable material such as a closed cell polyethylene foam or foil, includes a central opening 399 spaced away from the cap liner surface 599 by frustoconical wall 499. In one version of the invention, the cap liner 333a is sealed to the bottle 22 by way of conventional methods such as ultrasonic welding, radio frequency welding or heat sealing. In another version of the invention, the cap liner 333a is positioned between the bottle 22 and the bottle cap 86g but is not attached to the bottle 22 or the bottle cap 86g. 
Still referring to FIG. 33, when the bottle 22 is seated in the tray 56 by movement in direction ‘T’, piercing post 98 will puncture the piercable area 132g of the bottle cap 86g, and go through the central opening 399 of the cap liner 333a to permit discharge of the cleanser and venting of the bottle. The cap liner 333a can provide a compliant seal around the piercing post 98. This prevents leakage down the sides of the piercing post 98. The cylindrical inlet conduit 133g is configured in a raised arrangement from the bottle cap surface 130g as described above in order to provide clearance for the chad 299a (drawn in phantom in FIG. 33) that may remain attached to the cylindrical inlet conduit 133g after puncturing the piercable area 132g. Meanwhile, the raised ring 134g of the bottle cap 86g presses the contact plunger 114, pushes the valve downward to unseat gasket 118 from valve plate 96 and open the discharge orifice.
Turning now to FIG. 34A, there is shown an alternative valve plate 496a suitable for use with the invention of FIG. 30. The valve plate 496a includes a circular piercing post 511a (which extends upwardly from the floor 485 of the circular upper section 484 of the well 480 when installed in the well 480 in the manner shown in FIG. 30). The valve plate 496a is secured to the well 480 with screws as described above with reference to valve plate 96. In particular, mounting holes 515a are provided to accept screws that attach the valve plate 496a to the well 480 as shown in FIG. 30 and described above with reference to screws 97 in FIG. 3. Access hole 517a is also provided to accept plunger 441 and valve cover 443 as shown in FIG. 30. The piercing post 511a has an outer wall 521a, and an inner wall 527a that defines an air vent path 525a and a cleanser conduit 528a in the piercing post 511a. The air vent path 525a extends from the top end of the piercing post 511a to the vent nipple 90a which is shown in FIG. 30. The cleanser conduit 528a provides a fluid flow path to the lower chamber 490 of the well 480 as shown in FIG. 30.
Still referring to FIG. 34A, the cleanser conduit 528a terminates at an opening 541a of the piercing post 511a, and the air vent path 525a terminates at another opening 543a of the piercing post 511a. The opening 543a of the air vent path 525a is at a position above the opening 541a of the cleanser conduit 528a. In particular, the outer wall 521a of the piercing post 511a is lower at the side of the piercing post 511a nearest the cleanser conduit 528a. Because of this arrangement, the opening 543a of the air vent path 525a is at a position further into the bottle than the opening 541a of the cleanser conduit 528a when the bottle is installed in the inverted orientation in the tray. As a result, the mixing of the air flow from the air vent path 525a into the liquid cleanser flow in the cleanser conduit 528a is controlled to avoid levels of mixing of the air flow into the liquid flow that prevents appropriate dispensing of the liquid cleanser. In other words, the short circuiting of vent air into the liquid flow is reduced.
Turning now to FIG. 34B, there is shown an alternative valve plate 496b suitable for use with the invention of FIG. 30. The valve plate 496b includes a circular piercing post 511b (which extends upwardly from the floor 485 of the circular upper section 484 of the well 480 when installed in the well 480 in the manner shown in FIG. 30). The valve plate 496b is secured to the well 480 with screws as described above with reference to valve plate 96. In particular, mounting holes 515b are provided to accept screws that attach the valve plate 496b to the well 480 as shown in FIG. 30 and described above with reference to screws 97 in FIG. 3. Access hole 517b is also provided to accept plunger 441 and valve cover 443 as shown in FIG. 30. The piercing post 511b has an outer wall 521b, and an inner wall 527b that defines an air vent path 525b and a cleanser conduit 528b in the piercing post 511b. The air vent path 525b extends from the top end of the piercing post 511b to the vent nipple 90a which is shown in FIG. 30. The cleanser conduit 528b provides a fluid flow path to the lower chamber 490 of the well 480 as shown in FIG. 30.
Referring still to FIG. 34B, the cleanser conduit 528b terminates at an opening 541b of the piercing post 511b, and the air vent path 525b terminates at another opening 543b of the piercing post 511b. The opening 543b of the air vent path 525b is at a position above the opening 541b of the cleanser conduit 528b. Also, the opening 541b of the cleanser conduit 528b extends into the outer wall 521b of the piercing post 511b at the side of the piercing post 511b nearest the cleanser conduit 528b. Because of this arrangement, the opening 543b of the air vent path 525b is at a position further into the bottle than the opening 541b of the cleanser conduit 528b when the bottle is installed in the inverted orientation in the tray. As a result, the mixing of the air flow from the air vent path 525b into the liquid cleanser flow in the cleanser conduit 528b is controlled to avoid levels of mixing of the air flow into the liquid flow that prevents appropriate dispensing of the liquid cleanser. In other words, the short circuiting of vent air into the liquid flow is reduced.
Turning now to FIG. 34C, there is shown an alternative valve plate 496c suitable for use with the invention of FIG. 30. The valve plate 496c includes a circular piercing post 511c (which extends upwardly from the floor 485 of the circular upper section 484 of the well 480 when installed in the well 480 in the manner shown in FIG. 30). The valve plate 496c is secured to the well 480 with screws as described above with reference to valve plate 96. In particular, mounting holes 515c are provided to accept screws that attach the valve plate 496c to the well 480 as shown in FIG. 30 and described above with reference to screws 97 in FIG. 3. Access hole 517c is also provided to accept plunger 441 and valve cover 443 as shown in FIG. 30. The piercing post 511c has an outer wall 521c, and an inner wall 527c that defines an air vent path 525c and a cleanser conduit 528c in the piercing post 511c. The air vent path 525c extends from the top end of the piercing post 511c to the vent nipple 90a which is shown in FIG. 30. The cleanser conduit 528c provides a fluid flow path to the lower chamber 490 of the well 480 as shown in FIG. 30.
Still referring to FIG. 34C, the cleanser conduit 528c terminates at an opening 541c of the piercing post 511c, and the air vent path 525c terminates at another opening 543c of the piercing post 511c. The opening 543c of the air vent path 525c is at a position above the opening 541c of the cleanser conduit 528c. Also, the opening 541c of the cleanser conduit 528c extends into the outer wall 521c of the piercing post 511c at the side of the piercing post 511c nearest the cleanser conduit 528c. Furthermore, the inner wall 527c in the piercing post 511c extends outward from the piercing post 511c between the opening 543c of the air vent path 525c and the opening 541c of the cleanser conduit 528c. Because of this arrangement, the opening 543c of the air vent path 525c is at a position further into the bottle than the opening 541c of the cleanser conduit 528c when the bottle is installed in the inverted orientation in the tray. As a result, the mixing of the air flow from the air vent path 525c into the liquid cleanser flow in the cleanser conduit 528c is controlled to avoid levels of mixing of the air flow into the liquid flow that prevents appropriate dispensing of the liquid cleanser. Also, the extended inner wall 527c in the piercing post 511c between the opening 543c of the air vent path 525c and the opening 541c of the cleanser conduit 528c further serves to block the mixing of the air flow into the liquid cleanser flow. In other words, the short circuiting of vent air into the liquid flow is reduced.
Turning now to FIG. 34D, there is shown an alternative valve plate 496d suitable for use with the invention of FIG. 30. The valve plate 496d includes a circular piercing post 511d (which extends upwardly from the floor 485 of the circular upper section 484 of the well 480 when installed in the well 480 in the manner shown in FIG. 30). The valve plate 496d is secured to the well 480 with screws as described above with reference to valve plate 96. In particular, mounting holes 515d are provided to accept screws that attach the valve plate 496d to the well 480 as shown in FIG. 30 and described above with reference to screws 97 in FIG. 3. Access hole 517d is also provided to accept plunger 441 and valve cover 443 as shown in FIG. 30. The piercing post 511d has an outer wall 521d, and an inner wall 527d that defines an air vent path 525d and a cleanser conduit 528d in the piercing post 511d. The air vent path 525d extends from the top end of the piercing post 511d to the vent nipple 90a which is shown in FIG. 30. The cleanser conduit 528d provides a fluid flow path to the lower chamber 490 of the well 480 as shown in FIG. 30.
Referring still to FIG. 34D, the cleanser conduit 528d terminates at an opening 541d of the piercing post 511d, and the air vent path 525d terminates at another opening 543d of the piercing post 511d. The opening 543d of the air vent path 525d is at a position above the opening 541d of the cleanser conduit 528d when the bottle is installed in the inverted orientation in the tray as described above. Also, the opening 541d of the cleanser conduit 528d extends into the outer wall 521d of the piercing post 511d at the side of the piercing post 511d nearest the cleanser conduit 528d. Because of this arrangement, the opening 543d of the air vent path 525d is at a position further into the bottle than the opening 541d of the cleanser conduit 528d when the bottle is installed in the inverted orientation in the tray. As a result, the mixing of the air flow from the air vent path 525d into the liquid cleanser flow in the cleanser conduit 528d is controlled to avoid levels of mixing of the air flow into the liquid flow that prevents appropriate dispensing of the liquid cleanser. In other words, the short circuiting of vent air into the liquid flow is reduced.
Turning now to FIG. 34E, there is shown an alternative valve plate 496e suitable for use with the invention of FIG. 30. The valve plate 496e includes a circular piercing post 51e (which extends upwardly from the floor 485 of the circular upper section 484 of the well 480 when installed in the well 480 in the manner shown in FIG. 30). The valve plate 496e is secured to the well 480 with screws as described above with reference to valve plate 96. In particular, mounting holes 515e are provided to accept screws that attach the valve plate 496e to the well 480 as shown in FIG. 30 and described above with reference to screws 97 in FIG. 3. Access hole 517e is also provided to accept plunger 441 and valve cover 443 as shown in FIG. 30. The piercing post 511e has an outer wall 521e, and an inner wall 527e that defines an air vent path 525e and a cleanser conduit 528e in the piercing post 511e. The air vent path 525e extends from the top end of the piercing post 511e to the vent nipple 90a which is shown in FIG. 30. The cleanser conduit 528e provides a fluid flow path to the lower chamber 490 of the well 480 as shown in FIG. 30.
Still referring to FIG. 34E, the cleanser conduit 528e terminates at an opening 541e of the piercing post 511e, and the air vent path 525e terminates at another opening 543e of the piercing post 511e. The opening 543e of the air vent path 525e is at a position above the opening 541e of the cleanser conduit 528e. Also, the opening 541e of the cleanser conduit 528e extends into the outer wall 521e of the piercing post 511e at the side of the piercing post 511e nearest the cleanser conduit 528e. Furthermore, the inner wall 527e in the piercing post 511e extends outward from the piercing post 511e between the opening 543e of the air vent path 525e and the opening 541e of the cleanser conduit 528e. The inner wall 527e terminates in a curved chisel top. Because of this arrangement, the opening 543e of the air vent path 525e is at a position further into the bottle than the opening 541e of the cleanser conduit 528e when the bottle is installed in the inverted orientation in the tray. As a result, the mixing of the air flow from the air vent path 525e into the liquid cleanser flow in the cleanser conduit 528e is controlled to avoid levels of mixing of the air flow into the liquid flow that prevents appropriate dispensing of the liquid cleanser. Also, the extended inner wall 527e in the piercing post 511e between the opening 543e of the air vent path 525e and the opening 541e of the cleanser conduit 528e further serves to block the mixing of the air flow into the liquid cleanser flow. In other words, the short circuiting of vent air into the liquid flow is reduced.
The invention thus provides an automated dispenser that can accept inverted bottles of cleaning fluid and can deliver the fluid from the bottle with improved fluid flow characteristics. In particular, the invention provides for improved air venting of the inverted bottle (by way of, among other things, the air vent path in the piercing post, the slots in the segmented ridges of the cap, and the air passage created between the bottle and an inner surface of the well) and provides for improved control of delivery of cleaning fluid from the dispenser (by way of, among other things, the cleanser conduit in the piercing post and the valve).
It should also be noted that the inventive aspects of the invention could be used to dispense a cleaning or disinfecting solution in applications other than a tub/shower surround. In this regard, U.S. Pat. No. 4,183,105 depicts how one type of automated cleansing equipment could be installed to clean the bowl. The inventors envision an embodiment of their invention designed to mount to the underside of a toilet bowl cover with the supply cleaning fluid being delivered from a reservoir near the tank, and the chemical being sprayed in the bowl. Such a structure should be considered to be an “enclosure” for purposes of this application.
Preferred embodiments of the invention have been described in considerable detail above. Many modifications and variations to the preferred embodiments will be apparent to those skilled in the art, which will be within the spirit and scope of the invention. Therefore, the invention should not be limited to the described embodiments. To ascertain the full scope of the invention, reference should be made to the following claims.
INDUSTRIAL APPLICABILITY
The invention provides a sprayer for automatically spraying the walls of bath and shower enclosures and the like.

## Claims

1. An automated sprayer for spraying an enclosure with a liquid cleanser, the sprayer comprising:
a bottle suitable to contain a liquid cleanser,
a reservoir tray having an upwardly extending well for supporting the bottle in an inverted orientation;
a spray head having an outlet orifice through which cleanser from the bottle can be expelled if there is such liquid cleanser in the bottle;
a dispenser line in fluid communication with the well and the spray head;
a piercing post extending from the reservoir tray into the bottle at the cap, the piercing post including a cleanser conduit in fluid communication with the well for delivering cleanser to the well, the piercing post further including an air vent path separate from the cleanser conduit, the piercing post only being operable with the bottle, wherein the cleanser conduit terminates at a first opening of the piercing post, and the air vent path terminates at a second opening of the piercing post; and
a valve for controlling outflow of cleanser from the well, the valve being located downstream of the piercing post.

2. The sprayer of claim 1 wherein: the air vent path is in fluid communication with a vent outlet of the well.

3. The sprayer of claim 2 wherein: the vent outlet of the well is in fluid communication with a check valve such that cleanser does not leak out via the vent outlet of the well.

4. The sprayer of claim 1 wherein an inner wall of the piercing post is located between the air vent path and the cleanser conduit.

5. The sprayer of claim 1 wherein a wall extends outward from the piercing post between the opening of the air vent path and the opening of the cleanser conduit.

6. The sprayer of claim 1 further comprising: a gasket, wherein the gasket is configured to seal against the piercing post when the bottle is installed in the inverted orientation in the tray.

7. The sprayer of claim 1 wherein: the enclosure is a toilet bowl.

8. The sprayer of claim 1 wherein: the spray head is a rotating spray head.

9. The sprayer of claim 1 further comprising: a pump for moving cleanser through the dispenser line from the well to the spray head.

10. The sprayer of claim 9 further comprising: timing circuitry for controlling operation of the pump.

11. An automated sprayer for spraying an enclosure with a liquid cleanser, the sprayer being of the type that receives a bottle containing the liquid cleanser, the sprayer comprising:
a reservoir tray having an upwardly extending well suitable for supporting a bottle in an inverted orientation when the bottle is inserted in the tray;
a spray head having an outlet orifice through which cleanser from the bottle can be expelled if there is such liquid cleanser in the bottle;
a dispenser line in fluid communication with the well and the spray head;
a piercing post extending from the reservoir tray into the bottle when the bottle is inserted in the tray, the piercing post including a cleanser conduit in fluid communication with the well for delivering cleanser to the well, the piercing post further including an air vent path separate from the cleanser conduit, wherein the cleanser conduit terminates at a first opening of the piercing post, and the air vent path terminates at a second opening of the piercing post, the piercing post only being operable with the compatible bottle; and
a valve for controlling outflow of cleanser from the well, the valve being located downstream of the piercing post.

12. The sprayer of claim 11 wherein: the air vent path is in fluid communication with a vent outlet of the well.

13. The sprayer of claim 12 wherein: the vent outlet of the well is in fluid communication with a check valve such that cleanser does not leak out via the vent outlet of the well.

14. The sprayer of claim 11 wherein an inner wall of the piercing post is located between the air vent path and the cleanser conduit.

15. The sprayer of claim 11 wherein a wall extends outward from the piercing post between the opening of the air vent path and the opening of the cleanser conduit.

16. The sprayer of claim 11 wherein: the spray head is a rotating spray head.

17. The sprayer of claim 11 further comprising: a pump for moving cleanser through the dispenser line from the well to the spray head.

18. The sprayer of claim 17 further comprising: timing circuitry for controlling operation of the pump.