Abstract:
A fluid dispensing system, fluid reservoir, refill container for refilling the fluid reservoir, and method of refilling the fluid reservoir are provided. The fluid dispensing system includes a refill connection port or nozzle to which a refill container is connected when refilling the fluid reservoir. The fluid reservoir includes a piston head and an actuator for moving the piston head in a first direction and in a second direction. When the piston head is moved in the first direction, the fluid within the fluid reservoir is pressurized, causing the fluid to be dispensed through an outlet of the fluid reservoir. When the piston head is moved in the second direction, a vacuum is created within the fluid reservoir that draws fluid, from the refill container, into the fluid reservoir. The fluid dispensing system includes a valve to enable multiple refill containers to be coupled to the nozzle and/or the refill connection port.

Description:
RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Application 61/912,052, titled “PRODUCT DISPENSING SYSTEM” and filed on Dec. 5, 2013, which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The current invention relates generally to sanitary bulk soap dispensers and in particular to dispensing systems having multiple refill reservoirs and air-tight refill connections. 
     BACKGROUND OF THE INVENTION 
     It is commonplace for publicly accessible facilities to provide soap dispensers in washrooms and other areas. Many dispensers have reservoirs that are open to the atmosphere. Such reservoirs are easily and inexpensively refilled from bulk soap stored in bottles or jugs. However, studies have shown that over time soap containers open to the atmosphere generate unsanitary bio-films. Soap used from these containers actually deposits germs onto the hands of the user during use. Even after cleaning the reservoir, remediation studies have determined that bio-films regenerate despite using strong oxidizers like bleach. 
     To overcome the detriments of open top dispensers, the reservoir in some dispensers is not refilled when the system is replenished. These systems are designed to receive disposable refill units produced in a sanitary environment. When empty of product, the whole reservoir is replaced along with the accompanying nozzle and pump. In this way, every part wetted by soap is disposed of when the dispenser is replenished. This greatly reduces and/or eliminates the germination of bio-films. However, determining how much soap is remaining in the reservoir, and when to replace it, can be difficult. If the reservoir is replaced before it is empty, then product is wasted. If the dispenser runs out of soap, then users are unable to clean their hands. 
     What is needed is a way of conveniently replenishing soap reservoirs without exposing the reservoir or the product to ambient air and without interrupting service or running out of product. The embodiments of the invention described herein obviate the aforementioned problems. 
     SUMMARY OF THE INVENTION 
     In one embodiment of the subject invention, a fluid product dispensing system is provided that includes multiple reservoirs for holding fluid product, in which the storage and delivery system is sealed from exposure to ambient air. The system may be replenished from a sealed sanitary refill container connected to a port fluidly connected to the dispensing system. When one of the multiple reservoirs is empty, the dispensing system is operable to automatically dispense product from another reservoir. 
     In one particular embodiment, the port for refilling the dispensing system is mounted to a fixture, along with a separately mounted nozzle used to dispense product. 
     In another embodiment of the dispensing system, the dispensing system is refilled through the dispensing nozzle. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  depicts a fluid dispensing system according to the embodiments of the subject invention. 
         FIG. 2  is a cross sectional view of a fixture of the dispensing system according to the embodiments of the subject invention. 
         FIG. 3  is a cross sectional view of the fixture of the dispensing system shown in  FIG. 2  attached to a refill unit, according to the embodiments of the subject invention. 
         FIG. 4  is a partial cross sectional view of the fixture depicted in  FIG. 2 , along with control system circuitry and a schematic representation of a control valve of the fluid dispensing system, according to the embodiments of the subject invention. 
         FIG. 5  is cross sectional view depicting multiple reservoirs of the fluid dispensing system, according to the embodiments of the subject invention. 
         FIG. 6  is a cross sectional view of another embodiment of the fixture of the dispensing system and a refill unit, according to the embodiments of the subject invention. 
         FIG. 7  is a front elevation view of a wall mounted dispenser, according to yet another embodiment of the subject invention. 
         FIG. 8  is a perspective view of a wall mounted dispenser showing multiple reservoirs of the fluid dispensing system depicted in  FIG. 7 . 
     
    
    
     DETAILED DESCRIPTION 
     A product dispensing system, depicted in  FIG. 1 , dispenses a measured amount of fluid product according to the embodiments of the subject invention. In one exemplary instance, the dispensing system, shown generally at  10 , dispenses hand care products like soap, lotion or sanitizers, although other types of products may similarly be dispensed from the dispensing system. 
     In the embodiment depicted in  FIGS. 1 and 2 , the dispensing system  10  includes a generally rigid fixture  14  having a product dispensing nozzle  16  received in an end  17  thereof. The fixture  14  may be mounted to a supporting structure  12 , like for example a countertop  13 , and positioned adjacent a source of clean water and a sink  15 . It is noted that the fixture  14  may be mounted to other types of supporting structures, like a wall or dispenser stand, discussed further below. In one embodiment, fixture  14  has a faucet-like configuration including a base  19  for mounting it to the supporting structure  12  and an outwardly extending cantilevered arm  22 . The nozzle  16  is positioned at the distal end of the arm  22 . Conduits  27  in the fixture  14  are fluidly connected to a source of product, i.e. reservoir  60 , that is designed to be replenished by way of the fixture  14 . 
     Internally the fixture  14  may be at least partially hollow comprising one or more generally concave parts that fasten together to form a fixture assembly. One or more fluid conduits  27  may be received in the hollow interior for protection against damage from direct contact. As such, the fixture  14  may be constructed from impact resistance plastic or corrosion resistant metal. Fasteners or other means of affixing the concave parts together, not shown, may be chosen with sound engineering judgment. Alternative embodiments are contemplated where the fixture  14  may be generally solid formed as a single piece; having fluid channels molded or machined directly therein. These and other fixture configurations are to be construed as falling within the scope of coverage of the embodiments described herein. 
     The one or more conduits  27  in the fixture  14  function both: to channel product to the nozzle  16  and to refill the reservoir  60 . In one particular embodiment, two fluid conduits  27   a ,  27   b  are provided. The first fluid conduit  27   a  is connected at a first end to the nozzle  16  as mentioned above. The distal end of fluid conduit  27   a  terminates at a manifold (reference  FIG. 3 ), which may comprise a selectively engage-able valve  50 , to be discussed further below. The second fluid conduit  27   b  similarly connects at one end to the manifold, but terminates at a refill connection port  25  mounted onto the fixture  14 . 
     With reference to  FIGS. 2 and 3 , the refill connection port  25  provides a fluid tight inlet for connecting to a soap refill container  31 . When not in use, the connection port  25  may be closed off from exposure to the atmosphere. In one embodiment, the connection port  25  comprises a quick connect fitting. In this way, fluid flow through the connection port  25  is established only when the mating connector  37  from the soap refill container  31  is connected to it. Alternatively, the connection port  25  may be sealed by a cap secured via threads, not shown in the figures. Still any type of connection port  25  may be used that eliminates or substantially prevents exposure to the air. 
     The soap refill container  31  stores a predetermined quantity of fluid product in a reservoir area  32 . In one particular embodiment, the volume in the reservoir area  32  may be substantially equivalent to the storage capacity of one of the dispensing system reservoirs  60 . In this way, no product is left over or wasted when the dispensing system  10  is refilled. However, other volumes of refill storage area  32  may be used without limiting the scope of coverage of the embodiments described herein. 
     The refill container  31 , referred to as refill bag  31   a , may be constructed from pliable plastic material. In this way, as material flows out of the bag  31   a , the walls of the container will collapse making it easy to dispose of once emptied of product. An outlet connection fitting  33  may be incorporated into the refill bag  31   a . The fitting  33  may be affixed to an aperture formed in the bag  31   a  via any process known in the art, as long as a fluid tight seal is ensured. A hose  35  may extend from the outlet fitting  33 . A second connection fitting  37  may be affixed to the hose  35  at its distal end for establishing fluid flow with the connection port  25 . It follows that the second connection fitting  37  may also be a quick connect fitting that mates with the connection port  25 . However, any type of fittings may be used as is necessary to provide a connection that does not expose the fluid product to the air. 
     With continue reference to  FIG. 3 , a validation key or tag may be implemented between refill container  31  and dispensing system  10  for validating the contents of the refill container  31 . In one particular embodiment, connection fitting  37  includes an electronic key  40 . The key  40  may comprise a RFID (Radio Frequency Identification) tag, which may be either passive or active. A corresponding interrogator  42  may be positioned proximal to the connection port  25 . Accordingly, when the connection fitting  37  is brought near or installed onto the connection port  25 , the interrogator  42  will automatically “ping” the electronic key  40  to verify that the correct refill container is being used. If the incorrect refill container is connected to the dispensing system  10 , the control system will not initiate the refilling sequence. Depending on the range, i.e. strength, of the RFID signals, it is contemplated that the interrogator  42  may be mounted onto a circuit board located in the system controller or elsewhere in the dispensing system  10 . Skilled artisans will appreciate that other forms of tagging, i.e. verification, may be used, like for example keyed mechanical fittings or optical sensor systems. Still, any manner of ensuring that the dispensing system  10  works only with the proper refill container  31  may be chosen as is consistent for use with the embodiments of the subject invention. 
     With reference now to  FIGS. 4 and 5 , conduits  27  are connected to a valve, shown schematically at  50 . The valve  50  functions to direct fluid to and from multiple fluid storage reservoirs  60 , shown in  FIG. 5 . While the valve  50  is schematically depicted as a solenoid activated directional valve, it is to be construed that any type of valve mechanism may be used that switches fluid flow to the nozzle  16  from between the multiple reservoirs  60 . In the current embodiment, the dispensing system  10  employs two reservoirs  60   a ,  60   b . However, persons of skill in the art will recognize the application to three or more fluid storage reservoirs. It is noted that multiple reservoirs function to provide a constant supply of fluid product. Stated differently, the inclusion of multiple reservoirs means that one reservoir supplies fluid product while the other reservoir remains available for serviced, i.e. to be refilled with product. 
     From the aforementioned description and the accompanying figures, it can be seen that, in one state, valve  50  establishes a fluid pathway from the output of reservoir  60   a  to the nozzle  16 . At the same time, valve  50  also establishes a fluid pathway between the connection port  25  and the second reservoir  60   b . When reservoir  60   a  has been emptied of fluid product, the control system  70  will shift valve  50  to the second state, i.e. second position, whereby fluid reservoir  60   b  will be fluidly connected to the nozzle  16  and reservoir  60   a  will be in fluid communication with connection port  25 . 
     With continue reference to  FIG. 5 , each of the fluid reservoirs  60  may comprise a generally elongate and cylindrical canister  61 , although any geometric configuration may be selected with good judgment. Canister  61  defines a fluid tight, internal region having a volume V. In the current embodiment, each of the respective canisters  61  have the same volume V, but canisters having different volumes may be employed as well. By way of example, volume V may range from 100 milliliters up to several liters of fluid product. However, canisters  61  having a broader range of volumes may also be used. 
     Each canister  61  may include a piston head  63 . The piston head  63  is constructed having an outer diameter, or other geometric configuration as may be the case, that closely matches the inner diameter of the canister  61 . Grooves  64  may be formed on the perimeter of the piston head  63  for receiving sealing material  65 , like for example an O-ring. However, it is noted that certain fluid products may inherently possess a viscosity that does not require the use of O-rings or any sealing material to be used between the piston head  63  and canister wall. In any instance, it will be appreciated that the whole dispensing system  10  is sealed from exposure to ambient air. 
     The canisters  61  include an outlet  66 . The outlet  66  may reside at one end of the canister  61 ; preferably the top. Tubes  67  may extend from the outlet  66  to respective ports of the valve  50 . Of course, tubes  67  are connected to their respective inlet and outlet in a fluid tight manner so as to prevent exposure to the atmosphere. Any manner of connecting the tubes  67  may be chosen including but not limited sealed connection fittings. 
     Still referencing  FIG. 5 , to expel fluid product from the reservoirs  60 , i.e. canisters  61 , each respective piston head  63  is connected to an actuator  80 . While  FIG. 5  depicts two different actuators  80 , i.e. one for each canister, it does so only for illustrative purposes. Ideally, dispensing system  10  will use the same type of actuator  80  in both (or all) reservoirs  60 . Examples of actuators include, but are not limited to: pneumatic pressure and vacuum sources, mechanical ballscrews, electric motors or coil springs. Still, other types of actuators may be used to displace the piston head  63 . 
     The actuator  80  is generally capable of driving the piston in first and second directions. That is to say that the actuator  80  is functional both to push the piston head  63  in the direction of the outlet  66 , and to draw the piston head  63  away from the outlet  66 . Skilled artisans will immediately understand that driving the piston head  63  in the direction of the outlet  66  will pressurize the product in the canister  61 . It follows that incremental advancement of the piston head  63  results in metered dispensing of the fluid product. When actuated in the opposite direction, the piston head  63  will conversely create a vacuum. In one embodiment, engaging the actuator  80  to move the piston head  63  away from the outlet  66  is used to automatically refill the canister  61  with product, as explained below. 
     With reference again to  FIG. 4 , dispensing system  10  includes a control system  70  comprising one or more electronic circuits  71  for controlling the sequence of operation of the dispensing system  10 . The electronic circuitry  71  may reside on a printed circuit board and received in a suitable enclosure, not shown. An electrical power supply, also not shown, may be provided to power the electronic circuits  71 . In one embodiment, electrical power for the control system  70  may comprise mains power supplied from the facility in which the dispensing system  10  is installed. Alternatively, onboard power may be provided in the form of one or more batteries, also not shown. 
     The electronic circuitry  71  of the control system  70  may comprise digital electronic circuitry  72  designed to receive and process data relating to operation of the dispensing system  10 . In particular, the digital electronic circuitry  72  functions to receive input signals from the electronic validation key and onboard sensors  90 . Such circuitry may utilize analog-to-digital converters. In one embodiment, the digital electronic circuitry  72  may comprise one or more logic processors  73 , which may be programmable. Accordingly, circuitry  72  may further include electronic data storage  75  or memory  75 . 
     The digital electronic circuitry  72  also functions to output signals used to control operation of the dispensing system  10 , like for example operation of the valve  50  and activation of the actuators  80 , which may include one or more electric motors  82 . The output signals may therefore comprise low voltage DC signals and/or AC signals. Whatever the configuration, persons of skill in the art will understand the use and implementation of a wide array of circuitry as may be necessary for controlling operation of the dispensing system  10 . 
     With reference again to  FIG. 5 , sensors  90  may be incorporated into the reservoirs  60  for determining the amount of fluid product remaining in each canister  61 . The types of sensors used may include: limit switches, pressure sensors, encoders, or non-contact proximity sensors, like for example Hall-effect sensors. However, persons of skill in the art will understand that other types of sensors may be used. In determining how much fluid is remaining in the reservoirs  60 , the sensors  90  may be configured to directly sense the presence or absence of fluid. Alternatively, the sensors  90  may be configured to detect the location of the piston head  63  and subsequently correlate position of the piston head to the amount of product remaining in the canisters  61 . In still another embodiment, sensors may detect how much product remains by detecting activation or position of the actuators  80 . These and other methods are to be construed as falling within the scope of coverage of the embodiments described herein. 
     In one particular embodiment, sensors  91  may also be incorporated into the fixture  14 . These sensors  91  are used to detect motion for hands-free activation of the dispensing system  10 . The sensors  91  may comprise one or more IR emitters and detectors. The emitter-detector pairs may be oriented in any manner to ensure consistent activation in a particular region under the nozzle  16 . 
     With reference again to  FIGS. 1 through 5 , one embodiment of operating the dispensing system  10  will now be described. Upon initial activation or reset of the control system  70 , a default reservoir (for discussion purposes fluid reservoir  60   a ) may be predetermined, i.e. programmed, from which to begin dispensing fluid product. When the dispensing system  10  is activated by the user, via sensors  91 , the control system  70  will check to see if there is product in the canister  61   a  by reading the output of sensor  90   a . If fluid product is present, the control system  70  will output a signal to actuator  80   a  to drive piston head  63   a  forward for dispensing a metered amount of fluid product. As long as sensor  90   a  continues to indicate that fluid product is present, control system  70  will engage actuator  80   a  with every activation of the sensors  91 . When the signal from sensor  90   a  indicates that the canister  61   a  is empty, the control system  70  will then begin drawing fluid product from reservoir  60   b  by shifting the valve  50  to its alternate state. Additionally, control system  70  will output a signal to turn on an indicator for signaling to service personnel that maintenance is required. In one embodiment, the indicator may be an indicator light  94  positioned on the fixture  14 . Alternatively, the indicator may be audible in nature. Moreover, the indicator may be a wireless signal sent to a network monitored by service personnel. Still, any manner of signaling that the dispensing system  10  requires service may be chosen. 
     During the refill cycle, service personnel may attach the connection fitting  37  from a refill container  31  to the connection port  25  of the fixture  14 . The control system  70  will check the signal received by the interrogator  42  to ensure that the correct refill unit has been installed. Upon verification, the control system  10  will output a signal to the actuator of the canister that is signaling “empty.” The actuator will then draw the piston head away from the outlet  66  creating a vacuum that refills the canister. 
     With reference now to  FIG. 6 , an alternate embodiment of the dispensing system  10  is illustrated. In this embodiment, the dispensing system  10  uses the nozzle  16  both to dispense product and to refill the reservoirs  60 . Accordingly, the fixture  14  contains a single conduit  27   a . When it is required to refill the reservoirs, the connection fitting  37  of the refill container  31  is connected to the nozzle  16 . The interrogator  42  similarly verifies that a proper refill container  31  is being used. In this instance, it may be necessary to cycle valve  50  so that the fluid pathway is connected to the appropriate reservoir  60 , namely the reservoir empty of product. Subsequently, the control system  70  engages the appropriate actuator  80  to create a vacuum thereby drawing fluid product into the reservoir. After the refill cycle has been completed, the control system  70  will switch valve  50  back to its previous state so that fluid product may continue to be dispensed from the other reservoir. 
     In the current embodiment, the connection fitting  37  may be configured with a bleed port  38 . To ensure that no fluid product that has been exposed to ambient air is drawn back into the reservoirs  60 , a purge cycle may be programmed into the control system  70 . During the purge cycle, the control system  70  may drive the appropriate actuator  80  forward to bleed out fluid product residing at the nozzle  16  that may have been exposed to the air. It follows that when the fitting  37  is connected to the nozzle  16 , fluid product will flow through the bleed port  38 . Subsequently, the control system  70  will automatically engage the actuator in the opposite direction to draw fluid from the refill container  31  into the empty reservoir. Skilled artisans will comprehend that the connection fitting  37  may be designed to include one or more valves, which may be a check valves  39 , to prevent leakage of fluid product through the bleed port  38  during the refill process. 
     Referencing  FIGS. 7 and 8 , the aforementioned embodiments have been directed to a counter mounted dispensing system. In these embodiments, the fixture and reservoir are separately mounted. However, alternate embodiments are contemplated where the components of the dispensing system  10  are contained in a single enclosure  11 . In one particular embodiment, reservoirs  60   a ,  60   b , valve  50 , control system  70  and nozzle  16  are all contained in a single enclosure  11 . As illustrated by the figures, the enclosure  11  may be a wall mounted enclosure. The multiple reservoirs received within the enclosure may function in the same manner as that described above. Refilling of the dispensing system  10  may be accomplished through the nozzle  16 , or alternatively by way of a separately provided connection port, not shown in  FIGS. 7 and 8 . 
     Having illustrated and described the principles of the multi-reservoir dispensing system in one or more embodiments, it should be readily apparent to those skilled in the art that the invention can be modified in arrangement and detail without departing from such principles.