Patent Publication Number: US-11659965-B2

Title: Bulk refill protection sensor for dispensing system

Description:
RELATED APPLICATIONS 
     This application is a continuation of U.S. Ser. No. 15/211,582, which will issue as U.S. Pat. No. 11,058,261 on Jul. 13, 2021 and is titled BULK REFILL PROTECTION SENSOR FOR DISPENSING SYSTEM, and which is incorporated herein by reference in its entirety. This application also claims priority to and the benefits of U.S. Provisional Application Ser. No. 62/192,835, filed on Jul. 15, 2015 and titled BULK REFILL PROTECTION SENSOR FOR DISPENSING SYSTEM, and which is also incorporated herein by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     The present invention relates generally to liquid dispenser systems, such as liquid soap and sanitizer dispensers and bulk refill units. 
     BACKGROUND OF THE INVENTION 
     Liquid dispensing systems, such as liquid soap and sanitizer dispensers, provide a user with a predetermined amount of liquid or foam upon actuation of the dispenser. Liquid dispensing systems typically have a container for holding dispensable liquid. The container is typically sealed to prevent contaminants from entering the dispensing system, thereby maintaining the system in a sanitary condition. To maintain the sanitary condition of the system, empty containers are disposed of and new containers are installed in the dispenser. The system may become contaminated, however, if the seal of the container is breached, for example, to refill the container with liquid rather than installing a new, sealed, container. In some refillable systems, bulk refill units are used to fill one or more refillable sensors. However, such systems may be prone to growing bacteria in either the bulk refill or the refillable dispenser if the bulk refill is not maintained in a sanitary condition, which may occur if someone attempts to refill the sealed bulk refill. 
     SUMMARY 
     Exemplary embodiments of liquid dispensing systems are disclosed herein. 
     In one exemplary embodiment, a dispensing system includes a container for holding fluid, a fluid pump for pumping fluid from the container, and an outlet nozzle. An actuator is included that causes the dispenser to dispense fluid. A sensor monitors the integrity of the container. A controller receives a signal from the sensor and generates at least one output signal. The at least one output signal includes a breach signal that is indicative of a breach in the integrity of the container. 
     In another exemplary embodiment, a dispensing system includes a dispenser having a refill unit and a housing with a receptacle for receiving the refill unit. The refill unit includes a container for holding fluid. An actuator causes the dispenser to dispense fluid from the container. The dispensing system also includes a sensor and a controller. The sensor generates an input signal indicative of the integrity of the container of the refill unit. The controller receives the signal from the sensor and generates at least one output signal indicating whether or not the integrity of the container has been breached. 
     An exemplary method for controlling a dispensing system comprises receiving an instruction to dispense fluid, receiving an input signal from a sensor for monitoring the integrity of a container, dispensing fluid if the input signal from the sensor indicates that the container has not been breached, and not dispensing fluid if the input signal from the sensor indicates that the container has been breached. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other features and advantages of the present invention will become better understood with regard to the following description and accompanying drawings in which: 
         FIG.  1    is a schematic diagram of an exemplary dispensing system; 
         FIG.  2    is a block diagram illustrating the steps of an exemplary method for controlling a dispensing system; and 
         FIG.  3    is a schematic diagram of an exemplary bulk refill unit for a dispensing system. 
     
    
    
     DETAILED DESCRIPTION 
     “Circuit communication” as used herein indicates a communicative relationship between devices. Direct electrical, electromagnetic and optical connections and indirect electrical, electromagnetic and optical connections are examples of circuit communication. Two devices are in circuit communication if a signal from one is received by the other, regardless of whether the signal is modified by some other device. For example, two devices separated by one or more of the following—amplifiers, filters, transformers, optoisolators, digital or analog buffers, analog integrators, other electronic circuitry, fiber optic transceivers or satellites—are in circuit communication if a signal from one is communicated to the other, even though the signal is modified by the intermediate device(s). As another example, an electromagnetic sensor is in circuit communication with a signal if it receives electromagnetic radiation from the signal. As a final example, two devices not directly connected to each other, but both interfacing with a third device, such as, for example, a CPU, are in circuit communication. 
     Also, voltages and values representing digitized voltages are considered to be equivalent for the purposes of this application, and thus the term “voltage” as used herein refers to either a signal, or a value in a processor representing a signal, or a value in a processor determined from a value representing a signal. 
     “Signal,” as used herein includes, but is not limited to one or more electrical signals, analog or digital signals, one or more computer instructions, a bit or bit stream, or the like. 
     “Logic,” synonymous with “circuit” includes, but is not limited to hardware, firmware, software and/or combinations of each to perform a function(s) or an action(s). For example, based on a desired application or needs, logic may include a software controlled microprocessor or microcontroller, discrete logic, such as an application specific integrated circuit (ASIC) or other programmed logic device. Logic may also be fully embodied as software. The circuits identified and described herein may have many different configurations to perform the desired functions. 
     Values identified in the detailed description are exemplary and they are determined as needed for a particular system. Accordingly, the inventive concepts disclosed and claimed herein are not limited to the particular values or ranges of values used to describe the embodiments disclosed herein. 
       FIG.  1    illustrates an exemplary embodiment of a foam dispensing system  100 . The foam dispensing system  100  includes a housing  102 , a container  110 , a foam pump  120  comprising a liquid pump  130  and an air pump  132 , a liquid pump actuator  140 , an air pump actuator  144 , a controller  150 , and a sensor  152 . Although a foam dispensing system is shown and describe, the system may be a liquid dispensing system that dispenses liquid in the form of a liquid, i.e. without adding air to create a foam. The foam dispensing system  100  may be a wall-mounted system, a counter-mounted system, an un-mounted portable system movable from place to place, or any other kind of dispenser system. As used herein, actuator or actuating members or mechanism includes one or more parts that cause the dispensing system  100  to move liquid, air or foam. 
     The container  110  forms a liquid reservoir that contains a supply of dispensable liquid  112 . In various embodiments, the contained liquid could be for example a soap, sanitizer, a cleanser, a disinfectant, a foamable liquid, or some other dispensable liquid. The container  110  may advantageously be refillable, replaceable or both refillable and replaceable. In the exemplary dispensing system  100 , the container  110  is a non-collapsible container and can be made of thin plastic. A non-collapsing container usually includes a vent (not shown) to vent the container. In other embodiments, the container  110  may be a collapsible container made of a thinner plastic than its non-collapsible counterpart, or a flexible bag-like material. 
     An optional housing  102  of the dispensing system  100  may contain all components of the system, or may enclose only some components of the system  100 . For example, the container  110  may be outside of the housing  102  so that it is exposed to ambient light and is visible to the user. In some other embodiments, multiple housings may enclose various combinations of components of the system  100 . The container  110  may be located separate from the dispenser housing  102 , and may, for example, rest on the floor. 
     In various embodiments, the dispensing system  100  includes a disposable refill unit  101  that includes the container  110 . In some embodiments, the refill unit  110  includes the foam pump  120 . Although the embodiments disclosed herein show and describe a foam pump, other embodiments include liquid pumps without the air pumps or foam cartridge. In the event the liquid stored in the container  110  of the installed disposable refill unit  101  runs out, or the installed refill unit  101  otherwise has a failure, the installed refill unit  101  may be removed from the dispenser  100 . The empty or failed disposable refill unit  101  may then be replaced with a new disposable refill unit  101 . The refill unit  110  may be secured within the dispenser  100  by any means, such as, for example, a quarter turn connection, a threaded connection, a flange and fastener connection, a clamped connection, or any other reusable connection. 
     The liquid pump  130  and air pump  132  of the foam pump  120  are shown in  FIG.  1    as separate pumps, with the liquid pump  130  being inside a pump housing  121  while the air pump  132  is disposed outside the pump housing  121 . The concept of having a foam pump that has a liquid pump portion separable from an air pump portion may be referred to as a “split pump”. In a split pump configuration, one of the liquid pump  130  and air pump  132  may be included in the refill unit  101  while the other pump is attached to the housing  102  of the dispensing system  100 . 
     The foam pump  120  combines foamable liquid  112  from the container  110  and air from the atmosphere in a premix chamber  122 . The liquid pump  130  pumps foamable liquid  112  from the container  110  through a liquid inlet  114  into the premix chamber  122 . Simultaneously, the air pump  132  pumps air through an air inlet  134  into the premix chamber  122 . The air and liquid mixture in the premix chamber  122  flows through the foaming media  124  disposed in the outlet nozzle  126  to be dispensed as rich foam through an aperture  104  in a bottom plate  103  of the housing  102 . Foaming media  124  may include screens, porous members, sponges, baffles, or the like. 
     The liquid pump actuator  140  includes an actuation member  142  that engages and actuates the liquid pump  130 . The air pump actuator  144  includes an actuation member  146  that engages and actuates the air pump  132 . In various embodiments, a single actuator may be used to actuate both the liquid pump  130  and air pump  132 . Electronic actuators may additionally include a sensor (not shown) to provide for a hands-free dispenser system with touchless operation 
     Liquid pump  130 , air pump  132 , and liquid and air actuators  140 ,  144  are generically illustrated because there are many different kinds of these components which may be employed in dispensing system  100 . The liquid pump  130  may be any kind of pump, such as, for example, a diaphragm pump, a piston pump, a peristaltic pump, or the like. The air pump  132  may be any type of air pump, such as a rotary pump, a piston pump, a fan pump, a turbine pump, a pancake pump, a diaphragm pump, or the like. The actuators  140 ,  144  of the dispensing  100  may be any type of actuator, such as a manual lever, a manual pull bar, a manual push bar, a manual rotatable crank, an electrically activated actuator or other means for actuating liquid pump  130  and air pump  132 . 
     The controller  150  may be any kind of electronic component, such as a processor, configured to receive an input signal from the sensor  152 . In some embodiments, the controller  150  generates at least one output signal. In the illustrated embodiment, the output signal is sent to the actuators  140 ,  144 . In other embodiments, an output signal (not shown) may be sent to a valve (not shown), an electromechanical latch, or other means of preventing the dispenser from actuating or dispensing liquid or foam. The controller  150 , sensor  152 , and actuators  140 ,  144  are shown hard wired with input signal wires  154  and output signal wires  156 , though these components may be connected by any means of transmitting a signal, such as, for example, by one or more busses, printed circuits, Wi-Fi, Bluetooth, NFC, or other means of wireless communication. The controller  150  is shown in  FIG.  1    inside of the housing  102 , but the controller  150  may be disposed remotely from the foam pump  120  and container  110 . The controller  150  and sensor  152  may be battery powered or may be wired into the electrical system of a building. 
     The sensor  152  senses one or more parameters associated with the integrity of the container  110 . The integrity of the container  110  is breached if the container  110  is opened, cut, ruptured, etc. so that fluid may be added to the container  110 . In an exemplary embodiment, the sensor  152  is a photodiode that measures the amount of light transmitted through a light transmitting portion  116  of the container  110 . In some embodiments, the container  110 , other than the light transmitting portion  116 , is opaque to prevent the transmission of light. If the container  110  is cut, ruptured, or breached in some way an increase in light will be detected by the sensor  152 . Though the sensor  152  is shown attached to a side of the container  110 , in other embodiments the sensor  152  may be inserted inside the container (not shown) so that no window  116  is necessary and the sensor is able to view the interior of the container  110  directly. In still other embodiments, a light pipe may be used between the container  110  and the sensor  152  so that the sensor  152  can be placed in a location that is remote from the container  110 . The light pipe may interface with the container  110  at the wall of the container  110  through a window  116 , or in a coupling of the container (not shown) or otherwise so that the sensor  152  may detect an increase in light level. The light detected by the sensor  152  may be ambient light or may be generated by a light source (not shown) configured to shine on the exterior of the container  110 . This configuration allows a breach in the container  110  to be detected when there is not enough ambient light to detect a breach. 
     During operation of the dispensing system  100 , the controller  150  determines if the container  110  has been breached before dispensing any foam to the user. Breaches are detected as described above by the sensor  152 . The sensor  152  transmits a signal to the controller  150 . When no breach in the container  110  is detected by the sensor  152 , the controller  150  allows foam to be dispensed from the dispensing system  100 . In some embodiments, when a breach in the container  100  is detected, the controller  150  prevents the dispensing system  100  from dispensing foam by any means, such as, for example, closing a liquid valve (not shown) disposed before or after the liquid pump  130 , preventing the actuators  140 ,  144  from actuating either by physically preventing actuation or not powering electrical actuators, or the like. Additionally, the controller  150  may illuminate an LED (not shown) on the exterior of the dispenser system  100  to notify a user that the container  110  has been breached and the system is potentially in an unsanitary condition. The controller  150  may even transmit a notification signal over a computer network to inform a remote user or administrator of a breach in the container  110 . 
     In some embodiments, the controller  150  monitors the sensor  152  to detect an increase in light above a set threshold. The threshold allows some light to pass into the container  110  without indicating a breach. In addition, the sensor  152  may be set to detect certain light wavelengths that are associated with a breach. In an embodiment including a light source, the light source may be set to transmit the wavelengths of light that the sensor  152  is set to detect. In some embodiments, a lens may be used to concentrate light from within the container  110  on the sensor  152 . 
       FIG.  2    illustrates a exemplary embodiment of a simple methodology  200  for preventing contamination of a dispenser system due to a breach in a container. The methodology begins with receiving an instruction to dispense fluid at block  202 . An input signal is received from a sensor at block  204 . At block  206  a determination is made as to whether there was a breach in the integrity of the container. If there has been a breach the system does nothing at block  208  and no fluid is dispensed. If there has not been a breach in the integrity of the container, fluid is dispensed at block  210 . 
       FIG.  3    illustrates an exemplary embodiment of a bulk refill system  300 . The bulk refill system  300  includes a bulk refill container  310 , an outlet  312 , a valve  314 , a nozzle  316 , sensor  320  and a refill controller  324 . In some embodiments, the system includes one or more dispenser  380 . The dispenser  380  includes a dispenser controller  382 . In some exemplary embodiments, the dispenser includes an inlet port  390 , an inlet valve  391  and a dispenser controller  382 . 
     Bulk refill container  310  forms a liquid reservoir that contains a supply of dispensable liquid. In various embodiments, the contained liquid could be for example a soap, sanitizer, a cleanser, a disinfectant, a foamable liquid, or some other dispensable liquid. The container may include a vent (not shown) to vent the container. 
     Refill controller  342  includes a processor  350  and memory  352 . In some embodiments, refill controller  324  includes a transceiver  354  for communicating with a dispenser controller  382  and/or a central station (not shown). 
     Refill controller  324  is configured to receive an input signal from the sensor  320 . Refill controller  320  is also configured to provide an output signal to actuate valve  314 . Valve  314  may be any type of valve capable of operating in response to a signal from refill controller  324 , such as, for example, a solenoid valve, and eclectically operated ball valve, or the like. 
     The refill controller  324 , sensor  320 , and valve  314  are shown hard wired however, these components may be connected by any means of transmitting a signal, such as, for example, by one or more busses, printed circuits, Wi-Fi, Bluetooth, NFC, or other means of wireless communication. Refill controller  324  and sensor  320  may be battery powered or may be wired into the electrical system of a building. 
     The sensor  320  senses one or more parameters associated with the integrity of the container  310 . The integrity of the container  310  is breached if the container  310  is opened, cut, ruptured, etc. so that fluid may be added to the container  310 . In some embodiment sensor  320  continuously monitors the integrity of bulk refill container  310 . In some embodiment, the monitoring is intermittent. In some embodiments, monitoring of the container is based on another condition, such as for example, motion, vibration, noise, shock, or the like. 
     In an exemplary embodiment, the sensor  320  is a photodiode that measures the amount of light transmitted through a light transmitting portion  321  of the container  310 . In some embodiments, the bulk refill container  310 , other than the light transmitting portion  321 , is opaque to prevent the transmission of light. If the bulk refill container  310  is cut, ruptured, or breached in some way an increase in light will be detected by the sensor  321 . Though the sensor  320  is shown attached to a side of the bulk refill container  310 , in other embodiments the sensor  321  may be inserted inside the container (not shown) so that no window  321  is necessary and the sensor is able to view the interior of the container  310  directly. In still other embodiments, a light pipe may be used between the bulk refill container  310  and the sensor  321  so that the sensor  321  can be placed in a location that is remote from the bulk refill container  310 . The light pipe may interface with the bulk refill container  310  at the wall of the container  310  through a window  321 , or in a coupling of the container (not shown) or otherwise so that the sensor  321  may detect an increase in light level. The light detected by the sensor  320  may be ambient light or may be generated by a light source (not shown) configured to shine on the exterior of the bulk refill container  321 . This configuration allows a breach in the bulk refill container  310  to be detected when there is not enough ambient light to detect a breach. Sensor  320 , the controller for valve  314 , memory  352 , transceiver  354  are in circuit communication with one another. 
     During operation of the bulk refill system  300 , the refill controller  324  determines if the bulk refill container  310  has been breached before transmitting a signal that causes valve  314  to open. In some embodiments, additional requirements are included before valve  314  is caused to open, such as to, for example, insuring that outlet nozzle  316  is inserted in an inlet  390  of a dispenser system. Breaches are detected as described above by the sensor  321 . The sensor  321  transmits a signal to the controller  324 . When no breach in the container  310  is detected by the sensor  321 , the controller  324  allows liquid to be dispensed from the bulk refill system  300 . Additionally, the controller  324  may illuminate an LED (not shown) to notify a user that the container  310  has been breached and the system is potentially in an unsanitary condition. The controller  324  may even transmit a notification signal over a computer network to inform a remote user or administrator of a breach in the container  310 . 
     In some embodiments, the controller  324  monitors the sensor  320  to detect an increase in light above a set threshold. The threshold allows some light to pass into the container  310  without indicating a breach. In addition, the sensor  321  may be set to detect certain light wavelengths that are associated with a breach. In an embodiment including a light source, the light source may be set to transmit the wavelengths of light that the sensor  320  is set to detect. In some embodiments, a lens may be used to concentrate light from within the container  310  on the sensor  321 . 
     In some embodiments bulk refill system  300  includes one or more dispensers  380 . Dispensers  380  include a valve  391 , outlet nozzle  390  and dispenser controller  382 . Dispenser controller  382  includes a processor  384 , memory  388  and in some embodiments, transceiver  394 . Processor  384 , controller for valve  391 , memory  388 , transceiver  386  are in circuit communication with one another. 
     In some embodiments, refill controller  324  transmits a signal  392  to dispenser controller  382 . In some embodiments, signal  392  is a signal indicating that there has been no breach in the integrity of container  310 . In some embodiments, signal  392  includes an information indicative of the identity of the bulk refill container  310 . In some embodiments, if there has not been a breach in container  310 , dispenser controller  382  will send a signal to open valve  391  and allow fluid to flow in from outlet nozzle  316  of bulk refill container  310 . 
     While the present invention has been illustrated by the description of embodiments thereof, and while the embodiments have been described in considerable detail, it is not the intention of the applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Moreover, elements described with one embodiment may be readily adapted for use with other embodiments. Therefore, the invention, in its broader aspects, is not limited to the specific details, the representative apparatus and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicants&#39; general inventive concept.