Patent Publication Number: US-8991649-B2

Title: Keyed dispensing systems and related methods

Description:
TECHNICAL FIELD 
     The present invention is generally directed to dispensing systems. In particular, the present invention is directed to keyed dispensers which allow only designated refill containers with dispensable material to be installed therein and, if desired, installed by selected distributors. More specifically, the present invention is directed to electronically keyed fluid dispensing systems. 
     BACKGROUND ART 
     It is well known to provide fluid dispensers for use in restaurants, factories, hospitals, bathrooms and the home. These dispensers may contain fluids such as soap, anti-bacterial cleansers, disinfectants, lotions and the like. It is also known to provide dispensers with some type of pump actuation mechanism wherein the user pushes or pulls a lever to dispense a quantity of fluid into the user&#39;s hands. “Hands-free” dispensers may also be utilized wherein the user simply places their hand underneath a sensor and a quantity of fluid is dispensed. Related types of dispensers may be used to dispense powder or aerosol materials. 
     Dispensers may directly hold a quantity of fluid, but these have been found to be messy and difficult to service. As such, it is known to use refill bags or containers that hold a quantity of fluid and provide a pump and nozzle mechanism. These refill bags are advantageous in that they are easily installed into a dispenser without a mess. And the dispenser can monitor usage to indicate when the refill bag is low and provide other dispenser status information. 
     Manufacturers of these fluid materials enlist distributors to install the dispensers at various locations and place the manufacturer&#39;s products in the dispensers. Further, the manufacturers rely on the distributors to put the correct refill container in the dispenser housing. For example, it would be very upsetting to hospital personnel to have hand moisturizing lotion dispensed when they instead desire anti-bacterial soap. Therefore, manufacturers provide keyed nozzle and pump mechanisms for each type of fluid refill bag so that only appropriate refill bags are installed in corresponding fluid dispensers. 
     Distributors prefer such a keying system so that their dispensers can only be refilled by them instead of their competitors. Replacement of refill containers by unauthorized distributors is sometimes referred to as “stuffing.” In addition to providing keying between the dispenser and the fluid refill bag to ensure the compatibility of the product with the dispenser, keying is used to ensure that competitors of the distributor do not obtain the distributor&#39;s business. And it is also critical to the manufacturer that competitors do not stuff their product into the manufacturer&#39;s dispensers. Such activity prevents the manufacturer from obtaining an adequate financial return on the dispensers which are typically sold at cost or less. 
     Although mechanical keys are helpful in ensuring that the proper refill bag is installed into the proper dispenser and that the distributors maintain their business clientele, these keying systems have been found to be lacking. For example, if a distributor&#39;s competitor cannot install their refill packages into the distributor&#39;s dispenser device, the competitor may remove or alter the keying mechanism. As such, inferior fluid may be installed into a particular dispenser and the preferred distributor will lose sales. Mechanical keying also necessitates significant tooling costs underwritten by the manufacturer to design special nozzles and dispensers that are compatible with one another. In other words, each dispenser must be keyed for a particular product, a particular distributor and perhaps even a particular location. Accordingly, the inventory costs for maintaining refill bags with a particular key is significant. And the lead time for manufacturing such a refill bag may be quite lengthy. Moreover, the particular identification of a particular keying device may be lost or damaged so that it is difficult to determine which type of keying configuration is needed for the refill bags. 
     One attempt at controlling the type of product associated with a dispenser is disclosed in U.S. Pat. No. 6,431,400 B1. This patent discloses a refill bag that utilizes a wafer with an embedded magnet that must be properly oriented into a housing in order for the magnet to be detected and effectively close an on/off switch. If the magnet is not detected then the dispenser is disabled. Although effective in its&#39; stated purpose, the device disclosed in the patent is lacking in that a specific orientation is required for installation of the refill container. The patent also discloses the use of a spiral coil on a printed circuit wafer on the bag which is inductively coupled to a similar spiral coil on the housing&#39;s base supporting surface. A capacitor connected to the spiral coil on the bag establishes a resonant frequency for a conventional frequency-measuring circuit to provide identification. It is believed that this scheme is lacking in that it provides no teaching for adaptability for use with multiple dispensers. It is also believed that the disclosed configuration is subject to a mis-alignment of the coils which may lead to mis-identification of the bag. And the use of a single coil as the emitting and receiving coils may lead to mis-identification of the bag. 
     Another approach to the “stuffing” problem is to provide a wire coil wrapped around a neck of a refill container, wherein a capacitor is attached to the coil to serve as an identifier key. The dispensing system that receives the refill container includes a pair of similar sized spaced apart wire coils connected to a controller which maintains a matching key. The controller energizes the first coil which in turn generates a signal detected by the refill container&#39;s coil. Together the connected coil and capacitor generate a signal detected by the other coil connected to the controller. The controller then compares the detected signal to the matching key. If there is a match, then the dispenser is enabled. If there is not a match, then the dispenser is disabled. Although this approach is effective, the wire coils must be specially manufactured and are costly. Another drawback is the added power requirements to energize the first coil and detect output of the container&#39;s coil with the other coil. Finally, this configuration is unable to provide information related to a position of the refill container&#39;s pumping mechanism during a dispensing event. 
     Therefore, there is a need in the art for a dispensing system that utilizes low cost components so as to provide electronic keying to prevent “stuffing.” And there is a need to inexpensively provide a stroke position of the pumping mechanism as part of the electronic keying while utilizing minimal power. 
     SUMMARY OF THE INVENTION 
     In view of the foregoing it is a first aspect of the present invention to provide keyed dispensing systems and related methods. 
     Another aspect of the present invention is to provide a refill container for receipt in a dispensing system, the container comprising an enclosure for carrying dispensable material, a pump mechanism coupled to the enclosure and movable from a first position to a second position and back to the first position, and an identifier carried by the pump mechanism and movable between the first and second positions. 
     Still another aspect of the present invention is to provide a dispensing system comprising a housing, a refill container carrying a dispensable material and received in the housing, a pump mechanism coupled to the refill container and movable from a first position to a second position and back to the first position, an identifier carried by either the refill container or the pump mechanism, and a detection device carried by the housing, the detection device monitoring a status of the identifier and allowing operation of the pump mechanism based on a status change of the identifier. 
     Yet another aspect of the present invention is to provide a method for operating a keyed fluid dispenser, comprising installing a refill container with an identifier into a housing, detecting the presence and validity of the identifier with a detection device and setting a count value, deactivating the identifier with the detection device, and disabling an actuating mechanism if the identifier is not present or the count value is reached. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a complete understanding of the objects, techniques and structure of the invention, reference should be made to the following detailed description and accompanying drawings, wherein: 
         FIG. 1  is a schematic diagram of a keyed fluid dispenser made in accordance with the concepts of the present invention; 
         FIG. 1A  is a schematic diagram of an alternative embodiment used in the keyed fluid dispenser according to the concepts of the present invention; 
         FIG. 2  is a schematic diagram of an alternative keyed fluid dispenser made in accordance with the concepts of the present invention; and 
         FIG. 3  is an operational flow chart utilized by the alternative keyed fluid dispenser in accordance with the concepts of the present invention. 
     
    
    
     BEST MODE FOR CARRYING OUT THE INVENTION 
     Referring now to the drawings and in particular to  FIG. 1  it can be seen that a fluid dispenser made in accordance with the concepts of the present invention is designated generally by the numeral  10 . The concepts of the present invention may be directed to either a touch-free or hands-free dispenser, or a hand-actuated manual dispenser. Moreover, skilled artisans will appreciate that the present invention may also be utilized in any dispensing device which is battery operated or uses power from a source or conventional mains power to power at least one electrical component. In any event, the dispenser  10  includes a housing  12  which provides a cover or door  13  that when open allows a technician to install or replace a refill container  14 . The container  14 , includes a cartridge, a bag, or an enclosure  15  which contains a fluid material such as a soap, a sanitizer or other material that is dispensed in measured amounts. Associated with the refill container  14  is a nozzle  16  which is a conduit from the enclosure  15  to an object receiving the fluid such as a user&#39;s hands or any other object upon which the fluid is dispensed. As used herein, the term “user” refers to a person or object detected by the dispenser so as to initiate a dispensing cycle. In other words, in hands-free embodiments, the dispenser detects the presence of a user or an object in close proximity to where the fluid material is dispensed and the dispenser determines that the user or object intends to receive the fluid. It will further be appreciated that a user may be a single person, or object who actuates the dispenser once or repeatedly, or multiple users or objects that are detected, one after the other. As such, a “second” user may in fact be the first user. In any event, the dispenser  10  includes a pump mechanism  18  which is interposed between the container  14  and the nozzle  16 . The mechanism  18  is coupled to an actuating mechanism  20  which may be a motorized mechanism or solenoid that actuates the pump mechanism, or a manually-actuated push bar lever. 
     A proximity sensor  21  may be associated with the housing  12  and may be in the form of an infrared, sonic (ultrasonic and subsonic), or capacitive type sensor which detects the presence of an object or the user&#39;s hands for use in a hands-free embodiment. In some embodiments, an ambient light sensor  22  and/or a motion detection sensor  23  are carried by the housing  12 . These sensors can be used to assist in the operation and control of the dispenser. 
     A controller  24  is carried by the housing and is connected to the proximity sensor  21 , the ambient light sensor  22 , the motion detector  23 , the actuating mechanism  20  and in some embodiments, the pump mechanism  18 . A power source  26  provides electrical power to the sensors  21 ,  22  and  23  via the controller  24 ; the controller  24 ; the pump mechanism  18  if required; and the actuating mechanism  20 . The power source  26  includes one or more batteries, which may be referred to as cells throughout the specification. The batteries used for the power source may be recharged by solar cells or by other means. 
     In some embodiments, the controller  24  may also be connected to an indicator  27  and a wireless communication device  28 . Both the indicator  27  and the device  28  may be powered by the power source  26  directly through the controller  24 . The indicator  27  may be used to visually, audibly or otherwise convey to the user or maintenance staff a status of the dispenser  10  and in particular a status of selected components within the dispenser. The status may also be transmitted by the controller  24  through the wireless communication device  28  to a network that monitors the dispenser, to another dispenser in a mesh network made up of other dispensers and/or appliances, or to a remote indicator. 
     The pump mechanism  18  includes a collar  30  that is secured in a standard fashion to an opening provided by the enclosure  15 . As such, the collar  30  is fixed to the enclosure  15 . The pump mechanism  18  further includes a movable plunger  32  that is carried by the collar  30 . Extending from the plunger  32  is the nozzle  16  which may be a separate component or included as part of the plunger  32 . A spring  32  is coupled to the plunger  32  and biases the plunger to a closed position. In other words, the spring  34  forcibly keeps the plunger  32  in a closed position so as to prevent fluid from exiting through the nozzle. The actuating mechanism  20  is configured so as to be coupled to the plunger  32  and exerts a force to overcome the biasing forces of the spring  34  and move the plunger into an open position and allow for the dispensing of fluid from the enclosure  15 . 
     The plunger  32  carries an identifier designated generally by the numeral  36 . The identifier  36  moves with the plunger whenever actuated by the actuating mechanism  20  and returns as the plunger  32  returns when the spring bias forces of the spring  34  overcome the actuating mechanism forces or when the actuating forces are released. In the present embodiment, the identifier  36  may comprise a medium such as a ferrite bead or beads, a magnet, an optically reflective substance, a tank circuit or the like. In one embodiment a single ferrite bead  38  is utilized and maintained within the plunger  32  and the bead is configured so as to not come in contact with any of the fluid material maintained by the enclosure. The identifier  36  may be modified such that different types and/or amounts of ferrite material are part of the ferrite bead or beads. For example, two smaller ferrite beads of one ferrite material may provide the same signal response as a single bead of a different ferrite material that is not necessarily the same equivalent size as the two smaller beads. In another embodiment, an identifier  36 ′ is in the form of a tank circuit as shown in  FIG. 1A . The identifier—tank circuit  36 ′ includes a coil  39  with a capacitor  40  connected in parallel across the coil  39 . As with the ferrite bead/beads embodiment, no power is supplied directly to the tank circuit. The tank circuit resonates when placed in a time-variant electromagnetic field, and resonated with a much higher voltage (an oscillating current between the two components) as the frequency of the electromagnetic field gets closer to the resonant frequency of the tank circuit. 
     A detection device  44  is placed in proximity to the plunger  32  and typically carried by the collar  30 . The detection device  44  is connected to the controller  24  and is configured so as to read or observe the position of the identifier  36 . In the present embodiment the detection device is an air coil connected to the controller wherein movement of the ferrite bead  38  or other medium is detected by the air coil and this detection of position and/or change of position is communicated to the controller  24 . For the embodiment that uses the tank circuit, the position of the identifier  36 ′ can be determined by keeping the electromagnetic field of the detection device—air coil—at a constant frequency and measuring the voltage across the detection device which is emitting the electromagnetic energy. As the coil in the tank circuit gets closer to the middle of the encompassing air coil, the coil  39  absorbs more energy, resulting in a lower voltage across the air coil. This change in the voltage value is detected by the controller  24  which adjusts operation of the mechanism  20  accordingly. 
     In operation, the identifier  36  is placed on or otherwise carried by the plunger  32  which is maintained inside or within the air coil or detection device  44 . The controller  24  excites or energizes the air coil  44  at a constant frequency, such as two kHz, and the output detected by the coil is rectified and the associated voltage level is measured by the controller. When an identifier such as a ferrite material is present, an inductance value of the air coil is changed such that a corresponding detected voltage level changes. In other words, as the ferrite material changes position inside the cavity formed by the detector coil  44  the magnetic permeability of the core of the coil changes, which in turn, changes the inductance of the coil. Likewise, the resonance of the detector coil changes as its inductance changes, and this change is detected and measured by the controller. If more ferrite material, such as multiple beads  38  are added, the detected voltage level changes proportionally to the number of ferrite beads in the field generated by the air coil. As the ferrite material, bead or beads  38  move within the pump mechanism  18  during the dispensing cycle, the voltage level changes depending on the instantaneous position of the ferrite bead in the field generated by the coil, thus providing position information as well. Accordingly, if the controller  24  does not detect the presence of the ferrite identifier  36  when an actuation event is detected, then the controller stops the dispensing event by disabling the actuating mechanism and use of the dispensing mechanism stops. 
     The controller  24  can be configured to detect the presence of a ferrite material by the air coil, or the controller can be further refined to detect a specific voltage value, which may be associated with a specific number of ferrite beads or a particular type of ferrite material. In this manner, a different number of ferrite beads can be used as a keying mechanism so as to ensure that a proper refill container is being used with an appropriate dispenser. For example, the controller for each dispenser may be pre-programmed at the factory or modified at installation to look for a specific signal from the detection device  44 . As such, if the detection device  44  with the controller  24  only detects the presence of one ferrite bead when two beads should be observed, then the controller  24  disables or otherwise deactivates the actuating mechanism and the dispensing cycle. As a result, any number of keys could be developed for any corresponding number of fluid types. Accordingly, a “key” can be selected based on the number of beads  38 , the composition of the ferrite material used in the beads, other physical characteristics, and/or any combination of the foregoing that could be used as an identifier. Of course, other mediums could be used in place of the ferrite beads, such as an optically reflective material which is detectable by an appropriate sensor. In other words, use of the medium on the movable component of the dispensing mechanism allows for a clear indication of the presence of a proper refill container. 
     The use of the ferrite bead or beads as the identifier can provide for position information regarding the plunger  32  position in relation to the collar  30 . Accordingly, this feature can be utilized as an end of stroke switch or threshold so that the pumping mechanism  18  can be stopped by the actuating mechanism  20  at the appropriate time. By accurately determining the position of the plunger, the controller  24  and the actuating mechanism  20  can precisely control the dispensing cycle and a savings in the amount of fluid being dispensed. 
     Another method of obtaining the position of the ferrite would be to sweep across a range of frequencies and measure the voltage across the coil  34  across this range. Because the resonant frequency of the emitter coil  34  changes as the position of the ferrite identifier changes, so will the resonant frequency. This shift in resonant frequency indicates the shift in position of the ferrite. So, in summary, position of the plunger  32  can be determined by either relating the rectified emitter coil voltage to the ferrite position, or by relating the resonant frequency of the emitter coil and ferrite combination to the ferrite&#39;s position. 
     This embodiment is advantageous in that the modification to the pump mechanism and the dispenser is of low cost. In other words, the use of an air coil as a detection device and the ferrite bead or beads or other device as the identifier medium is of minimal cost. This configuration also allows for multiple keys to be utilized by utilizing one or more than one ferrite bead. Such a dispenser configuration is also “sustainable” in that no copper is utilized in the cartridge and that the magnetic material can easily be removed from the recycling stream. The detection circuit utilized is also of low cost and, as noted previously, it can replace an end of stroke switch in a dispenser. 
     Referring now to  FIG. 2 , it can be seen that an alternative embodiment dispenser is designated generally by the numeral  10 ′. This embodiment utilizes many of the same components as in the previous embodiment, but with a slightly different configuration of a medium and a detection device. In this embodiment, the dispenser  10 ′ includes an identifier  36 ′ that is secured to the refill container  14 . In the present embodiment, the identifier  36 ′ is a radio frequency identification device configured as an 8.2 MHz electronic article surveillance tag which is placed on the surface of the refill container  14 . A detection device  44 ′, which in this present embodiment is an air coil, is placed near the identifier  36 ′ and a range of frequencies from below 8.2 MHz to above 8.2 MHz are generated by the controller together with the detection device  44 ′. Of course, any other appropriate range of frequencies could be used. After application of the designated frequency is detected, the output of the air coil is the rectified and measured by the controller. If the controller detects a significant “dip” in the voltage, a tag is known to be present. This detection method is sometimes referred to as a “grid dip” oscillator. 
     Associated with the controller  24  is a counter  48  which is reset each time a new refill container is detected. In other words, each time a new container is inserted into the dispenser housing a count value is set at the counter  48  to a predetermined value such as zero. Next, after a refill container is validated, the counter allows the certain number of dispense events to occur by either counting up to a predetermined value or counting down to zero without requiring detection of a new identifier. After validation, the controller then deactivates the RFID identifier  36 ′ by utilizing a frequency sweep to determine the exact resonant frequency of the tag and then transmitting the frequency at a high power level. This degrades the dielectric material in the identifier  36 ′ and shifts its resonant frequency out of the detection band. In other words, the identifier  36 ′ is deactivated so that it is no longer detectable. Next, the controller then begins counting up or down the number of uses of the dispenser as they occur which can be associated with the amount of material in the fluid container  14 . When the count reaches the predetermined value or zero, then the actuating mechanism is rendered inoperative and this serves as an indication that the refill container must be replaced. Some type of notice by the indicator  27  and/or the wireless communication device  28  may convey the operational status of the dispenser. 
     To clearly set out operation of the dispenser  10 , reference is made to  FIG. 3 , which shows a method of operation designated generally by the numeral  100 . At step  102 , the container  14  is installed into the dispenser housing  12  and the cover  13  is closed. At step  104  the controller  24  energizes the detection device  44 ′ at the appropriate frequency and transmits a return output signal back to the controller  24  for evaluation. Then the controller determines whether the identifier  36 ′ is present and valid. If the identifier  36 ′ is not present, or if the identifier  36 ′ is present, but not valid, then at step  106  the actuating mechanism  20  is disabled by the controller  24  or otherwise so as to prevent dispensing of any material from the container. Alternatively at step  106 , the controller  24  can signal the indicator  26  and/or enable the wireless communication device  27  to display or send an indication or status to the user or maintenance staff that the count value has been reached and that the container is ready for replacement. It will be appreciated that both disablement of the mechanism and sending of a notice can take place simultaneously. In any event, if the identifier  36 ′ is present and valid at step  104 , then at step  108  the controller  24  sets a count value in the counter  48 , wherein the count value is the number of dispense cycles associated with the material carried by the container. At about the same time the count value is set, the controller  24  deactivates the detection device as described previously. 
     At step  110 , the dispenser undergoes a dispense cycle upon action by the user and at step  112  the controller  24  adjusts the count value accordingly. Finally, at step  114  the controller  24  determines whether the count value has been reached or not. If the predetermined count value has not been reached, then the method returns to step  110 . However, if the count value has been reached at step  114 , then the actuating mechanism  20  is disabled and/or notice is sent as set out in step  106 . 
     This embodiment is advantageous in that an identifier or tag can be deactivated to prevent refilling of the enclosure with non-approved material. The method of implementation of this embodiment is relatively inexpensive as there are no modifications to existing refill containers and no motion detection of the pump mechanism is required. 
     Thus, it can be seen that the objects of the invention have been satisfied by the structure and its method for use presented above. While in accordance with the Patent Statutes, only the best mode and preferred embodiment has been presented and described in detail, it is to be understood that the invention is not limited thereto or thereby. Accordingly, for an appreciation of the true scope and breadth of the invention, reference should be made to the following claims.