Patent Description:
Liquid dispenser systems, such as liquid soap and sanitizer dispensers, provide a user with a predetermined amount of liquid upon actuation of the dispenser. In addition, it is sometimes desirable to dispense the liquid in the form of foam by, for example, injecting air into the liquid to create a foamy mixture of liquid and air bubbles. Foam density may be vary as the types of fluid being foamed is changed. In addition, some customers prefer foam that is denser than other customers. The foam densities may be changed by changing the ratio of liquid to air that is combined to form the foam, however, changing the volume of the liquid or air chambers on a sequentially activated multi-diaphragm foam pump. <CIT> discloses a foam dispenser according to the preamble of claim <NUM> and a sequentially activated foam pump according to the preamble of claim <NUM>.

The present invention provides a foam dispenser according to claim <NUM> and a sequentially activated foam pump according to claim <NUM>.

The present application discloses exemplary embodiments of sequentially activated multi-diaphragm foam pumps, refill units and dispenser systems and refill units sequentially activated multi-diaphragm foam pumps and wobble plates are disclosed herein; An exemplary foam dispenser includes a housing, a receiver for receiving a container of foamable liquid and a foam pump is in fluid communications with the container of foamable liquid when the container of foamable liquid is inserted in the receiver. The foam pump includes a housing, a molded multi-diaphragm pumping member having a liquid pump diaphragm and one or more air pump diaphragms. One or more outlet valves are located downstream of the liquid pump diaphragm and the one or more air pump diaphragms. A mixing chamber located downstream of the one or more outlet valves for mixing foamable liquid from the liquid pump diaphragm with air from one or more air pump diaphragms. A drive motor is included and the foam pump is operatively coupled to the drive motor by a wobble plate. The wobble plate has two or more wings. The first wing has a fist wing profile distance between a first surface that contacts a body of the liquid pump diaphragm and a second surface that contacts a retention member of the liquid pump diaphragm. The second wing has a second wing profile distance between a first surface that contacts a body of one of the one or more air pump diaphragm and a second surface that contacts a retention member of the one of the one or more air pump diaphragm. The first wing profile distance is different than the second wing profile distance. An outlet for dispensing foam is also included.

An exemplary wobble plate for a sequentially activated multi-diaphragm foam pump includes three or more wings, a wobble plate shaft, an aperture located in each of the three or more wings. The first wing having a first thickness proximate the aperture in the first wing. The second wing having a second thickness proximate the aperture in the second wing and the third wing has the second thickness proximate the aperture in the second wing.

An exemplary embodiment of a sequentially activated foam pump includes a housing, a liquid inlet, and a molded multi-diaphragm pumping member. The molded multi-diaphragm pumping member includes a liquid pump diaphragm having a first volume and two or more air pump diaphragms each having a second volume. Te first volume is less than the second volume. One or more outlet valves are also included. A mixing chamber is located downstream of the one or more outlet valves for mixing foamable liquid from the liquid pump chamber with air from each of the two or more air pump chambers. A wobble plate is included. The wobble plate has two or more wings. The first wing has a fist wing profile distance and the second wing has a second wing profile distance. The first wing connects to the liquid pump diaphragm and the second wing connects to one of the two or more air pump diaphragms. The first wing profile distance is different than the second wing profile distance. An outlet for dispensing foam is also included.

Another exemplary sequentially activated foam pump includes a housing, a molded multi-diaphragm pumping member having a liquid pump diaphragm and one or more air pump diaphragms, one or more outlet valves located downstream of the liquid pump diaphragm and the one or more air pump diaphragms and a mixing chamber located downstream of the one or more outlet valves for mixing foamable liquid from the liquid pump diaphragm with air from one or more air pump diaphragms. A drive motor and non-uniform wobble plate are also included. The foam pump is operatively coupled to the drive motor by the non-uniform wobble plate. The non-uniform wobble plate comprises two or more wings. The two or more wings each have a pump diaphragm contact surface. A first wing has a first pump diaphragm contact surface that is a first distance away from a first pump diaphragm and a second wing has a second pump diaphragm contact surface that is a second distance away from a second pump diaphragm, and the first distance is greater than the second distance.

Another exemplary wobble plate for a sequentially activated multi-diaphragm foam pump includes three or more wings, a wobble plate shaft, and an aperture located in each of the three or more wings. A first wing is configured to have a first distance from first contact surface of a first pump diaphragm. A second wing is configured to have a second distance from a first contact surface on a second pump diaphragm, and a third wing is configured to have substantially the second distance from a first contact surface on a third pump diaphragm.

The present application discloses exemplary embodiments of foam dispensers, and refill units that having sequentially activated multi-diaphragm foam pumps. Some exemplary embodiments include a wobble plate and three or more pump diaphragms. The three or more pump diaphragms include at least one liquid pump diaphragm and at least two air pump diaphragms. Each liquid pump diaphragm has a liquid inlet for receiving liquid, such as, for example, a soap, a sanitizer, or a lotion, and each air pump diaphragm has an air inlet for receiving air. The three or more pump diaphragms operate sequentially, and each pump diaphragm operates once in an operating cycle. An operating cycle begins with the operation of a liquid pump diaphragm. Additionally, the sequentially activated multi-diaphragm foam pump includes a mixing chamber. Each liquid pump diaphragm pumps liquid into the mixing chamber, and each air pump diaphragm pumps air into the mixing chamber. The liquid mixes with the air in the mixing chamber to create a foam mixture that is dispensed out of the pump outlet. In some embodiments of the present invention, the foam mixture has an air to liquid ratio of between about <NUM> to <NUM> and about <NUM> to <NUM>. In some embodiments, the air to liquid ratio is greater than <NUM> to <NUM>, and in some embodiments is less than <NUM> to <NUM>.

The sequentially activated multi-diaphragm foam pumps may be used in foam dispensers. An exemplary foam dispenser comprises a housing, a motor, a refill unit, a sequentially activated multi-diaphragm foam pump, and a foam cartridge. The pump receives a foamable liquid from the refill unit, mixes the foamable liquid with air to create a foam mixture, forces the foam mixture through the foam cartridge to enrich the foam, and dispenses the foam to a user.

<FIG> illustrates a refill unit <NUM> for a foam dispenser. The refill unit <NUM> includes a collapsible container <NUM>. Collapsible container <NUM> includes a neck <NUM> and a drip-free quick connector <NUM>. Exemplary drip-free quick connectors are disclosed in <CIT> titled Bag and Dispensing System Comprising Such A Bag, and <CIT> titled Connector Apparatus And Method For Connecting The Same For Controlling Fluid Dispensing. Refill units contain a supply of a foamable liquid. In various embodiments, the contained foamable liquid could be for example a soap, a sanitizer, a cleanser, a disinfectant, a lotion or the like. The container is a collapsible container and can be made of thin plastic or a flexible bag-like material. In other embodiments, the container may be a non-collapsing container formed by a rigid housing member, or any other suitable configuration for containing the foamable liquid without leaking. In the case of a non-collapsing container, a vent system may be included. Exemplary venting systems are disclosed in <CIT> titled Closed system for venting a dispenser reservoir; Publication No.<CIT>titled Pumps With Container Vents and Application No. <CIT>, titled Vented Refill Units And Dispensers Having Vented Refill Units.

<FIG> illustrates an exemplary embodiment of a touch-free foam dispenser <NUM>. The touch-free foam dispenser <NUM> includes a housing <NUM>, a motor <NUM>, a foam pump <NUM>, a refill unit connector <NUM>, a foam cartridge <NUM>, and a nozzle <NUM>. Exemplary embodiments of foam cartridges <NUM> are shown and described in <CIT>. A refill unit <NUM> may be connected to the refill unit connector <NUM> as shown in <FIG>. The refill unit <NUM> contains a foamable liquid, such as a soap, a sanitizer, a lotion, a cleanser, a disinfectant or the like. The touch-free foam dispenser <NUM> is activated when sensor <NUM> detects the presence of a user or object. Upon detection of an object or user, the sensor <NUM> provides a signal to the processor (not shown) in the electronic control board <NUM>. The electronic control board <NUM> provides an output signal that causes the motor <NUM> to rotate an eccentric wobble plate actuator drive mechanism <NUM>. The sensor <NUM> and the electronic control board <NUM> receive power from a power source <NUM>. In some embodiments, the motor <NUM> receives power from the power source <NUM>, and, in other embodiments, the refill unit includes a power source (not shown) that provides power to a rechargeable power source (not shown). Exemplary embodiments of refill units with power supplies that provide power to the wobble plate actuator drive mechanism <NUM> (<FIG>) are shown and described in <CIT> titled Power Systems For Touch Free Dispensers And Refill Units Containing A Power Source. Providing power to the motor <NUM> causes wobble plate actuator drive mechanism <NUM> to rotate. Rotation of eccentric wobble plate actuator drive mechanism <NUM> sequentially compresses and expands the diaphragms of foam pump <NUM> and pumps liquid and air into mixing chamber <NUM>. The liquid and air mix together and form a foamy mixture. The foamy mixture is forced through the foam cartridge <NUM>, which enhances the foam into a rich foam. The rich foam is dispensed from the foam dispenser <NUM> through the nozzle <NUM>.

The refill unit <NUM> and the foam dispenser <NUM> illustrated in <FIG> and <FIG>, respectively, are drawn generically because a variety of different components may be used for many of the refill unit <NUM> and the foam dispenser <NUM>. Although foam pump <NUM> is illustrated generically above, it is described in detail below. Some exemplary dispenser components that may be used in accordance with the present invention are shown and described in <CIT> titled Touch-Free Dispenser With Single Cell Operation And Battery Banking; <CIT> titled Off-Axis Inverted Foam Dispensers And Refill Units and Pub. No. <CIT> titled Power Systems For Touch Free Dispensers And Refill Units Containing a Power Source.

<FIG> is an exploded view of an exemplary embodiment of foam pump <NUM>. Foam pump <NUM> is driven by motor <NUM>. Foam pump <NUM> includes a pump base <NUM>, a wobble plate <NUM>, a diaphragm assembly seat <NUM>, a diaphragm assembly <NUM>, a valve seat <NUM>, outlet valves 323A, 323B, 323C, screws <NUM>, and a cover <NUM>. The valve seat <NUM>, diaphragm assembly seat <NUM>, and pump base <NUM> are secured together by screws <NUM> in screw holes 308A, 312A, 324A. The cover <NUM> is attached to the valve seat <NUM>. Outlet valves 323A, 323B 323C are secured to and seated in the valve seat <NUM>.

The diaphragm assembly <NUM> includes three pump diaphragms 310A, 310B, 310C, and each pump diaphragm 310A, 310B, 310C has a connector 311A, 311B, 311C. The diaphragm assembly <NUM> is located in the diaphragm assembly seat <NUM>. The pump diaphragms 310A, 310B, 310C are disposed in the receiving holes 313A, 313B, 313C of the diaphragm assembly seat <NUM>, and the three connectors 311A, 311B, 311C connect to the wobble plate <NUM> by inserting the three connectors 311A, 311B, 311C in the three wobble plate links 314A, 314B, 314C.

Air enters the foam pump <NUM> through pump air inlet 424B (<FIG>), and liquid, such as for example, foamable soap or sanitizer enters the foam pump <NUM> through liquid inlet <NUM>. Two of the pump diaphragms 310B, 310C receive air, and the other pump diaphragm 310A receives foamable liquid, such as, for example soap or sanitizer.

<FIG> is another exploded view of the exemplary foam pump <NUM> from a different perspective. As described above, the diaphragm assembly <NUM> includes three pump diaphragms 310A, 310B, 310C. Each pump diaphragm 310A, 310B, 310C has a corresponding inlet valve 316A, 316B, 316C (better seen in <FIG>). <FIG> also provides a view of the bottom of the valve seat <NUM>. The bottom of valve seat <NUM> has three areas that correspond to the three pump diaphragms 310A, 310B, 310C. Each area has three fluid outlet apertures 309A, 309B, 309C that extend through valve seat <NUM>, a valve stem retention aperture 329A, 329B, 329C (<FIG>), and a fluid inlet groove 319A, 319B, 319C. The fluid inlet grooves 319A, 319B, 319C do not extend through valve seat <NUM>.

<FIG> illustrate a top view and a bottom view, respectively, of the exemplary diaphragm assembly <NUM> for foam pump <NUM>. In some embodiments, the diaphragm assembly is made of natural rubber, EPDM, Silicone, Silicone rubber TPE, TPU, TPV, vinyl, or the like. The diaphragm assembly <NUM> includes three molded pump diaphragms 310A, 310B, 310C and three corresponding inlet valves 316A, 316B, 316C. The top of the diaphragm assembly <NUM> acts as a sealing gasket. The top of the diaphragm assembly <NUM> has a flat section 310F, and each pump diaphragm 310A, 310B, 310C has gasket walls 327A, 327B, 327C that surround the respective valves 316A, 316B, 316C and pump diaphragms 310A, 310B, 310C. The gasket walls 327A, 327B, 327C seal against the bottom of the valve seat <NUM> (<FIG> and <FIG>) to prevent fluid, such as, air and liquid soap or sanitizer from leaking out of the foam pump <NUM> at a location other than the pump outlet <NUM> (<FIG>). One-way inlet valves 316A, 316B, 316C allow air, liquid soap, or sanitizer to enter the pump diaphragms 310A, 310B, 310C when the pump diaphragms 310A, 310B, 310C have a negative pressure (i.e., when the pump diaphragms 310A, 310B, 310C are expanding), and seal against inlet apertures 321A, 321B, 321C when the pump diaphragms 310A, 310B, 310C have a positive pressure (e.g. when the pump diaphragms 310A, 310B, 310C are compressing). The one-way inlet valves 316A, 316B, 316C are formed by flexible tabs and are made of the same material as the diaphragm assembly <NUM>.

<FIG> is a top view of an exemplary valve seat <NUM> for the foam pump <NUM>. One-way liquid outlet valve 323A is shown transparently to more clearly illustrate the flow of liquid 331A through liquid outlet apertures 309A and into mixing chamber <NUM>. One-way liquid outlet valve 323A includes a valve stem 357A (<FIG>) that is inserted into aperture 329A to secure one-way liquid outlet valve 323A to valve seat <NUM>. One-way liquid outlet valve 323A is normally closed and prevents air or liquid from flowing from the mixing chamber <NUM>, back through air outlet apertures 309A, and into liquid pump diaphragm 310A. One-way liquid outlet valve <NUM> opens when liquid pump diaphragm 310A is being compressed to pump fluid.

Simalarly, one-way air outlet valves 323B, 323C are shown transparently to more clearly illustrate the flow of air 331B, 331C through air outlet apertures 309B, 309C and into mixing chamber <NUM>. One-way air outlet valves 323B, 323C each include a valve stem 357B, 357C (<FIG>) that are inserted into corresponding apertures 329B, 329C to secure the one-way air outlet valves to valve seat <NUM>. One-way air outlet valves 323B, 323C are normally closed and prevent air or liquid from flowing from the mixing chamber <NUM>, back through air outlet apertures 323B, 323C, and into air pump diaphragms 310B, 310C. One-way air outlet valves 323B, 323C open when corresponding air pump diaphragms 310B, 310C are being compressed to pump air.

The valve seat <NUM> also includes flow directional control walls 308E. The flow directional control walls 308E provide flow paths that aid in the mixing of liquid and air. In this embodiment the flow directional control walls 308E are curved and cause the liquid and air to intersect in a tangential relationship. In some embodiments, flow directional control walls 308E are designed and arranged to cause the liquid an air to intersect at a desired angle, such as, for example, each flow path may intersect at a <NUM> degree angle. In some embodiments, the flow directional control walls 308E are arranged so that the two air paths intersect the liquid flow path at about <NUM> degrees. The design of the flow path intersection may be different for different types of liquids, for example, a higher quality of foam may be obtained by causing the liquid soap to be intersected head on (<NUM> degrees) by the two air flow paths, while a higher quality foam may be obtained for foamable sanitizer by having the air paths tangentially intersect with the liquid path.

<FIG> is a bottom view of the exemplary valve seat <NUM> for the foam pump <NUM>. The valve seat <NUM> includes three liquid outlet apertures 309A that pass through valve seat <NUM> and a liquid outlet valve aperture 329A for retaining one-way liquid outlet valve 323A. Valve seat <NUM> also includes a liquid inlet groove 319A that extends partially into valve seat <NUM> to provide a liquid path from one-way liquid inlet valve 316A to the interior of liquid pump diaphragm 310A. In addition, the valve seat <NUM> includes a first set of three air outlet apertures 309B that pass through valve seat <NUM>, and a second set of three air outlet apertures 309C that pass through valve seat <NUM>. Also, valve seat <NUM> includes air outlet valve apertures 329B, 329C for retaining one-way air outlet valves 323B, 323C, and air inlet grooves 319B, 319C that extend partially into valve seat <NUM> to provide an air path from one-way air inlet valves 316B, 316C to the interior of air pump diaphragms 310B, 310C.

<FIG> is a top view of an exemplary diaphragm assembly seat <NUM> for the exemplary embodiment of a foam pump <NUM>. The diaphragm assembly seat <NUM> includes three receiving holes 313A, 313B, 313C and three inlet apertures 321A, 321B, 321C. In fluid communication with inlet aperture 321A is fluid inlet <NUM> which may be coupled to the liquid outlet of container <NUM>. Each receiving hole 313A, 313B, 313C is sized to receive a diaphragm 310A, 310B, 310C. Each inlet aperture 321A, 321B, 321C extends through diaphragm assembly seat <NUM> and allows either air, liquid soap, or sanitizer to enter one of the diaphragms 310A, 310B, 310C.

In some embodiments, the foam mixture has an air to liquid ratio of between about <NUM> to <NUM> and about <NUM> to <NUM>. In some embodiments, the air to liquid ratio is greater than <NUM> to <NUM>, and in some embodiments is less than <NUM> to <NUM>.

In some exemplary embodiments, a flow control valve (not shown) is located between the container <NUM> of foamable liquid and pump <NUM>. The flow control valve may be used to adjust the liquid to air ratio. If a higher liquid to air ratio is desired, the flow control valve is set at a lower flow rate that starves the liquid pump diaphragm 310A. Conversely, to increase the liquid to air ratio, the flow control valve may be opened wider allowing more liquid to flow into pump <NUM>. In some embodiments, the liquid pump diaphragm 310A may have a different volume than the air pump diaphragms 310B, 310C to adjust the ratio of liquid to air. In some embodiments, the volume of the liquid pump diaphragm 310A is reduced by inserting a sponge (not shown) in the liquid pump diaphragm 310A. Not only does the sponge (not shown) reduce the volume, but in some embodiments, the sponge slows the flow of liquid through the liquid pump diaphragm 310A. In some embodiments, a restrictor comprising an orifice that has a smaller diameter than the liquid inlet may be used to restrict the fluid flow.

<FIG> is a cross-sectional view taken along the lines A-A of <FIG> showing the liquid pump portion of foam pump <NUM>. In operation, liquid pump diaphragm 310A is moved downward, as shown by reference number 350B, to expand pump chamber <NUM>, which causes liquid inlet valve 316A to open allowing liquid to be drawn into pump chamber <NUM> through liquid inlet <NUM>, inlet aperture 321A, and liquid inlet groove 319A. Once the pump chamber <NUM> is expanded it is primed with liquid, such as, for example, liquid soap or sanitizer. When the liquid pump diaphragm 310A is compressed (i.e. the liquid pump diaphragm 310A moves in the direction shown by reference number 350A), the liquid is pumped in the direction shown by reference number 340A. The liquid travels through liquid outlet apertures 309A, past one-way liquid outlet valve 323A and into mixing chamber <NUM>. One-way liquid outlet valve 323A is normally closed, but one-way liquid outlet valve 323A opens due to pressure caused by compressing liquid pump chamber <NUM>. One-way liquid outlet valve 323A prevents air or liquid from flowing back through liquid outlet apertures 309A and into liquid pump diaphragm 310A. Subsequently, the liquid pump diaphragm 310A begins to expand, which starts the process again by causing liquid inlet valve 316A to open, and liquid is drawn into liquid pump chamber <NUM> through liquid inlet aperture 321A and liquid inlet groove 319A. A operating cycle of foam pump <NUM> includes one pump of liquid from liquid pump diaphragm 310A through liquid outlet apertures 309A, past liquid outlet valve 323A, and into mixing chamber <NUM> (<FIG>) (followed by two pumps of air as described below).

<FIG> are a cross-sectional view taken along the lines B-B and C-C, respectively, of <FIG> showing the air pump portions of foam pump <NUM>. In operation, air pump diaphragms 310B, 310C are moved downward, as shown by reference number 350B, to expand air pump chambers <NUM>, <NUM>, which causes air inlet valves 316B, 316C to open allowing air to be drawn into pump chambers <NUM>, <NUM> through air inlet apertures 321B, 321C and air inlet grooves 319B, 319C. Once the pump chambers <NUM>, <NUM> are primed with air, the air pump diaphragms 310B, 310C may be compressed (moved in the direction shown by reference number 350A). Compression of air pump diaphragms 310B, 310C pump the air in the direction shown by reference number 340A. The air travels through air outlet apertures 309B, 309C, past one-way air outlet valves 323B, 323C, and into mixing chamber <NUM> to mix with the foamable liquid. One-way air outlet valves 323B, 323C are normally closed, but one-way air outlet valves 323B, 323C open due to pressure caused by compressing air pump chambers <NUM>, <NUM>. One-way air inlet valves 323B, 323C prevent air or liquid from flowing back through air outlet apertures 309B, 309C and into air pump diaphragms 310B, 310C. Subsequently, the air pump diaphragms 310B, 310C begin to expand, which starts the process again by causing air inlet valves 316B, 316C to open, and air is drawn into air pump chambers <NUM>, <NUM> through air inlet apertures 321B, 321C and air inlet grooves 319B, 319C. An operating cycle of foam pump <NUM> includes one pump of liquid (as described above) followed by one pump of air from air pump diaphragm 310B through air outlet apertures 309B, past air outlet valve 323B, and into mixing chamber <NUM> (<FIG>). In addition, an operating cycle of foam pump <NUM> includes one pump of air from air pump diaphragm 310C through air outlet apertures 309C, past air outlet valve 323C, and into mixing chamber <NUM> (<FIG>).

The diaphragms 310A, 310B, 310C operate sequentially, in which one sequence of operation includes one pump of liquid, such as, for example, soap or sanitizer, or air by each of the three pump diaphragms 310A, 310B, 310C. The order of operation of the pump diaphragms 310A, 310B, 310C is dependent upon the configuration of the wobble plate <NUM> (<FIG>). As shown in <FIG>, each pump diaphragm 310A, 310B, 310C has a connector 311A, 311B, 311C, and the three pump diaphragms 310A, 310B, 310C connect to the wobble plate <NUM> by inserting the three connectors 311A, 311B, 311C in the three wobble plate links 314A, 314B, 314C. Wobble plate <NUM> connects to an eccentric wobble plate actuator that causes the wobble plate <NUM> to undulate. As the wobble plate <NUM> undulates, the wobble plate links 314A, 314B, 314C move in upward and downward motions. The upward motion causes the pump diaphragms 310A, 310B, 310C to compress, and the downward motion causes the pump diaphragms 310A, 310B, 310C to expand. The configuration of the wobble plate <NUM> causes one pump diaphragm 310A, 310B, 310C to compress at a time, which causes the pump diaphragms 310A, 310B, 310C to pump sequentially. The configuration of the wobble plate <NUM> also causes one pump diaphragm 310A, 310B, 310C to expand at a time, which causes the pump diaphragms 310A, 310B, 310C to prime sequentially. In the exemplary sequence of operation, the liquid pump diaphragm 310A pumps a shot of fluid, followed by air pump diaphragm 310B pumping a shot of air, and the sequence of operation ends with air pump diaphragm 310C pumping a second shot of air. The sequence may be repeated any number of times depending on the desired output dose of foam. The air from the air pump diaphragms 310B, 310C mixes with either the liquid or sanitizer from the liquid pump diaphragm 310A in the mixing chamber <NUM> (<FIG>), which creates a foam mixture. The foam mixture exits the foam pump <NUM> through the pump outlet <NUM>.

<FIG> illustrates the flow path of the liquid soap or sanitizer through the exploded view. When the liquid pump diaphragm 310A expands, liquid enters the foam pump <NUM> through liquid inlet <NUM>, which is shown by reference number 330A. The liquid travels through aperture 321A in the diaphragm assembly seat <NUM>, and past liquid one-way inlet valve 316A, as shown by reference number 330B. Inlet valve 316A opens, the liquid travels through groove 319A and into liquid pump diaphragm 310A, which is shown by reference numbers 330D and 330E.

The liquid pump diaphragm 310A compresses and pumps the liquid through liquid outlet aperture 309A, past one-way liquid outlet valve 323A, and into the mixing chamber <NUM> (<FIG>), which is shown by reference number 340A. Air follows a similar path for air pump diaphragms 310B, 310C. When air pump diaphragms 310B, 310C expand, air is drawn into air inlet 424B, travels through apertures 321B, 321C (<FIG>) in diaphragm seat assembly <NUM>, travels through one-way air inlet valves 316B, 316C (<FIG>), travels into grooves 319B, 319C, in the bottom of valve seat <NUM>, and travels into air pump diaphragms 310B, 310C. When air pump diaphragms 310B, 310C compress, air is forced through apertures 309B, 309C, past one-way air outlet valves 323B, 323C (<FIG>), and into mixing chamber <NUM> where it mixes with the liquid to form a foam mixture. The foam mixture is dispensed through outlet <NUM>, which is shown by reference number 304B.

<FIG> is a cross-sectional view of another exemplary embodiment of a sequentially activated multi-diaphragm foam pump <NUM>. The sequentially activated multi-diaphragm foam pump <NUM> includes a motor <NUM>, a motor shaft <NUM>, a wobble plate <NUM>, a wobble plate pin <NUM> an eccentric wobble plate drive <NUM>, a liquid pump diaphragm <NUM>, two air pump diaphragms <NUM> (only one is shown), mixing chamber <NUM>, and pump outlet <NUM>. The motor <NUM> drives the motor shaft <NUM>, which causes the motor shaft <NUM> to rotate. The rotation of the motor shaft <NUM> causes the eccentric wobble plate drive <NUM> to rotate, and rotation of the eccentric wobble plate drive <NUM> causes the wobble plate pin <NUM> to move along a circular path, which causes the wobble plate <NUM> to undulate. In some embodiments, wobble plate <NUM> includes a ball (not shown) that rides in a socket (not shown) on the pump housing and wobble plate pin <NUM> extends outward and connects to an eccentric wobble plate actuator <NUM> that causes the pin to move along a circular path which causes the wobble plate <NUM> to undulate. As the wobble plate <NUM> undulates, the ends connected to the three pump diaphragms <NUM>, <NUM> move in upward and downward motions, and the three pump diaphragms <NUM>, <NUM> are compressed sequentially. One sequence of operation of the mixing pump <NUM> includes one pump by each of the three pump diaphragms <NUM>, <NUM>. The liquid pump diaphragm <NUM> operates first in the cycle of operation, followed by sequential distributions by the two air pump diaphragms <NUM>.

Similar to the embodiments described above, during operation, the liquid pump diaphragm <NUM> expands and contracts to pump liquid, and the air pump diaphragms <NUM> (only one is shown) expand and contract to pump air. The expansion of the liquid pump diaphragm <NUM> opens the liquid inlet valve <NUM> and allows liquid, such as, for example, soap or sanitizer to enter liquid pump chamber <NUM> through liquid inlet <NUM>. The expansion of the air pump diaphragms <NUM> opens the air inlet valves <NUM> (only one is shown) and allows air to enter air pump chambers <NUM> (only one is shown) through air inlets <NUM>. Circular movement of the wobble plate pin <NUM> causes the ends of the wobble plate <NUM> to sequentially undulate. The undulation causes liquid pump diaphragm to compress, which causes liquid outlet valve <NUM> to open, and liquid to flow into the mixing chamber <NUM> through liquid outlet apertures <NUM>. Subsequently, one of the air pump diaphragms <NUM> is compressed by the undulating wobble plate <NUM>, which causes air outlet valve <NUM> to open, and air to flow the mixing chamber <NUM> through air outlet apertures <NUM>. Then, the other air pump diaphragm (not shown) will compress and pump air into mixing chamber <NUM>. The air and liquid soap or sanitizer mix in the mixing chamber <NUM> to create a foam mixture. The foam mixture exits the mixing pump <NUM> through pump outlet <NUM>.

<FIG> illustrate and exemplary embodiment of a refill unit <NUM>. <FIG> is a perspective view of an exemplary embodiment of a refill unit <NUM> having a sequentially activated multi-diaphragm foam pump <NUM>, and <FIG> is another perspective view of the exemplary refill unit <NUM>, having a back plate <NUM> removed to illustrate the plurality of diaphragms 1510A, 1510B and 1510C. <FIG> is a rear elevational view of the refill unit <NUM> and <FIG> is a rear elevational view of the refill unit <NUM> with the back plate <NUM> removed to illustrate the plurality of diaphragms 1510A, 1510B and 1510C. The refill unit <NUM> connects to a foam dispenser <NUM> (<FIG>, <FIG>). The refill unit <NUM> includes a container <NUM>, a foam pump <NUM>, a actuation mechanism <NUM> (<FIG>), a foam cartridge <NUM>, and a nozzle <NUM>. Refill unit <NUM> contains a supply of a foamable liquid. In various embodiments, the contained foamable liquid could be for example a soap, a sanitizer, a cleanser, a disinfectant, a lotion or the like. The container <NUM> is a collapsible container and can be made of thin plastic or a flexible bag-like material. In some embodiments, the container <NUM> is a non-collapsing container formed by a rigid, or semi-rigid housing member, or any other suitable configuration for containing the foamable liquid without leaking. In the case of a non-collapsing container, a vent system may be included, such as, for example, any of the venting systems in the patents/application incorporated above.

Foam pump <NUM>, is similar to the pumps described above, and includes a housing <NUM>, a liquid pump diaphragm 1510A (<FIG>), air pump diaphragms 1510B, 1510C, and a mixing chamber (not shown). The liquid pump diaphragm 1510A and the air pump diaphragms 1510B, 1510C are disposed in housing <NUM>. The liquid pump diaphragm 1510A receives liquid from the container <NUM> through liquid inlet <NUM> and liquid inlet apertures 1509A, and liquid pump diaphragm 1510A pumps the liquid into the mixing chamber. The air pump diaphragms 1510B, 1501C receive air through at least one air inlet (not shown) and air inlet apertures 1509B, 1509C, and air pump diaphragms 1510B, 1510C pump the air into the mixing chamber. The liquid pump diaphragm 1510A and the air pump diaphragm 1510B are sequentially activated by actuation mechanism <NUM> (<FIG>). An operating cycle of the foam pump <NUM> includes one pump of liquid from liquid pump diaphragm 1510A into mixing chamber <NUM> and one pump of air from air pump diaphragms 1510B, 1510C into the mixing chamber. The operating cycle begins with the one shot of liquid from liquid pump diaphragm 1510A, which is followed by the one shot of air form air pump diaphragm 1510B and one shot of air from air pump diaphragm 1510C. The liquid and air mix in mixing chamber (not shown) to form a foamy mixture, and the foamy mixture passes through foam cartridge <NUM> and exits the foam pump <NUM> through the outlet <NUM>. A dispense of foam typically requires one or more operating cycles or revolutions. In some embodiments of the present invention, the foam mixture has an air to liquid ratio of between about <NUM> to <NUM> and about <NUM> to <NUM>. In some embodiments, the air to liquid ratio is greater than <NUM> to <NUM>, and in some embodiments is less than <NUM> to <NUM>.

In some exemplary embodiments, a flow control valve (not shown) is located between the container <NUM> of foamable liquid and pump <NUM>. The flow control valve may be used to adjust the liquid to air ratio. If a higher liquid to air ratio is desired, the flow control valve is set at a lower flow rate that starves the liquid pump diaphragm 1510A. Conversely, to increase the liquid to air ratio, the flow control valve may be opened wider allowing more liquid to flow into pump <NUM>. In some embodiments, the liquid pump diaphragm 1510A may have a different volume than the air pump diaphragms 1510B, 1510C to adjust the ratio of liquid to air. In some embodiments, the volume of the liquid pump diaphragm 1510A is reduced by inserting a sponge (not shown) in the liquid pump diaphragm 1510A. Not only does the sponge (not shown) reduce the volume, but in some embodiments, the sponge slows the flow of liquid through the liquid pump diaphragm 1510A.

The foam pump <NUM> may include some or all of any of the embodiments described herein. Moreover, the foam pump <NUM> may have more than one liquid pump diaphragm and one or more air pump diaphragms.

The actuation mechanism <NUM> (<FIG>) releasably connects to a drive system of motor <NUM> (<FIG>) that is permanently attached to a foam dispenser <NUM>. Actuation mechanism <NUM> is covered by back plate <NUM>.

In some embodiments, the actuation mechanism <NUM> does not include a wobble plate <NUM>, but may include a circular plate (not shown) and one or more springs (not shown). The circular plate is connected to the liquid pump diaphragm 1510A and the air pump diaphragms 1510B, 1510C. The one or more springs bias the circular plate outward thereby urging the liquid pump diaphragm 1510A and the air pump diaphragms 1510B, 1510C to their extended position. The drive system (not shown) on the dispenser includes a wheel that travels around the perimeter of the circular plate. The point of contact between the wheel and the circular plate pushes that portion of the circular plate downward. As the wheel rotates around the perimeter it sequentially compresses the liquid pump diaphragm 1510A and the air pump diaphragms 1510B, 1510C. As the wheel moves past the diaphragms 1510A, 1510B, 1510C, the diaphragms 1510A, 1510B, 1510C expand to draw in fluid, as they are biased toward the expanded position by the diaphragm material as well as the one or more springs. In some embodiments, the springs are not needed and the diaphragm material is sufficient to bias the diaphragms 1510A, 1510B, 1510C to their expanded positions.

The above-mentioned embodiments are only exemplary, and the actuation mechanism <NUM> may be configured in any manner that causes sequential operation of the liquid pump diaphragm 1510A and air pump diaphragms 1510B, 1510C of foam pump <NUM>.

<FIG> is a back view of the exemplary embodiment of the refill unit <NUM> having a sequentially-activated multi-diaphragm foam pump <NUM> of <FIG> with back plate <NUM>. Back plate <NUM> has an aperture <NUM>. The refill unit <NUM> attaches to a foam dispenser <NUM> (<FIG>) by connecting the attachment mechanism <NUM> to the drive system of motor <NUM> through the aperture <NUM> of back plate <NUM>.

<FIG> and <FIG> are views of the exemplary embodiment of the refill unit <NUM> having the sequentially-activated multi-diaphragm foam pump <NUM> with the back plate <NUM> removed. The actuation mechanism <NUM> includes a wobble plate <NUM>, wobble plate connection links <NUM>, and pin <NUM>. Each wobble plate link <NUM> connects to pump diaphragms 1510A, 1510B, 1510C. In this exemplary embodiment, the pin <NUM> of actuation mechanism <NUM> releasably connects the actuation mechanism <NUM> to an eccentric drive system <NUM> (<FIG> and <FIG>) of motor <NUM>. Referring to <FIG> and <FIG>, a portion of pump <NUM> of refill unit <NUM> is received in socket <NUM> of foam dispenser <NUM>, and the actuation mechanism <NUM> releasably connects to the eccentric drive system <NUM>. Eccentric drive system <NUM> is attached to shaft <NUM> of motor <NUM>. The pin <NUM> of actuation mechanism <NUM> releasably engages with eccentric drive system <NUM> pin <NUM> engaging notch <NUM>. In some embodiments, the eccentric drive system <NUM> is connected to actuation mechanism <NUM> and is part of the refill unit <NUM> and releasably connects to the shaft <NUM> of motor <NUM>. The above-mentioned embodiments are only exemplary. The refill unit <NUM> and motor <NUM> may be configured in any manner that allows the refill unit <NUM> to releasably attach to motor <NUM> and allows motor <NUM> to operate foam pump <NUM>.

Referring to <FIG> and <FIG>, the eccentric drive system <NUM> (<FIG> and <FIG>) causes the wobble plate <NUM> to undulate, which causes sequential operation of the liquid pump diaphragm 1510A and air pump diaphragms 1510B, 1510C. As the liquid pump diaphragm 1510A expands, liquid travels from container <NUM>, through liquid inlet <NUM> and liquid inlet aperture 1509A, and into liquid pump diaphragm 1510A. The liquid pump diaphragm 1510A is in a primed position when it is filled with liquid. As air pump diaphragms 1510B, 1510C expand, air travels through at least one air inlet (not shown), through air inlet apertures 1509B, 1509C, and into respective air pump diaphragms 1510B, 1510C. The air pump diaphragms 1510B, 1510C are in primed positions when they are filled with air. An exemplary operating cycle includes one pump of liquid from liquid pump diaphragm 1510A, followed by one pump of air from air pump diaphragm 1510B, followed by one pump of air from air pump diaphragm 1510C.

In some embodiments, each pump diaphragm 1510A, 1510B, 1510C has a volume between about <NUM> and <NUM>. The pump diaphragms 1510A, 1510B, 1510C pump liquid and air into a mixing chamber (not shown), and the liquid and air mix to form a foamy mixture. The foamy mixture goes through a foam cartridge <NUM> to form a rich foam, and the rich foam exits the refill unit <NUM> through nozzle <NUM>. In some embodiments the liquid pump diaphragm 1510A has a volume of between about <NUM> and <NUM>.

In some embodiments the dose of foam dispensed by the foam dispenser contains between about. <NUM> and about <NUM> of liquid of liquid. In some embodiments, the dose of foam comprises between about <NUM> and <NUM> revolutions per dispense, including between about <NUM> and <NUM> revolutions, including between about <NUM> and <NUM> revolutions. In some embodiment, the dose of foam is about <NUM> for a highly concentrated light duty soap. In some embodiments, the dose of foam is about <NUM> of liquid for heavy duty soaps, such as grease cleaning soaps.

In some embodiments, the dispenser operates at a voltage of between about <NUM> volts and <NUM> volts, including between about <NUM> volts and about <NUM> volts, including between about <NUM> and about <NUM> volts, including between about <NUM> volts and <NUM> volts, including between about <NUM> volts and about <NUM> volts.

In some embodiments, the pump sequences for between about. <NUM> and <NUM> seconds to dispense a dose of foam, including between about. <NUM> seconds and <NUM> seconds, including between about. <NUM> and <NUM> seconds. In some embodiments, such as, for example, dispensing of foam sanitizer having about <NUM> of liquid, the dispense time is about. In some embodiments, such as, for example, light duty and heavy duty soap having between about <NUM> liquid to about <NUM> liquid, the dispense time in less than <NUM> sec.

In some embodiments, the wobble plate drive actuator rotates at between about <NUM> and about <NUM> revolutions per minute.

In some embodiments, there are multiple liquid pump diaphragms, such as for example, two liquid pump diaphragms, three liquid pump diaphragms, four liquid pump diaphragms. In some embodiments there are multiple air pump diaphragms, for example, two air pump diaphragms, three air pump diaphragms, four air pump diaphragms, five air pump diaphragms, six air pump diaphragms, seven air pump diaphragms and eight. air pump diaphragms. In some embodiments, the number of air pump diaphragms to liquid pump diaphragms is <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, <NUM>:<NUM>, and <NUM>:<NUM>.

<FIG>, and <FIG> illustrate various views of another exemplary embodiment of a sequentially-activated multi-diaphragm foam pump <NUM>. The foam pump <NUM> is coupled to foam cartridge housing <NUM> and container receiver <NUM>, and the foam cartridge housing <NUM> is coupled to a nozzle <NUM>. The foam pump <NUM> includes housing <NUM>, diaphragm assembly <NUM>, pump outlet <NUM>, and pump cover <NUM>. The diaphragm assembly <NUM> includes three pump diaphragms 1916a, 1916b, 1916c. The three pump diaphragms 1916a, 1916b, 1916c include one liquid pump diaphragm 1916a and two air pump diaphragms 1916b, 1916c. The diaphragm assembly <NUM> is only exemplary, and a diaphragm assembly <NUM> may include more than three pump diaphragms. Additionally, the diaphragm assembly may include one or more liquid pump diaphragms and/or one or more air pump diaphragms.

A container (not shown) is connected to container with closure <NUM> in a manner that allows liquid to enter liquid inlet <NUM>. During operation, when liquid pump diaphragm 1916a expands, liquid is drawn through liquid channel <NUM>, past liquid inlet valve 1922a, and into the liquid pump diaphragm 1916a. Similarly, when air pump diaphragms 1916b, 1916c expand, air is drawn through an opening, past air inlet valves 1922b, 1916c, and into the air pump diaphragms 1916b, <NUM> c respectively. When the liquid pump diaphragm 1916a compresses, liquid is forced out of liquid pump diaphragm 1916a and causes the wall of liquid outlet valve <NUM>, which is normally closed due to the natural resiliency of the member, to deflect away from side wall <NUM> and the liquid flows into mixing chamber <NUM> (<FIG>). Similarly, as the air pump diaphragms compress, air is forced out of air pump diaphragms 1916b, 1916c and causes the wall of liquid outlet valve <NUM> to deflect away from side wall <NUM> and the air flows into mixing chamber <NUM>. When pressure from the liquid or air is removed, e.g. when the liquid pump diaphragm 1916a or the air pump diaphragms 1916b, 1916c expand, liquid outlet valve <NUM> seals against side wall <NUM> and seals off the diaphragms 1916a, 1916b, 1916c from the outlet nozzle <NUM>.

The liquid and air mix in a mixing chamber <NUM> to create a foam mixture, and the foam mixture exits pump outlet <NUM>. After the foam mixture exits pump outlet <NUM>, the foam mixture travels through foam cartridge <NUM>. In this particular embodiment, foam cartridge <NUM> includes screens 1926a, 1926b and sponge <NUM>. The foam cartridge <NUM> may include various members, for example, foam cartridge <NUM> members may include one or more screens <NUM> and/or one or more sponges <NUM>. The foam exits the foam cartridge <NUM> and is dispensed out of outlet nozzle <NUM> as rich foam.

The pump diaphragms 1916a, 1916b, 1916c operate sequentially, and the operation of the pump diaphragms 1916a, 1916b, 1916c may take any form as described for the various embodiments of foam pumps described herein. In one embodiment, the liquid pump diaphragm 1916a operates first in an operating cycle, followed by sequential operation by the two air pump diaphragms 1916b, 1916c.

<FIG> is a cross-sectional view of another exemplary embodiment of a sequentially-activated multi-diaphragm foam pump <NUM>. The sequentially activated multi-diaphragm foam pump <NUM> is driven by a motor <NUM> that has a motor shaft <NUM>. The foam pump <NUM> includes a wobble plate <NUM>, a wobble plate pin <NUM> an eccentric wobble plate drive <NUM>, a liquid pump diaphragm <NUM>, two air pump diaphragms <NUM> (only one is shown), mixing chamber <NUM>, liquid inlet <NUM>, liquid inlet valve <NUM>, air pump chamber <NUM>, air inlet <NUM>, air inlet valve <NUM>, outlet valve <NUM>, mixing chamber <NUM> and outlet <NUM>.

The motor <NUM> drives the motor shaft <NUM>, which causes the motor shaft <NUM> to rotate. The rotation of the motor shaft <NUM> causes the eccentric wobble plate drive <NUM> to rotate, and rotation of the eccentric wobble plate drive <NUM> causes the wobble plate pin <NUM> to move along a circular path, which causes the wobble plate <NUM> to undulate. In some embodiments, wobble plate <NUM> includes a ball (not shown) that rides in a socket (not shown) on the pump housing and wobble plate pin <NUM> extends outward and connects to an eccentric wobble plate actuator <NUM> that causes the pin to move along a circular path which causes the wobble plate <NUM> to undulate. As the wobble plate <NUM> undulates, the ends connected to the three pump diaphragms <NUM>, <NUM>, move in upward and downward motions, and the three pump diaphragms <NUM>, <NUM> are expanded and compressed sequentially.

Expansion of the liquid pump diaphragm <NUM> causes the liquid inlet valve <NUM> to open and draws liquid, such as, for example, soap or sanitizer into liquid pump chamber <NUM> through liquid inlet <NUM>. Expansion of the air pump diaphragms <NUM> (only one is shown) causes the air inlet valves <NUM> to open (only one is shown) and draw air into air pump chambers <NUM> through air inlets <NUM> (only one is shown). Compression of the liquid pump diaphragm <NUM> causes liquid pump chamber <NUM> to compress, which causes outlet valve <NUM> to deflect and open, and causes liquid to flow into the mixing chamber <NUM>. Compression of one of the air pump diaphragms <NUM> causes air pump chamber <NUM> to compress, which causes outlet valve <NUM> to deflect away from the side wall and open to allow air to flow the mixing chamber <NUM>. The second air pump diaphragm similarly pumps air into the mixing chamber. The air and liquid soap or sanitizer mix in the mixing chamber <NUM> to create a foam mixture. The foam mixture travels through foam cartridge <NUM> and exits the foam pump <NUM> through pump outlet <NUM>.

One sequence of operation of the foam pump <NUM> includes one pump by each of the three pump diaphragms <NUM>, <NUM>. The liquid pump diaphragm <NUM> operates first in the cycle of operation, followed by sequential distributions by the two air pump diaphragms <NUM>.

<FIG> is an exploded view of another exemplary embodiment of a sequentially-activated multi-diaphragm foam pump <NUM>. Foam pump <NUM> is driven by motor <NUM>. Foam pump <NUM> includes a pump housing <NUM>, a wobble plate <NUM>, a diaphragm assembly seat <NUM>, a diaphragm assembly <NUM>, a valve seat <NUM>, inlet valves 2323a, 2323b, 2323c a gasket <NUM>, and a cover <NUM>. The cover <NUM> is attached to the valve seat <NUM>, and the gasket <NUM> is located between the cover <NUM> and gasket <NUM> forms a seal around air inlet apertures <NUM>, liquid inlet <NUM> and foam outlet <NUM> to prevent fluid leaks. Inlet valves 2323a, 2323b, 2323c are secured to and seated in the valve seat <NUM>.

The diaphragm assembly <NUM> includes three pump diaphragms 2311a, 2311b, 2311c, and each pump diaphragm 2311a, 2311b, 2311c has a connector <NUM> The diaphragm assembly <NUM> sits in the diaphragm assembly seat <NUM>. The pump diaphragms 2311a, 2311b, 2311c, are disposed in the receiving holes 2313a, 2313b, 2313c respectively, of the diaphragm assembly seat <NUM>, and the three connectors <NUM> connect to the wobble plate <NUM> by inserting the three connectors <NUM> into three respective wobble plate links <NUM>.

The bottom of valve seat <NUM> has three cylindrical projections 2351a, 2351b, 2351c that correspond to the three pump diaphragms 2311a, 2311b, 2311c respectively. The three pump diaphragms 2311a, 2311b, 2311c fit snugly over the three cylindrical projections 2351a, 2351b, 2351c and perform the function of one-way liquid outlet valves. When pump diaphragms 2311a, 2311b, 2311c expand and the interior of the pump diaphragms 2311a, 2311b, 2311c are under negative pressure, the pump diaphragms 2311a, 2311b, 2311c seal against the wall of cylindrical projections 2351a, 2351b, 2351c, respectively, and prevent the flow of fluid into the pump diaphragms 2311a, 2311b, 2311c from between the pump diaphragms 2311a, 2311b, 2311c and the wall of cylindrical projections 2351a, 2351b, 2351c. When pump diaphragms 2311a, 2311b, 2311c compress and the interior of the pump diaphragms 2311a, 2311b, 2311c are under positive pressure, the pump diaphragms 2311a, 2311b, 2311c flex away from the wall of cylindrical projections 2351a, 2351b, 2351c, respectively, and allow fluid to flow out of the pump diaphragms 2311a, 2311b, 2311c. When the positive pressure stops, or is below the cracking pressure of the pump diaphragms 2311a, 2311b, 2311c, the pump diaphragms 2311a, 2311b, 2311c move back to their normal position and form a seal against wall of cylindrical projections 2351a, 2351b, 2351c. In addition, each cylindrical projections 2351a, 2351b, 2351c has one or more fluid inlet apertures 2309a, 2309b, 2309c that extend through valve seat <NUM> and a valve stem retention aperture 2329a, 2329b, 2329c respectively.

Similar to the embodiments described above, during operation, when liquid pump diaphragm 2311a expands, a vacuum is crated and liquid is drawn in through liquid inlet <NUM>, through fluid inlet apertures 2309a, past fluid inlet valve 2323a and into liquid pump diaphragm 2311a. Similarly, when air pump diaphragms 2311b, 2311c expand, air is drawn in through air inlets <NUM>, through air inlet apertures 2309b, 2309c, past fluid inlet valves 2323b, 2323c and into air pump diaphragms 2311b, 2311c.

When liquid pump diaphragm 2311a contracts, a positive pressure is created in the diaphragm <NUM> and once the positive pressure reaches the selected cracking pressure, the diaphragm 2311a flexes away from the cylindrical wall 2351a and flows into mixing chamber <NUM>. When air pump diaphragm 2311b, 2311c contract, a positive pressure is created and once the positive pressure reaches the selected cracking pressure, diaphragms 2311b, 2311c flex away from the cylindrical wall 2351b, 2351c respectively and air flows into mixing chamber <NUM>. The air and liquid mix together to form a foamy mixture which is forced out of outlet <NUM>. The foam mixture may be dispensed as is or may be further refined with the use of foam cartridges, sponges, screens, baffles, or the like and combinations thereof (not shown).

In some embodiments, the liquid pump diaphragm 2311a includes a sponge (not shown) to limit the amount of liquid that may is drawn in and expanded to create different air to liquid mix ratios. In some embodiments, a flow control valve (not shown) is attached to liquid inlet <NUM> so that the flow of liquid can be controlled to adjust the air to liquid ratio.

The pump diaphragms 2311a, 2311b, 2311c are expanded and compressed by movement of wobble plate <NUM>. The shaft <NUM> of motor <NUM> connects to eccentric wobble plate drive <NUM>. Wobble plate pin <NUM> connects to eccentric wobble plate drive <NUM> in an area that is offset from the centerline of the motor shaft <NUM>. Having the wobble plate pin <NUM> offset from the motor shaft <NUM> causes circular movement of the wobble plate pin <NUM>, which causes the ends of the wobble plate <NUM> to sequentially undulate. The undulation causes the pump diaphragms 2311a, 2311b, 2311c to sequentially compress and expand to pump the liquid and the air.

<FIG> illustrate another exemplary embodiment of a sequentially-activated multi-diaphragm foam pump <NUM>. Foam pump <NUM> includes a pump housing <NUM>, liquid inlet valve <NUM>, three air inlet valves <NUM> (only one is shown), a wobble plate <NUM>, a liquid pump diaphragm <NUM>, three air pump diaphragms <NUM> (only one is shown), mixing chamber <NUM>, and foam pump outlet <NUM>. The foam pump <NUM> is coupled to, and in fluid communication with, foam cartridge housing <NUM>, which houses foam cartridge <NUM>. Foam cartridge <NUM> is in fluid communication with outlet nozzle <NUM>. Foam pump <NUM> also includes liquid inlet <NUM> that is in fluid communication with a container (not shown) holding foamable liquid. The liquid inlet <NUM> is coupled to foam pump <NUM> so that the foamable liquid is directed into liquid pump diaphragm <NUM>.

<FIG> is a prospective view of foam pump <NUM> and illustrates liquid inlet housing <NUM> that is upstream of the liquid pump diaphragm <NUM> and three air inlet areas 2424A, 2424B, and 2424C that upstream of and correspond to the three air pump diaphragms <NUM>. In some embodiments of the pumps described herein, the plurality of pump chambers, e.g. a liquid pump chamber and two or more air pump chambers, are formed by a molded multichamber diaphragm.

The liquid pumping portion includes pump diaphragm <NUM>, liquid pump diaphragm inlet <NUM>, liquid inlet valve <NUM>, liquid pump diaphragm chamber <NUM>, liquid pump diaphragm outlet <NUM>, and outlet valve <NUM>. In this embodiment, outlet valve <NUM> is integrally molded with the liquid pump diaphragm <NUM> and the air pump diaphragms <NUM>. The liquid pump diaphragm <NUM>, the liquid pump diaphragm inlet <NUM>, liquid inlet valve <NUM>, liquid pump diaphragm chamber <NUM>, liquid pump diaphragm outlet <NUM>, and liquid outlet valve <NUM> may take any form described herein. Each air pumping portion includes air pump diaphragm <NUM>, air pump diaphragm inlet <NUM>, air inlet valve <NUM>, air pump diaphragm chamber <NUM>, air pump diaphragm outlet <NUM>, and outlet valve <NUM>. Outlet valve <NUM> is a cylindrical member that deflects away from the sealing wall when the pump diaphragm is under positive pressure to let the air or liquid flow into the mixing chamber. The air pump diaphragms <NUM>, air pump diaphragm inlets <NUM>, air inlet valves <NUM>, air pump diaphragm chamber <NUM>, air pump diaphragm outlet <NUM>, outlet valve <NUM> may take any form described herein.

During operation, the liquid pump diaphragm <NUM> expands and contracts to pump liquid, and the three air pump diaphragms <NUM> expand and contract to pump air. The expansion of the liquid pump diaphragm <NUM> opens liquid inlet valve <NUM> and draws liquid into the liquid pump diaphragm chamber <NUM> through liquid inlet <NUM>. The expansion of each of the air pump diaphragms <NUM> opens the corresponding air inlet valves <NUM> and draws air into the corresponding air pump diaphragm chambers <NUM>. The air enters each air pump diaphragm <NUM> through the corresponding air inlets <NUM> (only one is shown). Wobble plate <NUM> is connected to a motor (not shown), which may take any form described herein. The motor causes the ends of the wobble plate <NUM> to sequentially undulate. The undulation causes the liquid pump diaphragm <NUM> to compress, which causes outlet valve <NUM> to be forced open by the liquid, which flows into the mixing chamber <NUM>. Outlet valve <NUM> is made of a flexible material, such as the same material as the pump diaphragms <NUM>, <NUM>, and in some cases the pump diaphragms <NUM>, <NUM> and outlet valve <NUM> are formed as one piece. The flexible material allows the outlet valve <NUM> to remain closed during expansion of the liquid pump diaphragm <NUM>, as well as when the liquid pump diaphragm <NUM> is in a primed stated. However, during compression of the liquid pump diaphragm <NUM>, the flexible material of the outlet valve <NUM> will be forced open to allow liquid to flow into the mixing chamber <NUM>.

Subsequently, one of the air pump diaphragms <NUM> is compressed by the undulating wobble plate <NUM>, which causes the outlet valve <NUM> to open and air to flow the mixing chamber <NUM>. The flexible material allows the outlet valve <NUM> to remain closed during expansion of the corresponding air pump diaphragms <NUM>, as well as when the air pump diaphragms <NUM> are in a primed stated. However, as with the liquid, during compression of an air pump diaphragm <NUM>, the flexible material of the outlet valve <NUM> will be forced open to allow air to enter mixing chamber <NUM>. Similarly, the remaining air pump diaphragms <NUM> will sequentially compress and pump air into the mixing chamber <NUM>. The air and liquid mix in the mixing chamber <NUM> to create a foam mixture. The foam mixture exits the foam pump <NUM> through pump outlet <NUM>.

As can be seen, the liquid is pumped directly into the mixing chamber <NUM> from liquid pump diaphragm <NUM>. In other words, the liquid does not need to travel through an additional conduit or channel after leaving the liquid pump diaphragm <NUM> and before entering the mixing chamber <NUM>. In some embodiments, the shorter distance between the liquid pump diaphragm outlet <NUM> and the mixing chamber <NUM> improves the efficiency of the foam pump <NUM>.

After the foam mixture exits the foam pump <NUM>, the foam mixture travels through conduit <NUM> of foam cartridge housing <NUM> and enters foam cartridge <NUM>. The foam cartridge housing <NUM> is an elbow component that directs the foam mixture to flow downward. The downward flow of the foam mixture improves the output efficiency of the foam mixture. However, the foam cartridge housing may take any form that allows the foam mixture to exit through outlet nozzle <NUM>.

In any of the above-mentioned embodiments, the size of the liquid path as compared to an air path may vary. In certain embodiments, the liquid path is between about <NUM> times greater and <NUM> times greater than an air path. Also, in certain embodiments, liquid inlet and/or outlet valves have a higher cracking pressure than air inlet and/or outlet valves.

The exemplary embodiments of foam pumps may be used in a soap or sanitizer dispenser. Refill units as described herein include at least a container for holding a liquid. The refill units are removable from the dispenser and may be replaced with a new refill unit. In some embodiments, the foam pump is a permanent part of the dispenser and the refill unit includes a container and a fitting for connecting to a fitting (not shown) on the foam pump. In some embodiments, the refill unit includes the foam pump that is secured to the containers and the foam pump releasably connects to a drive unit, such as a motor, that is permanently secured to the dispenser. In some embodiments, the refill unit includes the container, the foam pump and motor. In some embodiments, the refill unit includes a power source, such as, for example a battery.

In some embodiments, the dispensers include a direct current (DC) power supply. In some embodiments, the power supply has a voltage of between <NUM> and <NUM>, including between about <NUM> and about <NUM>, including between about <NUM> and about <NUM>, including about <NUM>, including about <NUM>, including about <NUM>, including about <NUM>, including about <NUM>, and including about <NUM>.

In some embodiments, the dispensers dispense at between about <NUM> and about <NUM> milliliters/second of foam, including between about <NUM> and <NUM> milliliters/second of foam, including about <NUM> milliliters/second of foam, including about <NUM> milliliters/second of foam, including about <NUM> milliliters/second of foam, including about <NUM> milliliters/second of foam, including about <NUM> milliliters/second of foam, including about <NUM> milliliters/second of foam and including about <NUM> milliliters/second of foam.

A conventional mechanical piston foam pump required <NUM> joules per <NUM> of foam dispensed resulting in <NUM> joules/milliliter of foam. The volume of liquid was <NUM> and the air to liquid ratio was <NUM> to <NUM>. An exemplary pump constructed in accordance with an embodiment the present invention required only <NUM> joules per <NUM> of foam dispensed resulting in <NUM> joules/milliliter of foam. The volume of liquid was <NUM> and the air to liquid ratio was <NUM> to <NUM>.

In some exemplary embodiments, the motor used to drive the foam pump consumes between about <NUM> and about <NUM> joules/<NUM> milliliters of foam output, including between about <NUM> and <NUM> joules/<NUM> milliliters of foam output, including between about <NUM> and <NUM> joules/<NUM> milliliters of foam output, including between about <NUM> and <NUM> joules/<NUM> milliliters of foam output, including between about <NUM> and <NUM> joules/<NUM> milliliters of foam output, including about <NUM> joules/<NUM> milliliters of foam output, including about <NUM> joules/<NUM> milliliters of foam output, including about <NUM> joules/<NUM> milliliters of foam output, including about <NUM> joules/<NUM> milliliters of foam output, including about <NUM> joules/<NUM> milliliters of foam output, including about <NUM> joules/<NUM> milliliters of foam output, including about <NUM> joules/<NUM> milliliters of foam output, including about <NUM> joules/<NUM> milliliters of foam output, including about <NUM> joules/<NUM> milliliters of foam output.

In some embodiments the volume of foam output is between about <NUM>-<NUM> milliliters of foam, including between about <NUM>-<NUM> milliliters of foam, including about <NUM> milliliters of foam, including about <NUM> milliliters of foam, including about <NUM> milliliters of foam, including about <NUM> milliliters of foam and including about <NUM> milliliters of foam.

In some embodiments the volume of foam output has a foam density of between about <NUM> and about <NUM> grams per milliliter of foam, including a foam density of about <NUM> grams per milliliter of foam, including a foam density of about <NUM> grams per milliliter of foam, including a foam density of about <NUM> grams per milliliter of foam, including a foam density of about <NUM> grams per milliliter of foam and including a foam density of about <NUM> grams per milliliter of foam.

In some embodiments, the foam pump is configured to produce a foam that has an air ratio of about <NUM> to <NUM>. In some embodiments, the foam pump is configured to produce a foam that has an air ratio of about <NUM> to <NUM>. In some embodiments, the foam pump is configured to produce a foam that has an air ratio of about <NUM> to <NUM>. In some embodiments, the foam pump is configured to produce a foam that has an air ratio of about <NUM> to <NUM>. In some embodiments, the foam pump is configured to produce a foam that has an air ratio of about <NUM> to <NUM>.

Although the embodiments described above generally included pumps that have one liquid pump chamber and multiple air chambers, in some embodiments the pumps have more than one liquid pump chamber. In some embodiments, the pumps have two or more liquid pump chambers. In some embodiments, the two or more liquid pump chambers pump two or more different liquids.

<FIG> is a prospective view of an exemplary foam outlet nozzle <NUM> that provides ultra-high volume foam soap. In this exemplary embodiment, outlet nozzle <NUM> is connected to a four chamber sequentially activated diaphragm foam pump <NUM> described herein, however, the outlet nozzle <NUM> may be used with other pumps. Pump <NUM> includes a liquid inlet <NUM> and three air inlets <NUM> (only two are visible) and an outwardly flared outlet nozzle <NUM>.

<FIG> is a cross-sectional view of the exemplary foam outlet nozzle <NUM> of <FIG>. Foam outlet nozzle <NUM> includes a fluid inlet <NUM>. Fluid inlet <NUM> receives a liquid/air mixture from foam pump <NUM>. The fluid travels through passage and passes through mix media <NUM>, which may be, for example a screen which causes turbulence in the mixture to create foam. The foamy mixture passes through a second mix media <NUM>, which may also be, for example, a screen. Although this exemplary embodiment contains two mix media <NUM>, <NUM>, it has been discovered that only one mix media <NUM> provides a high quality foam in the novel design of the outlet nozzle <NUM>. The foamy mixture passes through a passage having an inside diameter <NUM> and into a second passage having an inside diameter <NUM>. In some embodiments, the inside diameter <NUM> and <NUM> have an inside diameter of between about <NUM> (<NUM> inches) and about <NUM> (<NUM> inches). Foam outlet nozzle <NUM> includes a flared tip <NUM>. In some embodiments, flared tip <NUM> has an inside diameter of between about <NUM> (<NUM> inches) and about <NUM> (<NUM> inches). In addition, it has been discovered that the length <NUM> of the spout <NUM> has an effect on the quality of the foam output through the foam outlet nozzle <NUM>. In some embodiments, the length <NUM> of the spout is between about <NUM> (<NUM> inches) and about <NUM> (<NUM> inches). Exemplary embodiments of foam outlet spout <NUM> have produced foam densities as low as <NUM> grams/cubic cm, as low as <NUM> grams/cubic cm, as low as <NUM> grams/cubic cm and as low as. <NUM> gram/cubic cm. Without limiting effect, it is believed that high foam volume is due to the large diameter spout <NUM> and the flared tip <NUM>. The hold leading into the tube cannot be too small or foam will breakdown.

In some exemplary embodiments the liquid cylinder (not shown) of the foam pump <NUM> utilize a mechanism to throttle the liquid flow entering foam pump <NUM>, such as, for example, lost motion, smaller diameter liquid diaphragm, a restrictor valve, a restrictor inlet, a sponge located within the liquid diaphragm, or the like. In some embodiments, depending on the soap formulation level of alcohol and surfactant type the nozzle <NUM> of the foam pump <NUM> may differ in design. A larger diameter nozzle with a single screen will foam a soap formulation that is harder to foam, such as a soap with alcohol or a non-ideal surfactant and create a foam with large bubbles. A better foaming formulation will be able to create a high-volume foam with consistent and small bubbles when mated with a smaller nozzle diameter and dual screens.

As discussed above, in some instances it is desirable to adjust the volume of one or more of the pump diaphragms to control the liquid to air ratio that is combined to form a foam. The systems and methods described below may be applied to any of the exemplary embodiments disclosed herein. For example, the systems and methods may be applied to a three-diaphragm foam pump, a four-diaphragm foam pump, a five-diaphragm foam pump, etc. In some exemplary embodiments, the volume of the liquid pump diaphragm(s) is reduced. In some embodiments, the liquid pump diaphragm(s) moves a shorter distance than the corresponding air pump diaphragms due to "lost motion". That is the mechanism (in this case, a wobble plate) moves the same distance for both the air pump diaphragms and the liquid pump diaphragm(s), however, due to intentional lost motion in the connection between the liquid pump diaphragm(s) and the wobble plate, the liquid pump diaphragm(s) do not move over the entire course of movement of the wobble plate, but rather only move a portion of the distance the wobble plate moves, while the air pump diaphragms move substantially the same distance as the wobble plate moves. Although description above is directed to lost motion in the liquid pump diaphragms, the inventive concept works equally well for one or more air pump diaphragms. In some exemplary embodiments, the lost motion occurs between the wobble plate and one or more air pump diaphragms, with or without lost motion occurring between one or more liquid pump diaphragms.

<FIG> is a cross-sectional view of an exemplary embodiment of a pump diaphragm <NUM>. Pump diaphragm <NUM> includes a stem <NUM>, a retaining member <NUM>, a base <NUM>, a pump chamber <NUM> and an upper surface <NUM> of pump chamber <NUM>. In this exemplary embodiment, stem <NUM> has a length <NUM> and pump chamber <NUM> has a pump chamber depth <NUM>. Stem <NUM> is sized so that when pump diaphragm <NUM> is connected to a wobble plate <NUM> (<FIG>), there is little to no clearance between wobble plate <NUM> and the top of base <NUM> and the bottom of retaining member <NUM>. Accordingly, as wobble plate <NUM> moves in an upward direction, pump diaphragm <NUM> moves substantially the same distance as wobble plate <NUM>. Similarly, as wobble plate <NUM> moves in a downward direction, pump diaphragm <NUM> moves substantially the same distance as wobble plate <NUM>.

<FIG> is a cross-sectional view of an exemplary embodiment of a pump diaphragm <NUM> configured for lost motion. Pump diaphragm <NUM> includes a stem <NUM>, a retaining member <NUM>, a base <NUM>, a pump chamber <NUM> and an upper surface <NUM> of pump chamber <NUM>. In this exemplary embodiment, stem <NUM> has a length <NUM>. Length <NUM> is greater than length <NUM> of pump diaphragm <NUM>. Pump chamber <NUM> has a pump chamber depth <NUM>. In this exemplary embodiment, pump chamber depth <NUM> has been decreased to ensure that pump chamber <NUM> is fully compressed on each stroke, eliminating, or substantially eliminating the possibility of air remaining in pump chamber <NUM> during operation of the pump. In some embodiments, the depth of pump chamber <NUM> need not be reduced.

Stem <NUM> is sized so that when pump diaphragm <NUM> is connected to a wobble plate <NUM> (<FIG>), there is clearance between wobble plate <NUM> and the top of base <NUM> and/or between the wobble plate <NUM> and the bottom of retaining member <NUM>. Accordingly, as wobble plate <NUM> moves in an upward direction from base <NUM>, pump diaphragm <NUM> does not initially move upward. After wobble plate <NUM> contacts the bottom surface of retaining member <NUM>, pump diaphragm <NUM> moves the remaining distance that wobble plate <NUM> moves. Accordingly, pump diaphragm <NUM> does not move as far as wobble plate <NUM>. As wobble plate <NUM> moves in a downward direction, pump diaphragm <NUM> does not move until wobble plate <NUM> contacts base <NUM>. After wobble plate <NUM> contacts base <NUM>, continued movement in the downward direction causes the pump diaphragm <NUM> to move the remaining distance that wobble plate <NUM> moves, fully compressing pump chamber <NUM>.

In comparing pump diaphragm <NUM> and pump diaphragm <NUM>, preferably by the length of stem <NUM> is increased by lowering base <NUM> so that retaining member <NUM> is located at substantially the same place as retaining member <NUM>, while base <NUM> is lower than base <NUM>.

<FIG> is a partial cross-section of an exemplary embodiment of a pump <NUM> having two air pump chambers and a single liquid pump chamber having lost motion and a reduced pump diaphragm volume. Although the exemplary embodiment illustrates two air pump diaphragms and one liquid pump diaphragm, the inventive concepts may be applied to pumps having two or more air pump diaphragms and/or two or more liquid pump diaphragms.

Pump <NUM> includes a liquid inlet <NUM>, a liquid first inlet valve <NUM>, a second liquid inlet valve <NUM>, a fluid outlet valve <NUM> and a liquid pump diaphragm <NUM>. Liquid pump diaphragm <NUM> includes a liquid pump chamber <NUM>, a base <NUM>, a stem <NUM> and a retaining member <NUM>. In addition, pump <NUM> includes two air pump diaphragms <NUM> having two air pump chambers <NUM>, stems <NUM>, bases <NUM> and retaining members <NUM>. The air pump chambers <NUM> and liquid pump chamber <NUM> are in fluid communication with fluid outlet valve <NUM>. Downstream of fluid outlet valve <NUM> is fluid passage <NUM>, a first porous foaming member <NUM>, a foaming area <NUM>, a second porous foaming member <NUM> and a foam outlet <NUM>.

Liquid pump chamber <NUM> is smaller than the corresponding air pump chambers <NUM>. In addition, stem <NUM> of liquid pump diaphragm <NUM> is longer than stems <NUM> of air pump diaphragms. Retaining members <NUM> and <NUM> are all substantially the same size and located substantially in the same plane. Accordingly, as described above with respect to the wobble plates, as an actuator, such as the wobble plate, actuates the liquid pump diaphragm <NUM> and the air pump diaphragms <NUM>, the base <NUM> of liquid pump diaphragm <NUM> moves less than the wobble plate, because of the lost motion caused by the increased length in stem <NUM>.

<FIG> is a cross-sectional view of another exemplary embodiment of a pump diaphragm <NUM>. Pump diaphragm <NUM> is similar to pump diaphragm <NUM> and includes a stem <NUM>, a retaining member <NUM>, a base <NUM>, a pump chamber <NUM> and an upper surface <NUM> of pump chamber <NUM>. In this exemplary embodiment, stem <NUM> has a length <NUM> and pump chamber <NUM> has a pump chamber depth <NUM>. Stem <NUM> is sized so that when pump diaphragm <NUM> is connected to a wobble plate (not shown), there is little to no clearance between wobble plate and the top of base <NUM> and the bottom of retaining member <NUM>. Accordingly, as wobble plate moves in an upward direction, pump diaphragm <NUM> moves substantially the same distance as wobble plate. Similarly, as wobble plate moves in a downward direction, pump diaphragm <NUM> moves substantially the same distance as wobble plate. The difference between pump diaphragm <NUM> and pump diaphragm <NUM> is the volume of pump chamber <NUM> has been reduced by reducing the width <NUM> of the pump diaphragm <NUM>. Accordingly, if pump diaphragm <NUM> is the liquid pump diaphragm and the pump includes two air pump diagrams that are similar to pump diaphragm <NUM>, for each rotation of the wobble pump, there will be greater than <NUM> times the volume of air pumped as the volume of liquid pumped.

While, changing the volume of one or more pump chambers in a multi-diaphragm foam pump is effective, it may not be suitable for having multiple pump lines with slightly different liquid to air volume ratios Furthermore, there is often some "guess work" involved in adjusting the volume sizes to arrive at the desired liquid to air ratio. In addition, different formulations may require minor tweaks to the liquid to air ratios. Making minor changes or fine tuning by changing the volumes of the pump chambers is time consuming and it may be cost prohibitive.

In some embodiments, the wobble plate is modified so that one or more of the pump diaphragms do not move the same distance as the one or more other pump diaphragms, and/or do not move as far as the wobble plate wing moves. For example, the wobble plate wing may be thinner (with respect to other wobble plate wings) at the point of connection to the liquid pump diaphragm resulting in a greater degree of movement of the wobble plate verses the liquid pump diaphragm. Although the this description is with respect to the liquid pump diaphragm, the concept may be used on one or more of the air pump diaphragms as well.

<FIG> is a partial cross-section of an exemplary sequentially activated foam pump <NUM> with an exemplary non-uniform wobble plate <NUM> for controlling and/or fine tuning the liquid to air ratio for adjusting foam density. A "non-uniform" wobble plate means that one or more of the wobble plate wings has one or more contact surfaces that are positioned differently than one or more other contact surfaces of another wobble plate wing.

Use of a non-uniform wobble plated allows for foam density of a liquid to air mixture may be controlled, changed and/or tweaked by changing the liquid to air ratio without necessitating a change in the volume of one or more of the pump chambers. In some exemplary embodiment, the liquid pump chamber has a different volume than the air pump chamber and a non-uniform wobble plate may be used to fine tune the sequentially activated foam pump for a desired formulation and/or a desired foam density. In some embodiments, however, the liquid pump chamber has the same volume as the one or more air pump chambers and a non-uniform wobble plate may be used to change, fine tune and or tweak the liquid to air ratio of the sequentially activated foam pump.

Sequentially activated foam pump <NUM> is similar to the sequentially activated foam pumps described above and like components may not be redescribed with respect to foam pump <NUM>. In this exemplary embodiment, sequentially activated foam pump <NUM> includes three air pump chambers and one liquid pump chamber. In some embodiments, fewer than three air pump chambers are used. In some embodiments, more than three air pump chambers are used. In some embodiments, more than one liquid pump chamber is used. The inventive concepts disclosed herein may be used with any number of liquid pump chambers and any number of air pump chambers, provided the pump contains at least one liquid pump chamber and at least one air pump chamber.

Sequentially activated foam pump <NUM> includes a liquid inlet <NUM> and a liquid pump chamber <NUM>. Liquid inlet <NUM> is configured to connect to a container (not shown) and may be located in a foam dispenser (not shown). Liquid pump chamber <NUM> is formed in part by flexible liquid pump diaphragm <NUM>. When liquid pump chamber <NUM> expands, liquid flows through the liquid inlet <NUM>, past one way liquid inlet check valve <NUM> and into liquid pump chamber <NUM>. Flexible liquid pump diaphragm <NUM> includes a body <NUM>. Body <NUM> has a tail <NUM> that includes a reduced engagement section <NUM> and an enlarged retention member <NUM>.

Sequentially activated foam pump <NUM> also includes one or more air inlets (not shown) and three air pump chambers. When air pump chamber <NUM> expands, air flows through one or more air inlets (not shown), past one-way air inlet check valve <NUM> and into air pump chamber <NUM> (this exemplary embodiment includes two additional air pump chambers configured in the same way). Air pump chamber <NUM> is formed in part by flexible air pump diaphragm <NUM>. Flexible air pump diaphragm <NUM> has a body <NUM> that includes a tail <NUM> that has a reduced engagement section <NUM> and an enlarged retention member <NUM>.

Sequentially activated foam pump <NUM> also includes an exemplary non-uniform wobble plate <NUM>. Wobble plate <NUM> is a four wing wobble plate. Wobble plate <NUM> includes a first wing <NUM>, a second wing <NUM>, a third wing <NUM> (<FIG>) and a fourth wing <NUM>. First wing <NUM> includes aperture <NUM>, second wing <NUM> includes aperture <NUM>, third wing <NUM> includes aperture <NUM> and forth wing <NUM> includes aperture <NUM>.

Flexible liquid pump diaphragm <NUM> is secured to wobble plate <NUM> by pulling liquid pump diaphragm tail <NUM> through aperture <NUM> in wing <NUM>. Enlarged retention member <NUM> elongates and pulls through aperture <NUM> and then returns to its enlarged shape. Once flexible liquid pump diaphragm <NUM> is connected to wobble plate <NUM>, engagement section <NUM> is located within aperture <NUM> and wobble plate <NUM> is connected to liquid pump diaphragm <NUM>. Wing <NUM> contacts and applies force to the enlarged retention member <NUM> when the liquid pump chamber <NUM> is expanded and applies force to body <NUM> to compress liquid pump chamber. In some embodiments, liquid pump chamber <NUM> will expand on its own, due to the resilient nature of the liquid pump diaphragm <NUM>. In some embodiments, liquid pump chamber <NUM> will expand partially on its own, due to the resilient nature of the liquid pump diaphragm <NUM>.

Flexible air pump diaphragm <NUM> is connected to wobble plate <NUM> by pulling air pump diaphragm tail <NUM> through aperture <NUM> in wing <NUM>. Enlarged retention member <NUM> elongates and pulls through aperture <NUM>. Once the enlarged retention member <NUM> passes through aperture <NUM> it expands to its original enlarged size. When flexible air pump diaphragm <NUM> is connected to wobble plate <NUM>, engagement section <NUM> is located in aperture <NUM> and wobble plate <NUM> is connected to air pump diaphragm <NUM>. The remaining air pump chambers are likewise connected to the wobble plate <NUM>.

<FIG> is a top plan view of the exemplary non-uniform wobble plate <NUM> and <FIG> is a cross-sectional view of the exemplary wobble plate <NUM>. Wobble plate <NUM> includes an annular extension <NUM> for receiving wobble plate shaft <NUM>.

In this exemplary embodiment, wing <NUM> has a reduced cross-section and surface <NUM> is located inward of surface <NUM> on second wing <NUM>, third wing <NUM> and forth wing <NUM>.

Motor <NUM> is connected to sequentially activated multi-diaphragm foam pump <NUM>. The motor <NUM> has a motor shaft <NUM> that is connected to an eccentric gear <NUM>. Eccentric gear <NUM> connects to wobble plate shaft <NUM>. As the motor shaft <NUM> rotates, wobble plate <NUM> sequentially moves each wing <NUM>, <NUM>, <NUM>, and <NUM> towards sequentially activated multi-diaphragm foam pump <NUM> and away from sequentially activated multi-diaphragm foam pump <NUM>.

When liquid pump chamber <NUM> compresses, liquid in liquid pump chamber <NUM> flows out of liquid pump chamber <NUM>, past outlet valve <NUM> into mixing chamber <NUM>. Similarly, when air pump chamber <NUM> is compressed, air flows out of air pump chamber <NUM>, past outlet valve <NUM> and into mixing chamber <NUM>. Sequential compression of the remaining air pump chambers (not shown) causes additional air to flow past outlet valve <NUM> into mixing chamber <NUM>. The air/liquid mixture flows through outlet conduit <NUM>, through first screen <NUM>, into foaming chamber <NUM>, past a second screen <NUM> and out of outlet <NUM>, where it is dispensed as a foam having a desired density.

In this exemplary embodiment, because contact surface <NUM> is undercut, or located further away from the pump diaphragm, movement of a first distance in the inward direction, may not cause the liquid pump chamber <NUM> to compress because surface <NUM> is undercut or thinned as described below in more detail. Accordingly, wing <NUM> moves a first distance resulting in no compression of the liquid pump chamber <NUM> until surface <NUM> contacts body <NUM>. Further movement of a second distance in the first direction causes compression of the liquid pump chamber <NUM>. Accordingly, a first portion of the inward travel of wing <NUM> toward liquid pump chamber <NUM> does not compress liquid pump chamber <NUM>. In some embodiments, liquid pump chamber <NUM> does not fully compress because of the undercut contact surface.

When wing <NUM> of wobble plate <NUM> moves in a second direction, wing <NUM> pushes against enlarged retention member <NUM> and expands liquid pump chamber <NUM>. In this exemplary embodiment, the bottom surface <NUM> of wing <NUM> is symmetrical with the bottom surface of the remaining wings. By changing the location of contact surface <NUM>, one can change the amount of compression of liquid pump chamber <NUM> without changing the changing the overall movement of wobble plate <NUM>. In this exemplary embodiment, liquid pump chamber <NUM> does not fully compress during the compression cycle.

For the air pump diaphragm <NUM>, when the wobble plate <NUM> moves in a first direction, wing <NUM> pushes against body <NUM> and compresses air pump chamber <NUM>. When wobble plate <NUM> moves in a second direction, wing <NUM> pulls against enlarged retention member <NUM> and expands air pump chamber. In this exemplary embodiment, movement of wings <NUM> (and the other two air pump chambers) result in substantially the same compression or expansion movement of the air pump diaphragms.

As a result, the volume of liquid pumped during operation may be adjusted without changing the size or volume of the liquid pump chamber. The ratio of liquid to air may be changed, tweaked or adjusted by modifying or changing the location of one or more contact surfaces of the wobble plate to adjust the amount of compression (or expansion as described in more detail below) of one or more of the liquid pump chambers or the air pump chambers. As a result, different formulations of fluids may be pumped through the same multi-diaphragm foam pump and be dispensed with different desired foam densities by providing a non-uniform wobble plates having different contact surface locations of one or more wings. In addition, a single formulation may be dispensed with different foam densities by providing non-uniform wobble plates having various non-uniform wobble plate configurations.

Although the exemplary embodiment discloses modifying only wing <NUM>, one or more of the other wings that compress and expand the air pump diaphragms may be similarly modified to fine tune the liquid to air ratio.

In this exemplary embodiment, engagement section <NUM> and engagement section <NUM> have the same length. Similarly, the remaining two air pump diaphragms (not shown) and their respective engagement sections (not shown) have the same length.

The term wing profile may be used to describe some embodiments herein. As described above, wobble plate <NUM> has a plurality of wings, In this exemplary embodiment, wobble plate <NUM> has a first wing <NUM>. First wing <NUM> has a first surface <NUM> for contacting a portion of the body <NUM> of the liquid pump diaphragm <NUM> to compress the liquid pump diaphragm <NUM>. In this exemplary embodiment, first surface <NUM> at least partially surrounds an upper portion of aperture <NUM>. First wing <NUM> has a second surface <NUM> for contacting the enlarged retention member <NUM> to expand liquid pump diaphragm <NUM>. In this exemplary embodiment, second surface <NUM> at least partially surrounds a lower portion of aperture <NUM>. The distance between a portion of first surface <NUM> and second surface <NUM> may be referred to herein as first wing profile distance.

In this exemplary embodiment, wobble plate <NUM> also has a second wing <NUM>. Second wing <NUM> has a first surface <NUM> for contacting a portion of the body <NUM> of the air pump diaphragm <NUM>. In this exemplary embodiment, first surface <NUM> at least partially surrounds an upper portion of aperture <NUM>. Second wing <NUM> has a second surface <NUM> for contacting the enlarged retention member <NUM>. In this exemplary embodiment, second surface <NUM> at least partially surrounds a lower portion of aperture <NUM>. The distance between at least a portion of first surface <NUM> and second surface <NUM> may be referred to herein as a second wing profile distance.

In some embodiments, one or more of the lower wing surfaces may be undercut (or thinned) with respect to one or more of the remaining lower wing surface as described in more detail below. Undercutting the lower wing surface reduces the amount of expansion that occurs with a wing expands a pump chamber. <FIG> illustrates an exemplary embodiment of a non-uniform wobble plate <NUM> having a lower wing surface undercut or reduced. Non-uniform wobble plate <NUM> is similar to non-uniform wobble plate <NUM> and like components are not redescribed herein. Non-uniform wobble plate <NUM> has a wing <NUM>. The lower surface <NUM> of wing <NUM> is undercut or thinned with respect to the lower surfaces <NUM> of the remaining wings <NUM>. In this exemplary embodiment, the upper surfaces of all of the wings are symmetrical. In some embodiments, one or more upper surfaces are undercut or thinned to reduce the amount of compression on one or more pump diaphragms.

In this exemplary embodiment, as wing <NUM> moves inward, contact is made with a diaphragm (not shown) and the pump chamber (not shown) compresses. As wing <NUM> moves outward, it will move a first distance without contacting the enlarged retention member (not shown). As the wing <NUM> moves further outward, contact surface <NUM> will contact the enlarged retention member (not shown) and start to expand the pump chamber (not shown). In this exemplary embodiment, the pump chamber (not shown) may not fully expand. In this exemplary embodiment, the pump chamber (not shown) fully compresses (or at least compresses to the same extent as the other pump chambers (not shown)) because the upper surface of wing <NUM> is the symmetrical with the upper surface of wing <NUM>.

Claim 1:
A foam dispenser (<NUM>) comprising:
a housing (<NUM>);
a receiver (<NUM>) for receiving a container (<NUM>) of foamable liquid;
a foam pump (<NUM>, <NUM>) in fluid communication with the container (<NUM>) of foamable liquid when the container (<NUM>) of foamable liquid is inserted in the receiver (<NUM>);
the foam pump (<NUM>, <NUM>) including:
a housing;
a molded multi-diaphragm pumping member having a liquid pump diaphragm (<NUM>) and one or more air pump diaphragms (<NUM>);
one or more outlet valves (<NUM>) located downstream of the liquid pump diaphragm (<NUM>) and the one or more air pump diaphragms (<NUM>);
a mixing chamber (<NUM>) located downstream of the one or more outlet valves (<NUM>) for mixing foamable liquid from the liquid pump diaphragm (<NUM>) with air from one or more air pump diaphragms (<NUM>);
a drive motor (<NUM>);
the foam pump (<NUM>, <NUM>) operatively coupled to the drive motor (<NUM>) by a wobble plate (<NUM>);
wherein the wobble plate (<NUM>) has two or more wings (<NUM>, <NUM>, <NUM>, <NUM>);
wherein a first wing (<NUM>) has a first wing profile distance between a first surface (<NUM>) that contacts a body (<NUM>) of the liquid pump diaphragm (<NUM>) and a second surface (<NUM>) that contacts a retention member (<NUM>) of the liquid pump diaphragm (<NUM>) and a second wing (<NUM>) has a second wing profile distance between a first surface (<NUM>) that contacts a body (<NUM>) of one of the one or more air pump diaphragm (<NUM>) and a second surface (<NUM>) that contacts a retention member (<NUM>) of the one of the one or more air pump diaphragms (<NUM>); and
an outlet (<NUM>) for dispensing foam,
characterized in that the first wing profile distance is different than the second wing profile distance.