Patent ID: 12239265

DETAILED DESCRIPTION OF THE DRAWINGS

FIGS.1and2show a fluid dispenser10in accordance with a first embodiment of the present invention. The fluid dispenser10has a removable cover12, a housing14, a fluid pump16, and a fluid reservoir18. The fluid pump16and the fluid reservoir18together form a replaceable cartridge110.

As best shown inFIG.3, the housing14has a back plate20that is adapted to be mounted vertically to a wall or other vertical support structure. A pump engagement body22extends forwardly from the back plate20at the bottom of the housing14. The pump engagement body22is configured to removably receive and support the replaceable cartridge110in a manner known in the art. The pump engagement body22may have any suitable structure, including for example those disclosed in U.S. Pat. No. 9,682,390 to Ophardt et al., issued Jun. 20, 2017; U.S. Pat. No. 8,113,388 to Ophardt et al., issued Feb. 14, 2012; and U.S. Pat. No. 5,373,970 to Ophardt, issued Dec. 20, 1994, which are each incorporated herein by reference.

As seen inFIG.3, a time of flight sensor24is mounted on the back plate20above the pump engagement body22. The sensor24is configured to emit a pulse of light horizontally forwardly towards a surface placed in front of the sensor24, and to detect when the pulse of light is reflected back to the sensor24from the surface. The sensor24is able to accurately determine the distance between the sensor24and the surface based on the time it takes for the pulse of light to be reflected back to the sensor24from the surface. Time of flight sensors24are known in the art and are described, for example, in U.S. Pat. No. 10,278,550 to Ophardt et al., issued May 7, 2019, which is incorporated herein by reference.

A processor100, a memory102, and a wireless transmitter104are also mounted on the back plate20adjacent to the sensor24. The processor100is configured to process measurement data received from the sensor24, the memory102is configured to store the measurement data and other information received from the processor100, and the wireless transmitter104is configured to wirelessly transmit the measurement data and other information received from the processor100. A visual indicator106in the form of an LED light108is positioned on the pump engagement body22. The LED light108is configured to turn on or off in response to instructions received from the processor100. The processor100, memory102, wireless transmitter104, and visual indicator106could be positioned at any suitable location or locations, and are not limited to those shown in the drawings. One or more of the processor100, memory102, wireless transmitter104, and visual indicator106could also be omitted in some embodiments of the invention.

A battery holder26extends forwardly from the back plate20at the top of the housing14. The battery holder26is configured to receive batteries for powering various electronic components of the dispenser10, including the time of flight sensor24. A cover locking mechanism28is positioned above the battery holder26. The cover locking mechanism28engages with a top opening30of the cover12to hold the cover12in place over the housing14, as shown inFIG.1. The cover locking mechanism28can be manipulated by a suitable tool, not shown, to remove the cover12and gain access to the housing14so that, for example, the replaceable cartridge110can be removed and replaced. The locking mechanism28has two positions that are indicated by one dot and two dots, respectively, around the perimeter of the top opening30. In a first position, when the triangular marker is pointed towards the one dot, the mechanism28acts as a latch and has no locking functionality. Upon turning the external button of the locking mechanism28ninety degrees counterclockwise by use of a key, so that the triangular marker is pointed towards the two dots, the mechanism28is put in a locked state. The cover12has a transparent window128that is aligned with the LED light108on the housing14, so that the LED light108is visible to a user standing in front of the dispenser10when the cover12is attached to the housing14. Alternatively, the transparent window128could be omitted and the LED light108could be seen through, for example, a thinned section of the cover12in opaque plastic, or the LED light108could be positioned at another location on the dispenser10where it is not hidden behind the cover12.

The fluid pump16is configured to dispense fluid from the fluid reservoir18out of a fluid outlet34of the fluid pump16. As best shown inFIG.3, the fluid pump16threadedly engages with a neck32of the fluid reservoir18. The fluid pump16may have any suitable construction, including for example those disclosed in U.S. Pat. No. 9,682,390 to Ophardt et al., issued Jun. 20, 2017; U.S. Pat. No. 8,113,388 to Ophardt et al., issued Feb. 14, 2012; and U.S. Pat. No. 5,373,970 to Ophardt, issued Dec. 20, 1994, which are each incorporated herein by reference. As is known in the art, the fluid pump16is unvented and generates a vacuum within the fluid reservoir18when the fluid is dispensed from the fluid reservoir18. Fluid pumps16that generate a vacuum are described, for example, in U.S. Pat. No. 7,530,475 to Ophardt, issued May 12, 2009; and United States Patent Application Publication No. 2014/0217117 to Mirbach, published Aug. 7, 2014, each of which is incorporated herein by reference. The fluid pump16is preferably associated with a proximity sensor, not shown, which detects when a user's hand is placed below the fluid outlet34. A motor, not shown, automatically activates the fluid pump16to dispense an allotment of fluid from the fluid reservoir18when the user's hand is detected below the fluid outlet34. The use of a proximity sensor and a motor to automatically activate a fluid pump16is described, for example, in U.S. Pat. No. 5,836,482 to Ophardt et al., issued Nov. 17, 1998, which is incorporated herein by reference. Any other suitable mechanism for automatically or manually activating the fluid pump16could also be used.

The fluid reservoir18is best shown inFIGS.4to20as being a collapsible bottle36for containing a hand cleaning fluid to be dispensed from the fluid dispenser10. The neck32of the bottle36is threaded for engagement with the fluid pump16, and extends concentrically about an axis38. As shown inFIG.20, the neck32defines an opening40that is in fluid communication with a variable volume internal compartment98of the bottle36for delivering the fluid from the internal compartment98to the fluid pump16.

The collapsible bottle36has a front wall42, a rear wall44, a bottom wall46, a top wall48, a right side wall50, and a left side wall52, as best shown inFIGS.4,5, and7. The right side wall50is connected to the rear wall44by a first connecting wall54, as best shown inFIG.5, and the left side wall52is connected to the rear wall44by a second connecting wall56, as best shown inFIG.7. The rear wall44is also referred to herein as the first exterior wall44, the front wall42is also referred to as the second exterior wall42, the bottom wall46is also referred to as the third exterior wall46, the right side wall50is also referred to as the fourth exterior wall50, the left side wall52is also referred to as the fifth exterior wall52, and the top wall48is also referred to as the sixth exterior wall48.

As shown inFIG.19, the front wall42, the rear wall44, and the top wall48are intersected by a first plane58that contains the axis38, and the right side wall50, the left side wall52, and the top wall48are intersected by a second plane60that contains the axis38and is perpendicular to the first plane58. The front wall42, the rear wall44, the right side wall50, and the left side wall52are each spaced from the axis38, with the rear wall44being spaced further from the axis38than the front wall42, the right side wall50, and the left side wall52. The axis38intersects the top wall48, as shown inFIG.19, and passes through the opening40of the neck32, as shown inFIG.7, the neck32extending axially away from the bottom wall46. The bottle36is preferably symmetrical about the first plane58. When viewed from the top, as shown inFIG.19, the bottle36has a substantially square shape, which allows the bottle36to fit within the substantially square cavity that is defined between the housing14and the cover12.

As can be seen inFIG.4, the front wall42has a central panel154with a rounded rectangular perimeter158. At the perimeter158of the central panel154, the central panel154extends a short distance forwardly from a surrounding base portion156of the front wall42. The perimeter158has four linear portions160and four rounded corner portions162. The central panel154, and in particular the curved and rounded portions of the perimeter158of the central panel154, help to reinforce the front wall42and resist deformation of the front wall42when the bottle36collapses.

As can be seen inFIGS.4to8, a groove62extends from near the bottom of the right side wall50up to the top wall48, across the top wall48from the right side wall50to the left side wall52, and down from the top wall48to near the bottom of the left side wall52. The groove62extends inwardly from the exterior surface of the right side wall50, the top wall48, and the left side wall52. As shown inFIG.5, the groove62divides the right side wall50into a front right side portion130that is positioned in front of the groove62, a bottom right side portion132that is positioned below the groove62, and a rear right side portion134that is positioned behind the groove62. As also shown inFIG.5, the groove62divides the top wall48into a front top portion136that is positioned in front of the groove62, and a rear top portion138that is positioned behind the groove62. As shown inFIG.7, the groove62also divides the left side wall52into a front left side portion140that is positioned in front of the groove62, a bottom left side portion142that is positioned below the groove62, and a rear left side portion144that is positioned behind the groove62. The groove62acts as a reinforcement structure64that resists deformation of the right side wall50, the left side wall52, and the top wall48. As can be seen inFIG.19, the groove62is located where a third plane66intersects the right side wall50, the top wall48, and the left side wall52, the third plane66being parallel to the second plane60and spaced towards the rear wall44from the axis38.

As shown in dotted lines inFIG.6, the right side wall50has a right side edge portion68where the right side wall50meets the first connecting wall54. The right side edge portion68extends from a bottom right corner70to a top right corner72of the bottle36. The bottom right corner70is closer to the axis38than the top right corner72is to the axis38, and so the right side edge portion68is slanted relative to the axis38, with the right side edge portion68extending laterally away from the axis38as the right side edge portion68extends axially upwardly from the bottom right corner70to the top right corner72.

The left side wall52likewise has a left side edge portion74where the left side wall52meets the second connecting wall56, as shown in dotted lines inFIG.8. The left side edge portion74extends from a bottom left corner76to a top left corner78of the bottle36. The bottom left corner76is closer to the axis38than the top left corner78is to the axis38, and so the left side edge portion74is also slanted relative to the axis38, with the left side edge portion74extending laterally away from the axis38as the left side edge portion74extends axially upwardly from the bottom left corner76to the top left corner78.

As shown inFIGS.5to8, the first connecting wall54and the second connecting wall56each have a generally triangular shape, with the first connecting wall54extending between the right side wall50and the rear wall44, from the bottom right corner70to the top right corner72, and the second connecting wall56extending between the left side wall52and the rear wall44, from the bottom left corner76to the top left corner78. The rear wall44has a first rear edge portion80where the rear wall44meets the first connecting wall54, as shown in dotted lines inFIG.6, and a second rear edge portion82where the rear wall44meets the second connecting wall56, as shown in dotted lines inFIG.8.

As shown inFIG.6, the first rear edge portion80has a first intermediate portion84where the first rear edge portion80is furthest from the right side edge portion68of the right side wall50. The first connecting wall54is widest at the first intermediate portion84, and narrows moving downwardly from the first intermediate portion84to the bottom right corner70, where the first rear edge portion80and the right side edge portion68meet. The first connecting wall54also narrows moving upwardly from the first intermediate portion84to the top right corner72, where the first rear edge portion80and the right side edge portion68meet again. As shown inFIG.8, the second rear edge portion82likewise has a second intermediate portion86where the second rear edge portion82is furthest from the left side edge portion74of the left side wall52. The second connecting wall56is widest at the second intermediate portion86, and narrows moving downwardly from the second intermediate portion86to the bottom left corner76, where the second rear edge portion82and the left side edge portion74meet, and moving upwardly from the second intermediate portion86to the top left corner78, where the second rear edge portion82and the left side edge portion74meet again.

As shown inFIGS.5to8, the rear wall44extends between a top edge portion88where the rear wall44meets the top wall48, shown in dotted lines inFIG.6, and a bottom edge portion90where the rear wall44meets the bottom wall46, shown in dotted lines inFIG.8. The bottom edge portion90is closer to the axis38than the top edge portion88is to the axis38. The rear wall44has a generally convex shape when viewed from the side, and protrudes laterally outwardly from the right side edge portion68of the right side wall50and from the left side edge portion74of the left side wall52. The convex shape of the rear wall44is defined by the generally triangular shape of the first connecting wall54and the second connecting wall56, as can be seen for example inFIGS.6and8. The convex shape of the rear wall44can also be seen in the cross-sectional side view shown inFIG.18, in which the rear wall44can be seen to bow outwardly relative to a hypothetical straight line146running between the top edge portion88and the bottom edge portion90.

As can be seen inFIG.7, the rear wall44has a flat portion150and a curved portion152. The flat portion150is substantially parallel to the axis38, and extends downwardly from the top edge portion88. Because the flat portion150is substantially parallel to the axis38, and the right side edge portion68and the left side edge portion74are slanted relative to the axis38, the distance between the flat portion150and the right side edge portion68, and the distance between the flat portion150and the left side edge portion74, increases as the flat portion150extends downwardly, as can be seen inFIGS.6and8. The curved portion152extends downwardly from the bottom of the flat portion150, and curves laterally inwardly towards the axis38, meeting the bottom wall46at the bottom edge portion90. As shown in dotted lines inFIG.8, an intermediate area92of the rear wall44where the rear wall44extends furthest from the right side edge portion68and the left side edge portion74is located between the first intermediate portion84of the first rear edge portion80and the second intermediate portion86of the second rear edge portion82.

The right side edge portion68is also referred to herein as the first edge portion68, the first rear edge portion80is also referred to as the second edge portion80, the left side edge portion74is also referred to as the third edge portion74, the second rear edge portion82is also referred to as the fourth edge portion82, the bottom edge portion90is also referred to as the fifth edge portion90, the top edge portion88is also referred to as the sixth edge portion88, the bottom right corner70is also referred to as the first corner portion70, the top right corner72is also referred to as the second corner portion72, the bottom left corner76is also referred to as the third corner portion76, and the top left corner78is also referred to as the fourth corner portion78.

As best shown inFIG.21, the bottom edge portion90, where the rear wall44meets the bottom wall46, has a generally concave shape as seen in side view. As can be seen inFIG.20, the right side edge portion68, where the right side wall50meets the first connecting wall54, and the left side edge portion74, where the left side wall52meets the second connecting wall56, also have a generally concave shape.FIG.20also best shows that the first connecting wall54and the second connecting wall56are substantially planar and are slanted towards the first plane58. More specifically, the first intermediate portion84of the first connecting wall54is closer to the first plane58than the bottom right corner70is to the first plane58, and the first intermediate portion84of the first connecting wall54is further from the second plane60than the bottom right corner70is from the second plane60. Similarly, the second intermediate portion86of the second connecting wall56is closer to the first plane58than the bottom left corner76is to the first plane58, and the second intermediate portion86of the second connecting wall56is further from the second plane60than the bottom left corner76is from the second plane60. In other words, the first connecting wall54and the second connecting wall56both extend towards the first plane58as they extend away from the second plane60. The slant of the first connecting wall54and the second connecting wall56, and many of the other structural features of the bottle36, can also be seen in the cross-sectional views shown inFIGS.10to17.

As can be seen inFIG.21, when the bottle36is coupled to the housing14, the rear wall44is positioned directly in front of the time of flight sensor24, with an outer surface94of the rear wall44being located in the horizontal measurement path of the sensor24. The pulses of light that are emitted by the sensor24are reflected back to the sensor24from the outer surface94of the rear wall44, and the sensor24determines a distance96between the sensor24and the outer surface94of the rear wall44based on the amount of time it takes for the light to be reflected. The outer surface94is also referred to herein as the preselected surface94.

The collapsible bottle36as shown inFIGS.4to22is in an initial configuration, which is the shape of the bottle36when the bottle36is filled with fluid up to its intended capacity. As fluid is dispensed from the bottle36by the fluid pump16, a vacuum pressure is generated within the internal compartment98, which causes the bottle36to collapse from the initial configuration towards a collapsed configuration. When in the collapsed configuration, the internal compartment98contains a much smaller volume of fluid than the initial volume of fluid that is contained in the internal compartment98when in the initial configuration. Preferably, the bottle36collapses until almost all of the fluid has been dispensed therefrom.

The bottle36is designed to collapse in a predictable manner, so that the distance96between the sensor24and the outer surface94can be used to determine the volume of fluid remaining in the bottle36. Various stages of collapse of the bottle36are shown inFIGS.22to26.FIG.22shows the bottle36in the initial configuration, in which the bottle36is 100% full of fluid up to its intended capacity.FIG.23shows the bottle36in a first partially collapsed configuration, in which the bottle36has less fluid than in the initial configuration.FIG.24shows the bottle36in a second partially collapsed configuration, in which the bottle36has less fluid than in the first partially collapsed configuration.FIG.25shows the bottle36in a third partially collapsed configuration, in which the bottle36has less fluid than in the second partially collapsed configuration.FIG.26shows the bottle36in a fourth partially collapsed configuration, in which the bottle36has less fluid than in the third partially collapsed configuration.

As can be seen by comparingFIGS.22to26, as the bottle36collapses, the front wall42and the rear wall44move towards the axis38and towards each other. The rear wall44, which is initially further from the axis38than the front wall42is from the axis38, moves a greater distance towards the axis38and towards the front wall42than the front wall42moves towards the axis38and towards the rear wall44. The rear wall44also inverts from its initial convex shape in side view, as shown inFIG.22, to a concave shape in side view, as shown inFIG.26. In the later stages of collapse, the rear top portion138of the top wall48buckles downwardly, as can be seen inFIG.26.

The bottle36has a number of features that are selected so that the rear wall44moves a relatively large distance towards the axis38, and away from the sensor24, in a predictable manner. For example, the rear wall44is preferably thinner than the front wall42, the bottom wall46, the top wall48, the right side wall50, and the left side wall52. This makes the rear wall44less rigid than the other walls42,46,48,50,52, so that the rear wall44deforms more readily under the vacuum pressure which is generated when the fluid is dispensed.

The convex shape of the rear wall44also allows the rear wall44to move a large distance towards the axis38relatively easily by inverting to a concave shape. A number of features assist with allowing the rear wall44to invert from convex to concave. For example, the slant of the first connecting wall54and the second connecting wall56towards the first plane58as the first connecting wall54and the second connecting wall56extend laterally away from the second plane60, as shown inFIG.20, allows the rear wall44to invert relatively easily by bending the first intermediate portion84and the second intermediate portion86towards the axis38. The concave shape of the bottom edge portion90, the right side edge portion68, and the left side edge portion74also make it easier to invert the rear wall44.

The groove62helps to reinforce the right side wall50, the top wall48, and the left side wall52, so that the rear wall44deforms preferentially over the right side wall50, the top wall48, and the left side wall52. This further ensures that the bottle36collapses in a predictable manner. The uncollapsed right side wall50, top wall48, and left side wall52furthermore provide a cavity for the rear wall44to go into as the bottle36collapses. In addition, the slant of the right side edge portion68of the right side wall50and the left side edge portion74of the left side wall52, as shown inFIGS.5to8, gives the rear top portion138of the top wall48less support than the front top portion136of the top wall48. This causes the rear top portion138of the top wall48, including the top edge portion88, to buckle downwardly in the later stages of collapse, as shown inFIG.26, which allows the rear wall44to continue moving further towards the axis38.

When the bottle36is coupled to the housing14, the neck32and the axis38remain stationary relative to the housing14. As the bottle36collapses, the rear wall44moves towards the axis38and away from the back plate20of the housing14, and thus away from the sensor24. The distance96between the sensor24and the outer surface94of the rear wall44thus increases as the bottle36collapses, with the distance96changing as a function of the volume of fluid remaining in the bottle36. The distance96as measured by the sensor24can thus be used to determine the amount of fluid remaining in the bottle36, provided the relationship between the distance96and the amount of fluid remaining in the bottle36is known.

Preferably at least one fluid dispenser10is used to establish the correlation between the distance96between the sensor24and the outer surface94and the amount of fluid remaining in the bottle36. The fluid dispenser10, or more preferably fluid dispensers10, which are used to establish the correlation are referred to herein as test fluid dispensers10. Once the testing is complete, the test fluid dispensers10may later be used to dispense fluid. Alternatively, the test fluid dispensers10may be produced for testing purposes only. In either case, the test fluid dispensers10are identical to production fluid dispensers10that are produced for the purpose of dispensing fluid, and which may not themselves be directly tested. Because the test fluid dispensers10and the production fluid dispensers10are identical, the correlation between the distance96and the amount of fluid remaining in the bottle36as determined with respect to the test fluid dispensers10can be applied to the production fluid dispensers10as well. The test fluid dispensers10and the production fluid dispensers10all correspond identically to the fluid dispenser10shown inFIGS.1to26.

The testing procedure optionally proceeds as follows. Each test fluid dispenser10is provided with a collapsible bottle36that is filled with a test fluid, with the collapsible bottle36in the initial configuration as shown inFIGS.4to22. The test fluid preferably corresponds to the fluid that will be dispensed from the production fluid dispensers10. The volume of fluid that is contained in the bottle36when in the initial configuration is measured and recorded, and the bottle36is coupled to a fluid pump16, as shown inFIG.3. The bottle36and the fluid pump16are then coupled to the housing14, as shown inFIG.2, so that the outer surface94of the rear wall44is positioned in the horizontal measurement path of the sensor24, as shown inFIG.21. The sensor24is then used to measure the distance96between the sensor24and the outer surface94while the bottle36is in the initial configuration, and this information is recorded in association with the previously measured volume of fluid contained in the bottle36.

The test fluid dispenser10is then repeatedly activated to dispense allotments of fluid from the bottle36, which causes the bottle36to collapse. The volume of fluid remaining in the bottle36as the bottle36collapses is measured at various stages of the collapse, such as the stages shown inFIGS.23to26, and preferably additional stages as well. The volume of fluid may be measured by any suitable direct or indirect method, including for example by weighing the bottle36, by placing the bottle36in water and measuring the displaced volume, or by pouring the fluid from the bottle36into a volumetric flask. For each of the various stages of collapse in which the volume of fluid is measured, the sensor24is also used to measure the distance96between the sensor24and the outer surface94, and this information is recorded in association with the measured volume of fluid.

Preferably, the testing is then repeated multiple times using multiple test fluid dispensers10and multiple collapsible bottles36, to provide a suitably large data set. The data is then processed to determine the correlation between the volume of fluid contained in the bottle36and the distance96between the sensor24and the outer surface94. This correlation can then be used to determine the volume of fluid contained in the bottle36of a production fluid dispenser10, without requiring the volume of fluid to be directly measured, by applying the correlation to the distance96as measured by the sensor24.

An exemplary method of using the fluid dispenser10will now be described with reference toFIGS.1to26. The housing14of the fluid dispenser10may be installed in any suitable location where the dispensing of hand cleaning fluid, such as soap or hand sanitizer, is desired, such as in a washroom or healthcare facility. After the housing14is installed, a replaceable cartridge110, which consists of the fluid pump16coupled to the collapsible bottle36as shown inFIG.3, is coupled to the pump engagement body22of the housing14. The collapsible bottle36is initially completely filled with the hand cleaning fluid and in the initial configuration as shown inFIGS.4to22. The replaceable cartridge110is coupled to the housing14with the rear wall44of the bottle36facing the sensor24, so that the outer surface94of the rear wall44is in the measurement path of the sensor24, as shown inFIGS.2and21. Once the replaceable cartridge110is in place, the cover12is placed over the replaceable cartridge110and coupled to the housing14, as shown inFIG.1. The fluid dispenser10is now ready to dispense the hand cleaning fluid.

To dispense an allotment of the fluid from the dispenser10, a user's hand is placed under the fluid outlet34. The proximity sensor detects the user's hand, which triggers the motor to activate the fluid pump16. This process is repeated for each user that requires a dose of the fluid. As the fluid is dispensed from the bottle36, the bottle36collapses as shown inFIGS.22to26.

The time of flight sensor24periodically measures the distance96between the sensor24and the outer surface94of the rear wall44of the bottle36, and transmits the measurement data to the processor100for processing. The sensor24may, for example, be configured to measure the distance96every time the fluid pump16is activated. This could be done by measuring the distance96immediately after the user's hand is detected below the fluid outlet34, but before the fluid pump16is activated, or by measuring the distance96immediately after each activation of the pump16. The sensor24could also be configured to measure the distance96at preset time intervals, such as every minute or every hour.

When the measurement data is received from the sensor24, the processor100applies the known correlation between the distance96and the volume of fluid contained in the bottle36to calculate the volume of fluid remaining in the bottle36. This information is then sent to the memory102for storage. The information may also, for example, be periodically transmitted by the wireless transmitter104to a server, where it can be compiled with data received from other dispensers10, monitored for hand hygiene compliance purposes, made available for remote viewing, or used for any other desired purpose.

Optionally, the processor100is configured to determine when the volume of fluid remaining in the bottle36falls below a preselected threshold. The preselected threshold could, for example, be set at 25% fluid remaining, 10% fluid remaining, 5% fluid remaining, or any other amount that is suitable in the circumstances. When the processor100determines that the volume of fluid remaining in the bottle36has fallen below the preselected threshold, the processor100sends an activation signal to the LED light108, which causes the LED light108to illuminate. The illuminated LED light108acts as a visual indicator106indicating to users and/or maintenance staff that the bottle36is nearly empty. Maintenance staff are thus able to determine whether the replaceable cartridge110needs to be replaced merely by looking to see whether the LED light108is illuminated, without having to remove the cover12and visually inspect the bottle36. In some embodiments, the dispenser10may also incorporate a passive infrared motion sensor, not shown, which detects when a person is near the dispenser10. The passive infrared motion sensor can be used to control the LED light108by, for example, only triggering the LED light108to be illuminated when motion is detected near the dispenser10. This can help reduce energy costs by having the LED light108turn off when there is no one nearby to see whether it is illuminated. The passive infrared motion sensor may, for example, be located in the back plate20.

The wireless transmitter104can also be used as a notification system112for notifying maintenance staff when the replaceable cartridge110needs to be replaced. For example, the processor100is optionally configured to send a notification alert to be transmitted by the wireless transmitter104when the volume of fluid remaining in the bottle36falls below the predetermined threshold. The notification alert may, for example, be in the form of a text message or e-mail that is sent to maintenance staff cell phones and/or computers. The alert may provide information such as the location of the dispenser10requiring a new cartridge110, the volume of fluid remaining in the bottle36, the type of cartridge110that is used in the dispenser10, and/or the type of fluid that is dispensed from the dispenser10.

To replace the replaceable cartridge110, the cover12is removed from the housing14using a suitable tool. The replaceable cartridge110can then be removed from the pump engagement body22by sliding the replaceable cartridge110horizontally forwardly. The replaceable cartridge110can then be disposed of, and a new replaceable cartridge110, with the bottle36completely filled with hand cleaning fluid and in the initial configuration, can be coupled to the housing14. Once the new replaceable cartridge110is coupled to the housing14, the cover12is placed back onto the housing14and the dispenser10is ready to continue dispensing fluid.

Optionally, the collapsible bottle36of the present invention may be produced by a blow molding process as described below. In a first stage of the process, a suitable material such as polyethylene or another polymer is melted, and the molten material is formed into a cylindrical preform114by injection molding, or by any other suitable process as known in the art. The preform114may, for example, have the shape and configuration as shown inFIG.27. As can be seen inFIG.27, the preform114includes the threaded neck32of the bottle36, and a cylindrical preform wall116that extends concentrically about the axis38. The preform wall116preferably has a substantially uniform thickness. In a second stage of the process, the preform114is heated above its glass transition temperature and placed in a mold, and high pressure air is injected into the opening40. This causes the preform wall116to inflate and expand into the shape of the mold, with the expanded preform wall116forming the front wall42, the rear wall44, the top wall48, the right side wall50, the left side wall52, the first connecting wall54, and the second connecting wall56of the bottle36. The bottle36is then removed from the mold once it has sufficiently cooled and hardened.

The blow molding process allows the rear wall44to be made thinner than the front wall42, the right side wall50, and the left side wall52. In particular, the thickness of the preform wall116decreases as it expands radially outwardly from the axis38. Because the rear wall44is further from the axis44than the front wall42, the right side wall50, and the left side wall52, as can be seen inFIG.19, this causes the rear wall44to be thinner than the front wall42, the right side wall50, and the left side wall52. As described above, this makes it easier to deform the rear wall44in comparison with the front wall42, the right side wall50, and the left side wall52, with the result that the rear wall44deforms first and to the greatest extent when the bottle36collapses.

The collapsible bottle36of the present invention could also be produced by any other suitable process, including by extrusion blow molding. In an extrusion blow molding process, a hot tube of a suitable polymer, called a parison, is extruded and captured by a cooled mold. Air is then blown into the parison, inflating it into the shape of the bottle36. As with the injection blow molding process described above, in an extrusion blow molding process the rear wall44can also be made thinner than the front wall42, the right side wall50, and the left side wall52, by positioning the rear wall44further from the axis38than the front wall42, the right side wall50, and the left side wall52.

Reference is now made toFIGS.28and29, which show a fluid dispenser10in accordance with a second preferred embodiment of the invention. The dispenser10shown inFIGS.28and29is identical to the dispenser10shown inFIGS.1to26, with the only difference being the addition of a second time of flight sensor118. Like numerals are used to denote like components.

As can be seen inFIG.28, the second time of flight sensor118is placed on an inside surface120of the cover12. When the cover12is coupled to the housing14, the second time of flight sensor118faces rearwardly towards an exterior surface122of the front wall42of the collapsible bottle36. The second time of flight sensor118is configured to emit a pulse of light horizontally rearwardly towards the exterior surface122, and to detect when the pulse of light is reflected back to the second sensor118from the exterior surface122. The second sensor118is able to determine a distance124between the second sensor118and the exterior surface122based on the time it takes for the pulse of light to be reflected back to the second sensor118from the exterior surface122. The exterior surface122is also referred to herein as the second preselected surface122.

As can be seen inFIGS.22to26, the front wall42moves towards the axis38as the collapsible bottle36collapses. As such, the distance124between the second sensor118and the exterior surface122changes in a predictable manner as a function of the volume of fluid remaining in the bottle36. The measurement data from the second time of flight sensor118can therefore supplement the measurement data from the first time of flight sensor24, and may help to provide a more accurate determination of the amount of fluid remaining in the bottle36. For example, if there is any variability in the positioning of the collapsible bottle36relative to the housing14, or in the collapse pattern of the bottle36, having measurement data from both sensors24,118may help to detect and control for this variability. The fluid dispenser10shown inFIGS.28and29functions identically to the dispenser10shown inFIGS.1to26, except that the second sensor118periodically measures the distance124between the second sensor118and the exterior surface122of the front wall42, and the processor100uses the measurement data from both sensors24,118to determine the volume of fluid remaining in the bottle36.

A collapsible bottle36in accordance with a third preferred embodiment of the invention is shown inFIGS.30and31. The collapsible bottle36shown inFIGS.30and31is identical to the bottle36shown inFIGS.2to26, with the only difference being that the groove62has been replaced by a rib126. Like numerals are used to denote like components.

The collapsible bottle36shown inFIGS.30and31may be used to dispense fluid from the fluid dispenser10shown inFIGS.1to3, and functions in the same way as the collapsible bottle36shown inFIGS.2to26. The rib126provides reinforcement to the right side wall50, the top wall48, and the left side wall52, similarly to the groove62. This helps to ensure that the bottle36collapses in a predictable manner, with the rear wall44deforming first and to the greatest extent. The rib126could be made larger or smaller than is shown inFIGS.30and31, and preferably the size of the rib126is selected so that it takes up relatively little space within the housing14. More than one rib126, more than one groove62, a combination of one or more ribs126and grooves62, or any other suitable reinforcement structure64or reinforcement structures64could also be used. The grooves62and the ribs126could also extend a shorter distance or a longer distance than is shown in the drawings, or could extend across different walls50,48,52than is shown in the drawings. For example, the groove62and/or the rib126could optionally extend all the way down to the bottom of the right side wall50and the left side wall52. Alternatively, the groove62and/or the rib126could optionally extend only about half way down the right side wall50and the left side wall52. In other embodiments, the right side wall50and the left side wall52could optionally each have a groove62which does not extend across the top wall48, or which only extends across part of the top wall48.

Each of the embodiments shown inFIGS.1to31and described above therefore provide a collapsible bottle36defining a variable volume internal compartment98for containing a fluid to be dispensed from a fluid dispenser10, the collapsible bottle36comprising: a first exterior wall44; a second exterior wall42; a third exterior wall46; and a neck32that extends along an axis38away from the third exterior wall46, the neck32having an opening40in fluid communication with the internal compartment98; wherein the internal compartment98contains an initial volume of the fluid when the collapsible bottle36is in an initial configuration; wherein, as the fluid is dispensed from the collapsible bottle36, the collapsible bottle36deforms from the initial configuration towards a collapsed configuration, the internal compartment98containing a smaller volume of the fluid when in the collapsed configuration than when in the initial configuration; wherein the first exterior wall44is thinner than the second exterior wall42; wherein the first exterior wall44is further from the axis38than the second exterior wall42is from the axis38when the collapsible bottle36is in the initial configuration; and wherein the first exterior wall44moves towards the axis38as the collapsible bottle36deforms from the initial configuration towards the collapsed configuration.

Each of the embodiments shown inFIGS.1to31and described above therefore also provide a method comprising: providing a fluid dispenser10, the fluid dispenser10having a distance measuring sensor24; providing a collapsible bottle36, the collapsible bottle36containing a fluid to be dispensed from the fluid dispenser10; coupling the collapsible bottle36to the fluid dispenser10so that a preselected surface94of the collapsible bottle36is positioned in a measurement path of the sensor24; activating the fluid dispenser10to dispense an allotment of the fluid from the collapsible bottle36, the collapsible bottle36collapsing as the fluid is dispensed from the collapsible bottle36; using the sensor24to measure a distance96between the sensor24and the preselected surface94of the collapsible bottle36, the distance96changing as the collapsible bottle36collapses; and determining a volume of the fluid contained in the collapsible bottle36based on the distance96between the sensor24and the preselected surface94of the collapsible bottle36.

Each of the embodiments shown inFIGS.1to31and described above therefore also provide a fluid dispenser10comprising: a collapsible bottle36containing a fluid to be dispensed; a fluid pump16for dispensing the fluid from the collapsible bottle36; and a distance measuring sensor24arranged to detect a distance96between the sensor24and a preselected surface94of the collapsible bottle36; wherein the collapsible bottle36collapses as the fluid is dispensed from the collapsible bottle36, and the distance96between the sensor24and the preselected surface94of the collapsible bottle36changes as the collapsible bottle36collapses.

It will be understood that, although various features of the invention have been described with respect to one or another of the embodiments of the invention, the various features and embodiments of the invention may be combined or used in conjunction with other features and embodiments of the invention as described and illustrated herein.

The fluid dispenser10is not limited to the particular construction shown and described herein. For example, the fluid dispenser10could be designed for manual operation rather than automatic operation. The fluid dispenser10could also be configured to dispense fluid from an upwardly oriented bottle36instead of a downwardly oriented bottle36, with the bottle36having the same construction or a different construction from that shown in the drawings. The bottle36could have any suitable construction that collapses in a predictable manner, and is not limited to the particular embodiments shown. For example, the bottle36could be designed so that the front wall42, the rear wall44, the bottom wall46, the top wall48, the right side wall50, and/or the left side wall52deform to a greater or lesser extent, and with a different order and/or pattern of movement, from that described in the preferred embodiments. The bottle36could incorporate any suitable structure or combination of structures that provide a predictable pattern of collapse. For example, in an alternative embodiment the bottle36could have a bellow shaped back region that allows the rear wall44to move towards the axis38as the bellow collapses. Although the preferred embodiments of the invention include a groove62and/or a rib126, these reinforcement structures64are not necessary in all embodiments of the invention. Nor is the convex shape of the rear wall44necessary in all embodiments. In other embodiments, the rear wall44could have a flat or concave shape. The rear wall44could also have a convex shape that differs from that shown in the drawings. For example, the rear wall44could have a convex shape when viewed from above rather than from the side, or could have a convex shape when viewed both from above and from the side. Nor is it strictly necessary for the rear wall44to be further from the axis38and/or thinner than the front wall42.

The sensor24could also be located at a different position than that shown in the drawings. For example, for bottles36having a collapse pattern in which the top wall48moves first and to the greatest extent, the sensor24could be positioned at the top of the cover12facing vertically downwardly towards the top wall48. Any positioning and/or orientation of the sensor24that is suitable for a given dispenser10construction and bottle36construction may be selected. The dispenser10could also be provided with more than two time of flight sensors24,118, with for example each time of flight sensor24,118measuring the distance to a different wall42,44,48,50,52,54,56of the bottle36, and/or to a different portion of the same wall42,44,48,50,52,54,56. Any type of sensor24,118that provides a suitably accurate distance measurement could be used, and the invention is not limited to time of flight sensors24,118as described in the preferred embodiments.

Optionally, the measurement data from the sensor24may be used to determine whether there is a replaceable cartridge110coupled to the housing14, and/or whether the replaceable cartridge110has been installed correctly. For example, if there is no replaceable cartridge110coupled to the housing14, then the sensor24will detect the distance between the sensor24and the cover12, which will be much greater than the expected distance96between the sensor24and the outer surface94of the rear wall44. This large distance measurement can be interpreted by the processor100as indicating that there is no replaceable cartridge110coupled to the housing14, and this information can be conveyed to maintenance staff by, for example, illuminating the LED light108or sending an notification alert via the notification system112. Likewise, if the replaceable cartridge110has been installed incorrectly, for example by placing the rear wall44facing forwards and the front wall42facing backwards, then the sensor24will detect a distance that is different than the expected distance96between the sensor24and the outer surface94of the rear wall44. This unexpected distance measurement can be interpreted by the processor100as indicating that the replaceable cartridge110has been installed incorrectly, and the processor100can notify maintenance staff by, for example, illuminating the LED light108or sending an notification alert via the notification system112.

The fluid dispenser10does not necessarily need to have a processor100, a memory102, a wireless transmitter104, a visual indicator106, an LED light108, and/or a notification system112. For example, the fluid dispenser10could be configured to transmit the measurement data from the sensor24directly to an external computer, for example through a wired connection or the like, and all processing and interpretation of the data could be done by the external computer. Other types of visual indicators106, such as electronic display screens or the like, could also be used.

Although the fluid is preferably a hand cleaning fluid, such as hand soap, hand disinfectant or hand sanitizer, the dispenser10could be used to dispense other fluids as well. The term “fluid” as used herein includes any flowable substance, including liquids, foams, emulsions, and dispersions.

Although this disclosure has described and illustrated certain preferred embodiments of the invention, it is to be understood that the invention is not restricted to these particular embodiments. Rather, the invention includes all embodiments which are functional or mechanical equivalents of the specific embodiments and features that have been described and illustrated herein.