REFILLABLE COUNTERMOUNT DISPENSERS

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001]This application claims priority to and any benefit of U.S. Provisional Application No. 63/642,927, filed May 6, 2024, the content of which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

[0002]Fluid dispensers are commonly used in restaurants, factories, hospitals, and public bathrooms. These dispensers may contain fluids such as, for example, soap and sanitizer dispensers. Some dispensers utilize some type of manual pump actuation mechanism wherein the user pushes or pulls a lever to manually dispense a quantity of fluid into the user's hands. “Hands-free” dispensers may also be utilized wherein the user simply places their hand underneath or in front of a sensor and an electromechanical pump mechanism dispenses a metered quantity of fluid.

[0003]In some embodiments, a dispenser includes a permanent container or reservoir into which additional fluid is poured from an external fluid source (e.g., an external bottle, bag, or other refill container). This arrangement may be preferred for dispensers for which access to the fluid source is inconvenient (e.g., countertop mounted dispensers that store fluid beneath the counter) or undesirable (e.g., dispensers for which user maintenance of the dispenser, such as disassembly and/or replacement of components, is preferably minimized), or to allow for refilling of the dispenser fluid container from a larger, more economical external refill container. Such dispensers are difficult and messy to refill. In addition, there is often a significant amount of waste, or residual fluid, that remains in the external refill container.

[0004]In addition, these dispensers are prone to individuals refilling the dispenser with unauthorized fluids. The unauthorized fluids may not provide the level of cleanliness, germ kill, dirt and germ removal, and the like, as a consumer expects to receive from the dispenser. In addition, unauthorized fluids may damage the dispenser or decrease its life expectancy.

[0005]A variety of mechanical and electronic mechanisms have been utilized to prevent replacement of a depleted installed refill container with an unauthorized or incorrect refill container, for example, to ensure the correct type and quality fluid is being provided, or to limit the source of replacement fluid to approved manufacturers or distributors. Examples of such mechanisms include mechanically, magnetically, electromechanically, or electronically keyed arrangements that require the refill container to have a proper connector or identifier (e.g., magnetic, electromechanical, or electronic identifier) to assemble with and/or enable functioning of the dispenser. Despite these measures, tactics for improper or unauthorized refilling of a dispenser remain, including reuse of an authorized refill container by injection of refill fluid into the container (often referred to as “stuffing” or “drill and fill”).

SUMMARY OF THE INVENTION

[0006]Exemplary soap and sanitizer dispensers are disclosed herein. An exemplary soap or sanitizer dispenser includes a refill port, a refill pump, a reservoir, a wireless communication device configured to read data from a refill container, a controller, memory, an object sensor, a dispensing pump, a foam generator, and a dispensing outlet. The controller receives data from the transceiver. The controller determines as a function of the data whether the refill container is an authorized refill container. If the refill container is an authorized refill container, the controller causes the refill pump to pump liquid from the refill container to the reservoir. If the refill container is not an authorized refill container, the controller does not cause the refill pump to pump liquid from the refill container to the reservoir, and if an object sensor detects an object proximate the dispensing outlet, the controller causes the dispensing pump to dispense a dose of fluid.

[0007]An exemplary reservoir for a soap or sanitizer dispenser is also disclosed. The exemplary reservoir includes a container. The container has a body that includes an outside wall and a first neck located on top of the body. In addition, the body includes a first molded-in cavity configured for receiving an optical emitter. The first molded-in cavity extends from the outside wall to an interior of the container. The body includes a second molded-in cavity configured for receiving an optical receiver. The second molded-in cavity extends from the outside wall to an interior of the container. The body further includes a third molded-in cavity in the body configured for receiving an optical receiver. The third molded-in cavity extends from the outside wall to an interior of the container. The first molded-in cavity is located on a first side of the body and the second molded-in cavity and third molded cavity are located on a second side of the body.

[0008]Another exemplary soap or sanitizer dispenser includes a refill port having a connector, a supply conduit, a liquid reservoir configured for holding soap or sanitizer and a first pump. The first pump is in fluid communication with the supply conduit and the liquid reservoir. The soap or sanitizer dispenser further includes a controller, memory, a transceiver, an object sensor and a second pump. The second pump includes an inlet in fluid communication with the liquid reservoir, and one or more pump outlets. A dispensing outlet is also included. The one or more pump outlets are in fluid communication with the dispenser outlet. The controller receives a signal from the transceiver and as a function of the signal determines whether a refill container is an authorized refill container. If the refill container is an authorized container, the controller causes the first pump to pump liquid, and if the refill container is not an authorized container, the controller does not cause the first pump to pump liquid.

BRIEF DESCRIPTION OF DRAWINGS

[0009]To further clarify various aspects of the present disclosure, a more particular description of inventive concepts will be made by reference to various aspects of the appended drawings. It is appreciated that these drawings depict only typical embodiments of the present disclosure and are therefore not to be considered limiting of the scope of the disclosure. Moreover, while the figures can be drawn to scale for some embodiments, the figures are not necessarily drawn to scale. Features and advantages of the present disclosure will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

[0010]FIG. 1 is a schematic view of an externally filled fluid dispensing system;

[0011]FIG. 2 is an upper perspective view of a counter mountable externally fillable fluid dispenser;

[0012]FIG. 3 is a side view of the fluid dispenser of FIG. 2;

[0013]FIG. 4 is a side cross-sectional view of the upper spout portion of the fluid dispenser of FIG. 2;

[0014]FIG. 5 is an upper perspective view of the upper spout portion of the fluid dispenser of FIG. 2, shown with the access door in an open position;

[0015]FIG. 6 is a side cross-sectional view of the upper spout portion of the fluid dispenser of FIG. 2, shown with the access door in an open position;

[0016]FIG. 7 is an exploded perspective view of the upper spout portion of the fluid dispenser of FIG. 2;

[0017]FIG. 8 is a top view of the lower housing and reservoir portion of the fluid dispenser of FIG. 2;

[0018]FIG. 9 is a side cross-sectional view of the lower housing and reservoir portion of the fluid dispenser of FIG. 2, taken along the line 9-9 of FIG. 8;

[0019]FIG. 10 is another side cross-sectional view of the lower housing and reservoir portion of the fluid dispenser of FIG. 2, taken along the line 10-10 of FIG. 8;

[0020]FIG. 11 is an exploded perspective view of the lower housing and reservoir portion of the fluid dispenser of FIG. 2;

[0021]FIG. 12 is a front view of a refill container for use with an externally fillable fluid dispenser;

[0022]FIG. 13 is a side cross-sectional view of the refill container of FIG. 12;

[0023]FIG. 14 is a partially exploded perspective view of the refill container of FIG. 12;

[0024]FIGS. 15 and 16 are prospective view of a reservoir having an exemplary level sensor;

[0025]FIG. 17 is prospective view of the reservoir with a shrink-wrap sleeve; and

[0026]FIG. 18 is an exemplary dispensing system.

DETAILED DESCRIPTION OF THE INVENTION

[0027]The following description refers to the accompanying drawings, which illustrate specific aspects of the present disclosure.

[0028]As described herein, when one or more components are described as being connected, joined, affixed, coupled, attached, or otherwise interconnected, such interconnection may be direct as between the components or may be indirect such as through the use of one or more intermediary components. Also as described herein, reference to a “member,” “component,” or “portion” shall not be limited to a single structural member, component, or element but can include an assembly of components, members, or elements. Also as described herein, the terms “substantially” and “about” are defined as at least close to (and includes) a given value or state (preferably within 10% of, more preferably within 1% of, and most preferably within 0.1% of).

[0029]Also, while certain exemplary embodiments described in the specification and illustrated in the drawings relate to externally filled counter-mounted fluid dispensers and external refill containers for hand hygiene applications, and systems and methods for monitoring and controlling external refilling of hand hygiene dispenser devices, it should be understood that many of the inventive features described herein may be applied to other devices, systems, and methods. For example, the features described herein may be utilized in other dispensing arrangements (e.g., internal refill cartridge based dispensers, wall mounted dispensers, stand mounted dispensers, standalone dispensers, tabletop dispensers, portable dispensers), dispensers for other types of fluids (e.g., sunscreen, pharmaceuticals), dispensers of solid materials (e.g., powders, particulate), and other types of containment devices.

[0030]“Circuit communication” as used herein indicates a communicative relationship between devices. Direct electrical, electromagnetic and optical connections and indirect electrical, electromagnetic and optical connections are examples of circuit communication. Two devices are in circuit communication if a signal from one is received by the other, regardless of whether the signal is modified by some other device. For example, two devices separated by one or more of the following--amplifiers, filters, transformers, optoisolators, digital or analog buffers, analog integrators, other electronic circuitry, fiber optic transceivers or satellites—are in circuit communication if a signal from one is communicated to the other, even though the signal is modified by the intermediate device(s). As another example, an electromagnetic sensor is in circuit communication with a signal if it receives electromagnetic radiation from the signal. As a final example, two devices not directly connected to each other, but both capable of interfacing with a third device, such as, for example, a CPU, are in circuit communication.

[0031]Also, as used herein, voltages and values representing digitized voltages are considered to be equivalent for the purposes of this application, and thus the term “voltage” as used herein refers to either a signal, or a value in a processor representing a signal, or a value in a processor determined from a value representing a signal.

[0032]“Signal”, as used herein includes, but is not limited to one or more electrical signals, analog or digital signals, one or more computer instructions, a bit or bit stream, or the like.

[0033]“Logic,” synonymous with “circuit” as used herein includes, but is not limited to hardware, firmware, software and/or combinations of each to perform a function(s) or an action(s). For example, based on a desired application or needs, logic may include a software controlled microprocessor or microcontroller, discrete logic, such as an application specific integrated circuit (ASIC) or other programmed logic device. Logic may also be fully embodied as software. The circuits identified and described herein may have many different configurations to perform the desired functions. The exemplary methodologies provide instructions for creating logic to control desired functions.

[0034]Values identified in the detailed description may be exemplary and may be different as needed for a particular dispenser and/or refill design. Accordingly, the inventive concepts disclosed and claimed herein are not limited to the particular values or ranges of values used to describe the embodiments disclosed herein.

[0035]An exemplary aspect of the present application involves systems and methods for monitoring and controlling the refilling of a fluid dispenser, for example, to prevent filling the dispenser with improper or incorrect fluids, or by unauthorized individuals. In one such embodiment, an externally filled soap dispenser is configured to monitor and control refilling of the fluid dispenser from an external refill container by identifying and/or preventing unauthorized or improper refill attempts. As used herein, an “externally filled fluid dispenser” includes any dispenser for which an internal reservoir is refilled by supplying fluid (e.g., from an external refill container) to an external supply port that is connected with or in fluid communication with the reservoir, as compared to a fluid dispenser that houses a replaceable or removable fluid refill container or cartridge, that remains in the dispenser and fluid is dawn out of the removable fluid refill container when fluid is dispensed on a user's hand. An externally filled fluid dispenser arrangement may be desirable for counter mounted dispensers having a spout or nozzle portion and external supply port mounted above a counter (or “above deck”) and a fluid containing portion (e.g., reservoir) mounted below the counter (or “below deck”), for example, to eliminate the need for below-counter access to the dispenser for refilling.

[0036]The exemplary systems illustrated herein are counter-mount dispensers, however, the inventive aspects of this system work well with many dispenser systems, such as, for example, through-the-wall dispenser systems, wherein the dispensing outlet is located on one side of a wall and the reservoir is located on the other side of the wall. In addition, while the illustrated examples show the external supply port in a dispensing spout, the external supply port may be located in any suitable location.

[0037]FIG. 1 schematically illustrates an exemplary fluid dispensing system 10 including an externally filled fluid dispenser 20 and an external refill container 90. The exemplary dispenser 20 includes a below deck reservoir 30 and dispensing mechanism 40 (disposed in housing 41), an above deck spout or nozzle portion 60 having an outlet nozzle 63 connected to the reservoir 30 by a dispense conduit 33, and an external supply port 70 is connected to the reservoir 30 by a supply conduit 35. The dispensing mechanism 40 is operable to pump or otherwise facilitate the flow of fluid from the reservoir 30 through the dispense conduit 33 to the outlet nozzle 63 in response to user manipulation of a user interface (shown schematically at 80).

[0038]An exemplary dispensing mechanism 40 includes a sequentially activated multi-diaphragm pump 41. Sequentially activated multi-diaphragm pump 41 may be, for example, the foam at a distance sequentially activated pumps are shown and described in U.S. Non-Provisional application Ser. No. 18/159,697, which is titled Sequentially Activated Multi-Diaphragm Foam-At-A-Distance Dispenser Systems, filed on Jan. 26, 2023, and which is incorporated herein by reference in its entirety. This pump is desirable for foam-at-a-distance systems, in which the pump pumps liquid and air separately through pump outlets and the liquid and air are mixed together remotely from the pump. Another exemplary sequentially activated multi-diaphragm pump that may be used in the dispensing mechanism 40 is shown and described in U.S. Pat. No. 10,143,339, titled Sequentially Activated Multi—Diaphragm Foam Pumps, Refill Units and Dispenser Systems, which is incorporated herein by reference in its entirety. This pump is desirable for dispensing systems that mix air and liquid proximate the pump and pump the resulting foam mixture up to the dispensing nozzle. Optionally, pump 41 may be a piston foam pump, such as that shown and described with respect to FIG. 9.

[0039]Dispensing mechanism 40 includes a motor 42 for driving pump 41 and an optional encoder 41. Encoder 41 provides a signal to controller 50. The signal may be used to control or change the volume of fluid dispensed during each actuation of the dispenser system 10. In addition, the signal may be used by the controller to determine an estimated amount of fluid remaining in the reservoir 30. In addition, the signal may be used to allow operation of the pump 42 for a selected number of dispenses after controller 50 receives a signal from level sensor 82 (discussed in more detail below) that the reservoir 30 is empty or near empty.

[0040]The user interface may include any suitable manual, electromechanical, or electronic actuating mechanism, including, for example, a manually depressible hand bar or plunger, an electrical switch engaging button, or a “hands free” voice, optic, motion, or proximity sensor. In the schematically illustrated example, the dispenser 20 includes a controller 50 in circuit communication with an electronic user interface 80 (e.g., an infrared object sensor) and in circuit communication with a dispensing mechanism 40. When the controller 50 receives an actuation signal from the user interface 80, the controller initiates operation of the dispensing mechanism 40 to dispense fluid from the reservoir 30 through the dispense passage 33 to the outlet nozzle 63.

[0041]An optional access door (shown schematically at 72) may be provided over the external supply port 70 to hide the external supply port 70 to make the dispenser 10 more aesthetically pleasing, or to prevent or inhibit unauthorized access. The access door 72 may include an optional locking or latching mechanism (e.g., mechanically, electromechanically, electronically), shown schematically at 73, to secure the access door 72 in a closed position covering the external supply port 70, for example, to prevent unauthorized access to the external supply port, and/or to prevent inadvertent or unintentional exposure of the supply port.

[0042]In an exemplary embodiment (described in greater detail below), the spout portion of the dispenser may include an access door panel that is movable (e.g., slideable, pivotable) to expose an external supply port carried by the spout portion. The access door may be unlocked using a variety of arrangements, including, for example, a mechanical key or other insertable tool, a keypad entered combination code, or a radio frequency identification device (RFID), near field communication (NFC.) or other wireless unlocking code. In some embodiments, an unlocking element (e.g., code carrying RFID tag) may be carried by the external refill container, such that an authorized external refill container must be brought into proximity with the access door locking mechanism to open the access door. In other embodiments, the unlocking element may be a separate user-carried component (e.g., a mechanical key or electronic (e.g., RFID) key card.

[0043]In another embodiment, the external supply port 70 of the dispenser 20 may additionally or alternatively include a keyed, self-sealing connector (e.g., a keyed quick disconnect fitting member), shown schematically at 74, that connects with a corresponding keyed, self-sealing connector 94 on the external refill container 90, while preventing an open-flow connection with non-keyed or incorrectly keyed external containers. This arrangement would prevent a user from simply pouring refill fluid into the open or exposed external supply port 70 to refill the reservoir 30, or from supplying refill fluid from an unauthorized or incorrect (i.e., non-keyed or incorrectly keyed) container. The keying mechanism of the connectors may, for example, be mechanically, magnetically, or electromechanically operable.

[0044]In still another embodiment, an external refill container may include an electronic keying mechanism configured to transmit an authorized supply data signal to a controller in the dispenser, to initiate controller operation of a pump to pump refill fluid supplied to the external supply port to pass to the reservoir.

[0045]The external supply port 70 may be located above the reservoir 30 as illustrated. The external supply port 70 may be located below the reservoir 30. The external supply port 70 may be located above the counter C. The external supply port 70 may be located below the counter C. The external supply port 70 may be located remote from the dispenser 10, such as, for example, on the other side of a wall or in a closet.

[0046]In the schematically illustrated exemplary embodiment of FIG. 1, the dispenser 20 includes a pump 36 in circuit communication with the controller 50 and disposed along (and defining a portion of) the supply passage 35. The external refill container 90 includes a keying transponder or tag 96 configured to directly or indirectly transmit an authorized supply data signal to the controller 50 (e.g., to an antenna of the controller) of the dispenser 20, to identify the external refill container 90 as an authorized refill container. In response to receiving the authorized supply data signal, the controller 50 controls operation of pump 36 to pump fluid from the external supply port 70 to the reservoir 30.

[0047]A prior art system includes a valve (not shown) instead of the pump 36. The valve opens up and allows fluid to flow from external refill to reservoir due to gravity. In such systems, the external refill container is a sealed system to prevent unauthorized refilling of the refill container. The refill container is made of a thin plastic and the refill container collapses inward when fluid flows out of the refill container. It takes vacuum pressure to collapse refill container. When the fluid in the refill container gets low, the vacuum pressure slows the flow of fluid out of the refill container. Eventually, the fluid flow out of the refill container stops leaving a large supply of residual waste in the container. In some instances, the maintenance workers squeeze or compress refill container to prevent so much residual waste, however, applying pressure to the refill container may damage the refill port, the reservoir or other components of the dispenser and still does not completely empty the container. In contrast, pump 36 draws sufficient vacuum pressure to completely empty external refill container 90. In addition, pump 36 provides a constant flow rate for fluid flowing from external refill container 90 to reservoir 30. In addition, because fluid can't flow from external refill container 90 to reservoir 30 without operating the pump 36, the system is harder to by-pass.

[0048]In addition, pump 36 provides for flexibility in the location of the external supply port 70, allowing the external supply port 70 to be located virtually any place, including below reservoir 30. When locating external supply port 70 below, or near the top of the reservoir 30, a one-way liquid valve (not shown) may be desired to prevent fluid from flowing out of the reservoir 30 and back through the pump 36.

[0049]Fluid dispensing system 10 includes a reservoir level sensor 82. Level sensor 82 may be any type of level sensor. The level sensor may sense one or more levels. The level sensor may be a continuous level sensor that measures the level at any time, or may detect one or more discrete levels of fluid in the reservoir. The illustrated level sensor 82 is a multi-level optical system (MLOS). Level sensor 82 is an infrared (IR) level sensor and includes a IR transmitter 83 and three IR receivers 84, 85, and 86. The number of IR receivers required will depend on the level of accuracy desired and what the detection of the level of fluid in reservoir is being used for in the dispensing system 90. While level sensor 82 is illustrated with three IR receivers, level sensor 82 may have one or more IR receivers. In some embodiments, level sensor 82 includes 4 or more IR receivers. In some embodiments, level sensor 82 includes 5 or more IR receivers. In some embodiments, level sensor 82 includes 6 or more IR receivers. In some embodiments, level sensor 82 includes 2 or fewer IR receivers.

[0050]IR transmitter 83 is located at the top of the reservoir 30. IR receiver 84 is located near the top of reservoir 30. IR receiver 86 is located proximate the bottom of the reservoir 30 and IR receiver 85 is located between IR receiver 84 and IR receiver 86. Liquid in reservoir 30 limits the IR signal transmission. When liquid is located above the IR receiver, the IR receiver does not receive enough IR radiation to indicate that the liquid is at or below the IR receiver. In this illustration, when reservoir 30 is completely filled, the liquid blocks sufficient radiation from IR receiver 84, IR receiver 85 and IR receiver 86 and controller 50 can determine that reservoir 30 is full. As the liquid drops below IR receiver 84, IR receiver 84 detects IR radiation from the IR transmitter 83 and the controller 50 can determine that the reservoir 30 is not completely full. As the liquid in the reservoir 30 continues to drop and drops below IR receiver 85, controller 85 can determine that the liquid is at the level of IR receiver 85.

[0051]The controller 50 utilizes the reservoir full, i.e. IR receiver 84 not receiving sufficient IR radiation from IR transmitter 83 to shut off pump 36. Optionally, controller 50 may track the time between IR receiver 84 detecting IR radiation from IR transmitter 83 and IR receiver 85 detecting IR radiation from IR transmitter 83 to determine a rate of use of the liquid in reservoir 30.

[0052]As the liquid in reservoir 30 continues to drop and IR receiver 86 receives IR radiation from IR transmitter 83, controller 50 may determine that the reservoir 30 is empty. Controller 50 may prevent operation of dispenser system 10 if the reservoir 30 is empty to prevent issues arising from pumping air out of reservoir 30 into dispensing mechanism 40. This feature is particularly useful in preventing priming issues, e.g. loss of prime. Dispensing mechanism 40 is preferably a sequentially activated multi-diaphragm pump (not shown) and if air gets into the liquid pump chamber (not shown) and liquid feed conduit 41, the air may prevent the pump from drawing liquid in from the reservoir 30 once the reservoir 30 is refilled. Optionally, controller 50 may permit a selected number of dispenses of fluid from dispensing outlet 63 to occur after the signal is received from IR receiver 86 before preventing operation of the system.

[0053]Optionally, as reservoir 30 is refilled, controller 50 may determine the time between when IR receiver 86 stops receiving sufficient IR radiation, due to it being covered by liquid, and the time IR receiver 85 stops receiving IR radiation from IR transmitter 83 to determine rate of fill. The rate of fill may be use, for example, to inform a user as to how much time it will take for the reservoir 30 to be filled.

[0054]Dispenser system 10 may include one or more optional indicators 88. The one or more optional indicators 88 may be one or more light emitting diodes (LEDs), one or more audible indicators, one or more liquid crystal displays (LCDs), one or more other displays, and/or combinations thereof. The one or more indicators 88 may be used to indicate, reservoir full, reservoir needs toped off, reservoir empty, rate of fill, rate of depletion, a dispenser error, and the like.

[0055]Optionally, pump 36 and/or its drive motor 37 may include an optional encoder 38. Controller 50 may receive signals from the encoder 38 and calculate the fill flow rate of the reservoir 30. In addition, the signal provided by the encoder 38 may be used to calculate the volume of liquid removed from the external refill container 90. As described in more detail, the amount of liquid removed, or the amount of liquid remaining, in the external refill container 90 may be written to a memory storage device 96 so that the next time memory storage device 96 is read, the correct volume of fluid that should be remaining in the refill is known by the dispenser.

[0056]In addition, if optional encoder 38 is used, controller 50 may utilize the signal received from the encoder 38 to approximate the level of liquid in the reservoir 30.

[0057]An external refill container 90 may utilize many different electronic keying mechanisms for communicating an authorized supply signal to the controller 20 of the dispenser 10. In an exemplary embodiment, an RFID transponder or tag 96 is located in or on the connector 94 of the container 90 and is arranged to transmit an authorized supply signal to a transceiver 95 housed in the above deck spout portion 60 of the dispenser 20, with the transceiver 95 being in wired or wireless circuit communication with the controller 50 disposed in the below deck housing 41. The proximity of the transponder or tag 96 to the transceiver 95 allows for the use of a passive RFID transponder tag, and the use of short range, low power RFID communication (e.g., Near Field Communication, Bluetooth® LE communication) between the transponder tag and the receiver. Transceiver 95 may conserve power by waking up and checking for an external refill container 90 periodically. The period of time may be adjusted based on system requirements, such as, for example, a desired battery life. The period may be a very short period, such as, for example, a period of time marked in milliseconds. The transceiver 95 transmits the authorized supply data signal to the controller 50 for evaluation of the data signal, and the controller actuates the motor 37 to operate the pump 36.

[0058]The authorization data signal may include one or more codes or other information that may be relevant to whether fluid from the corresponding container should be permitted to be supplied to the dispenser reservoir. For example, a unique serial code may be used to identify a specific batch of refill fluid being supplied, a product code may be used to identify the type of fluid stored in the refill container, and a distributor or manufacturer code may be used to identify the source of the fluid (e.g., to identify the supplier as an authorized distributor or manufacturer). A date code may identify the age of the fluid (e.g., to prevent refilling the dispenser with an expired fluid).

[0059]Transponder or tag 96 may be a writeable memory storage device, such that the controller 50 may transmit to the keying transceiver 95, for storage in the memory storage device 96, additional usage information that may be relevant to future usage of the external refill container. As one example, where an external refill container 90 is intended for a single use, the dispensing system 10 may be configured such that once the external refill container 90 has been connected to the dispenser 10 to supply refill fluid to the dispenser 10, with the keying transceiver 95 placed in circuit communication with the dispenser controller 50, the dispenser controller 50 transmits an invalidating data signal to the keying transceiver 95 to write an invalidating code to (or to erase an authorization code from) the memory storage device 96, to prevent unauthorized re-use of the refill container 90. The disabled refill container 90 may be configured to be recycled and reset by an authorized user or administrator by erasing the invalidating code or writing a new authorization code to the memory storage device.

[0060]As another example, where unauthorized refilling of the external refill container 90 is prohibited, the dispensing system may be configured such that the dispenser controller 50, through data signals received from a level sensor 82, time operation of pump 36 or data signals from encoder 41, determines a fill level of the refill container, or an amount of fluid supplied from the refill container into the reservoir 30, and writes to the writeable memory storage device 96 data corresponding to an amount of liquid in the refill container 90 or an amount of liquid removed from refill container 90. In a subsequent use of the external refill container 30, dispenser controller 50 may obtain an amount of liquid that should be remaining in the refill container 90 and only allow pump 36 to pump the volume of liquid that should be remaining in the refill container 90. In response to identifying an improper refilling of the container 90, the controller 50 may provide an alert, locally (e.g., audible alarm tone, display panel warning light on the user interface 80) and/or remotely (e.g., cell phone text alert, alert transmission to a central computer system). Still further, the controller 50 may transmit an invalidating data signal to the keying transceiver 95 to write an invalidating code to (or to erase an authorization code from) the container's memory storage device 96, to prevent subsequent use of the refill container 90.

[0061]FIGS. 2-11 illustrate various views of an exemplary fluid dispenser 120 for use with an external refill container (e.g., the external refill container 190 of FIGS. 12-14, described in greater detail below). The exemplary dispenser 120 includes a below deck reservoir 130 and pump housing assembly 140 and an above deck spout 160 connected to the pump house assembly by a stem portion 168 that extends through a countertop C (e.g., of a sink or other structure). Although fluid dispenser 120 is configured to be a counter-mount dispenser, fluid dispenser 120 may be any type of fluid dispenser, such as, for example, a through-the-wall dispenser, a stand mounted dispenser, a wall mounted dispenser or the like.

[0062]In the illustrated embodiment, an external supply port 170 (FIGS. 4-6) is disposed within the spout 160 and is concealed by an access door 172 assembled with the spout 160. The access door 172 forms an upper panel portion of the spout 160, such that the access door is flush with the other exterior surfaces of the spout 160 when the access door 172 is in a closed position. The access door 172 is slideable in a forward direction from the closed position to an open position exposing the external supply port 170. While many different structural arrangements may be used for a sliding access door mechanism, in the illustrated embodiment, as shown in FIG. 7, side recesses or tracks 173a in an access door insert 173 (attached to access door panel 171) slidingly interengage with side rails 162a of a spout body insert 162 (secured within a shell portion 161 of the spout 160). The access door 172 includes a latch 176, to secure the access door 172 in a closed position covering the external supply port 170 to prevent unauthorized access to the external supply port. A keyway 171a in the access door panel 171 allows insertion of a key or other tool T (e.g., paper clip) to release the latch 176 for movement of the access door 172. In the illustrated embodiment, the latch 176 includes a flexible tab 162b of the spout body insert 162 that is flexed out of engagement with a shoulder portion 173b of the access door insert when the tool T is inserted into the keyway 171a and pressed against the flexible tab 163b. In other embodiments (not shown), a bitted key or electronic/electromechanical locking mechanism may be utilized to provide increased security against unauthorized opening of the access door.

[0063]The external supply port 170 includes a quick disconnect socket 174 connected with a supply passage 135 extending to the reservoir 130. The quick disconnect socket 174 is configured for interlocking connection with a corresponding quick disconnect plug 194 disposed on the external refill container 190 (e.g., threaded onto an end port of the refill container, see FIG. 13), with the socket 174 and plug 194 self-sealing against fluid passage when disconnected. This self-sealing arrangement prevents a user from simply pouring refill fluid into the exposed external supply port (thereby preventing most incorrect or unauthorized fluid refill operations).

[0064]While many different types of couplings may be used, in an exemplary embodiment, a polypropylene quick coupling type quick disconnect fitting arrangement based on, for example, model no. 60PPV-SE2-06 (manufactured by LinkTech Quick Coupling, Inc.) is utilized. According to another aspect of the present application, a release button may be provided on the spout to facilitate disconnection of the socket and plug. In the illustrated embodiment, a release button 166 is disposed on a rear portion 161b of the spout shell portion 161 and is depressible to engage a spring-loaded release button 174a on the quick disconnect socket 174 for detachment of the refill container quick disconnect plug 194. The refill container 190 may include a removable cap 199 to cover the quick disconnect plug 194 when the refill container is not in use.

[0065]To further safeguard against the supplying of incorrect or unauthorized refill fluid to the reservoir 130, the pump housing assembly 140 of the dispenser 120 includes a pump 136 disposed along, and defining a portion of, the supply passage 135. When the pump 136 is not energized and is not pumping liquid, a refill fluid supplied to the external supply port 170 is blocked within the supply passage 135 by the pump 136, even when supplied by a refill container having the correct quick disconnect plug or other such keyed connector. To energize the pump 136 and cause liquid from the refill container 190 to be pumped into the reservoir 130, the refill container 190 is provided with an electronic keying mechanism 195 that communicates authorization data to a dispenser controller 150 disposed in the pump housing 141 (formed by housing members 141a, 141b, 141c, as shown in FIG. 11), which energizes pump 136 in response to verification of the authorization data until the reservoir 130 is full.

[0066]In the illustrated embodiment, a collar-shaped RFID transceiver 195 is assembled with the quick disconnect plug 194 of the refill container 190 (FIG. 114), and is positioned for short range, low power RFID communication (e.g., Near Field Communication) with a corresponding RFID transceiver 175 disposed in the external supply port 170. The supply port transceiver 175 receives refill container data (e.g., corresponding to supplier identifying distributor codes, fluid and/or container identifying serial numbers, and fluid fill level data) from the refill container transceiver 195, and transmits this data (e.g., by wired circuit communication) to the controller 150. Once the controller 150 verifies that the refill container 190 is from the correct supplier (e.g., by verifying the distributor code stored in the memory of the transceiver), contains the correct fluid (e.g., by verifying the serial number or product code stored in the memory of the transceiver), and/or contains sufficient fluid for refilling (e.g., by checking the fluid fill level data stored in the memory of the transceiver), the controller 150 initiates actuation of the pump 136 to pump liquid from the refill container 190 through the quick disconnect socket 174 to the reservoir 130.

[0067]Pump 136 is driven by a motor 137. Pump 136 may be any type of pump, such as, for example, a gear pump, a diaphragm pump, a sequentially activated diaphragm pump or the like. Pump 136 and/or motor 137 may include an encoder (not shown). The encoder may provide signals to the controller 150, such that the controller 150 may determine rate of fill of reservoir 130, whether refill container 190 is empty, the amount of fluid removed from refill container 190 or the like.

[0068]To trigger RFID communication, transceiver 175 periodically issues an interrogation signal to the refill container transceiver 195, and for receipt of a response transmission of the authorized supply data signal from the refill container transceiver 195. The supply port transceiver 175 transmits the authorized supply data signal to the below deck controller 150 for evaluation of the data signal, and the controller 150 energizes the pump 136 in response to confirmation that the authorized supply data signal corresponds to an authorized refill container (provided that the level of fluid in the reservoir 130 is not at a “full” level).

[0069]The refill container transceiver 195 includes a writeable memory storage device (not shown), such that the below deck controller 150 may transmit (through the supply port transceiver 175) to the refill container transceiver 195, for storage in the memory storage device, additional usage information that may be relevant to future usage of the external refill container 190. As discussed above, data transmitted to the refill container transceiver 195 for storage in the memory storage device may include, for example, fill level data based on the weight change of the dispenser reservoir 130 while the external refill container 190 is connected with the supply port 170 (e.g., as determined by wireless communication between the supply port transceiver 175 and the refill container transceiver 195), or an invalidating code in response to an indication that the external refill container has been improperly reused and/or refilled.

[0070]In the illustrated embodiment of FIGS. 2-11, the fill level of the external refill container 190 is determined based on a known initial or previously determined refill container fill level, and an increase in the fill level of the reservoir 130 as the external refill container 190 supplies fluid to the reservoir, as being equivalent to the corresponding decrease in the refill container fill level. The fill level of the external refill container 190 may also be determined by the volume of liquid pumped out of the refill container 190 by pump 136. The volume may be determined as a function of the run time of pump 136, as a function of the number of revolutions of pump 138, or the like. Optionally, the level of fill may be determined by a float.

[0071]Optionally, the weight of reservoir 130 may be used to determine the volume of liquid removed from the refill container 190 and/or the level of liquid in the reservoir 130. The weight of the reservoir 130 is measured using an optional strain gauge 155 (FIG. 11) having a bottom surface mounted at a first end to a mounting block portion 149 of the pump housing 141 and a top surface to be mounted at a second end to an underside of the counter. The strain gauge 155 includes strain sensing wires (not shown) that bend with the beam shaped strain gauge body as the weight of the reservoir 130 increases, causing a change in the resistance of the wires. These changes in resistance are correlated to weight values by the below deck controller 150.

[0072]When the connector 194 of the external refill container 190 is initially connected with the connector of the dispenser's external supply port, the dispenser controller 150 begins frequent (e.g., once every second) measurements of the current weight of the reservoir (based on data signals from the strain gauge 155). The controller compares the change in the reservoir weight (due to added refill fluid) to stored weight data from the refill container's memory storage device to identify an improper refilling of the container indicated by a reservoir weight increase that exceeds the previous refill container weight (and to initiate one or more of the notification or disabling operations described above). After each weight sensor measurement (e.g., once every second) the controller 150 may transmit the weight data to the refill container's memory storage device for storage of refill container weight data corresponding to the previous refill container weight less the measured increase in the reservoir weight, with the current weight data replacing the previously stored weight data. Alternatively, the weight data may be transmitted to the refill container less frequently, such as, for example, only when the refill procedure has completed. For example, when the connector 194 of the external refill container 190 is disconnected from the connector 174 of the dispenser's external supply port 170, by pressing the release button 166 on the dispenser spout portion 160, the dispenser controller 150 may be triggered or activated to measure a current weight of the reservoir 130 (based on data signals from the strain gauge 155) and transmits current weight data to the refill container's memory storage device corresponding to the previous refill container weight less the measured increase in the reservoir weight, with the current weight data replacing the previously stored weight data.

[0073]Optionally, the level of liquid in reservoir 130 may be determined by a level sensor 182 (FIG. 3). Level sensor 182 may be any type of level sensor. The level sensor may sense one or more levels. The level sensor may be a continuous level sensor that measures the level at any time or may detect one or more discrete levels of fluid in the reservoir. The illustrated level sensor 182 is a multi-level optical system (MLOS). Level sensor 182 is an infrared (IR) level sensor and includes an IR transmitter 183 and three IR receivers 184, 185, and 186. The number of IR receivers required will depend on the level of accuracy desired and what the level of fluid in reservoir is being used for in the dispensing system 120. While level sensor 182 is illustrated with three IR receivers, level sensor 182 may have one or more IR receivers. In some embodiments, level sensor 182 includes 5 or more IR receivers. In some embodiments, level sensor 182 includes 6 or more IR receivers. In some embodiments, level sensor 182 includes 6 or more IR receivers. In some embodiments, level sensor 182 includes 6 or more IR receivers.

[0074]IR transmitter 183 is located at the top of the reservoir 130. IR receiver 184 is located near the top of reservoir 130. IR receiver 186 is located proximate the bottom of the reservoir 130 and IR receiver 185 is located between IR receiver 184 and IR receiver 186. Liquid in reservoir 130 limits the IR signal transmission. When liquid is located above the IR receiver, the IR receiver does not receive enough IR radiation to indicate that the liquid is at or below the IR receiver. In this illustration, when reservoir 130 is completely filled, the liquid blocks sufficient radiation from IR receiver 184, IR receiver 185 and IR receiver 186 and controller 150 can determine that reservoir 130 is full. As the liquid drops below IR receiver 184, IR receiver 184 detects IR radiation from the IR transmitter 183 and the controller 150 can determine that the reservoir 130 is not completely full. As the liquid in the reservoir 130 continues to drop and drops below IR receiver 185, controller 185 can determine that the liquid is at the level of IR receiver 185.

[0075]The controller 150 utilizes the reservoir full, i.e. IR receiver 184 not receiving sufficient IR radiation from IR transmitter 183 to shut off pump 136. Optionally, controller 150 may track the time between IR receiver 184 detecting IR radiation from IR transmitter 183 and IR receiver 185 detecting IR radiation from IR transmitter 183 to determine a rate of use of the liquid in reservoir 130.

[0076]As the liquid in reservoir 130 continues to drop and IR receiver 186 receives IR radiation from IR transmitter 183, controller 150 may determine that the reservoir 130 is empty. Controller 150 may prevent operation of dispenser system 110 if the reservoir 130 is empty to prevent issues arising from pumping air out of reservoir 130 into dispensing mechanism 140. This feature is particularly useful in preventing priming issues. Dispensing mechanism 140 is preferably a sequentially activated multi-diaphragm pump (not shown) and if air gets into the liquid pump chamber (not shown) and liquid feed conduit 141, the air may prevent the pump from drawing liquid in from the reservoir 130 once the reservoir 130 is refilled. Optionally, controller 150 may permit a selected number of dispenses of fluid from dispensing outlet 163 after the signal is received from IR receiver 186 before preventing operation of the system.

[0077]Optionally, as reservoir 130 is refilled, controller 150 may determine the time between when IR receiver 186 stops receiving sufficient IR radiation, due to it being covered by liquid, and the time IR receiver 185 stops receiving IR radiation from IR transmitter 183 to determine rate of fill. The rate of fill may be use, for example, to inform a user as to how much time it will take for the reservoir 130 to be filled.

[0078]The pump housing assembly 140 includes a pump mechanism 142 disposed in the pump housing 141. While many different types of pump mechanisms may be utilized, in the illustrated embodiment, the pump mechanism includes a piston displacement pump 143 (e.g., a piston displacement foaming pump) actuated by a gear motor 144 that drives a cam 145 to rotate an actuator arm member 146 which reciprocates to actuate a lift member 147 secured with an outlet member 148 of the pump 142. The motion is terminated by an end-of-stroke switch (not shown).

[0079]A touch free sensor-based user interface 180 is disposed on a front portion 161a the spout shell 161. The exemplary user interface 180 includes a touch free sensor arrangement 185, with an infrared light emitting diode 186 and light detecting photo diode 187 that senses changes in the reflected light resulting from positioning of a user's hand under the spout. A microcontroller 184 in the user interface transmits an actuation signal to the below deck controller 150 to initiate operation of a pump motor, described in greater detail below. The pump mechanism may be activated within a brief predetermined time period (e.g., about 200 ms) after the user's hand passes within a detection range (or activation zone) of the sensor arrangement 185, to dispense a predetermined dose of fluid in the user's hand. To prevent excess dispensing of fluid, the user interface microcontroller may be configured to require an empty activation zone for a predetermined time period (e.g., about 0.12 seconds) before transmitting a new actuation signal in response to a subsequent detection of a user's hand in the activation zone. The user interface may further include a maintenance indicator light 188 to provide an indication of a dispenser condition requiring attention (e.g., low fluid, low battery, tampering indication).

[0080]The below deck controller 150 is in circuit communication with the user interface 180 and the pump mechanism 142. When the controller 150 receives an actuation signal from the user interface 180 (e.g., corresponding to detection of a user's hand in proximity with the sensor arrangement 185), the controller initiates operation of the pump mechanism 142 to dispense fluid from the reservoir 130 through the dispense passage 133 to the outlet port 163.

[0081]FIGS. 15 and 16 illustrate a reservoir 300 configured for use in a dispensing system. Reservoir 300 includes a container 302. Container 302 has an upper neck 304 and a lower neck 306. Connected to upper neck 304 is a cap 305. Cap 305 is configured to support liquid pumping system 330. Liquid pumping system 330 includes a motor 332, a liquid pump 331, a liquid inlet 334 and a liquid outlet 335 that flows into container 302. Liquid pump 331 is a sequentially activated diaphragm pump, however, liquid pump 331 could be other types of pumps, such as, for example, a gear pump. Container 302 has a neck 306 that receives a connector for placing the container 302 in fluid communication with a pump 440 (FIG. 18).

[0082]Exemplary container 302 is configured to receive a level sensing system 401 (FIG. 17). Container 306 includes a first molded in cavity 308. First cavity 308 is located on one side of the container and is configured for receiving an IR transmitter (not shown). Container 302 also includes a second molded in cavity 310 located on a second side of the container 302, preferably, substantially opposite the IR transmitter for receiving an IR receiver (not shown). Container 302 also includes a third molded in cavity 312 located on the second side of the container 302 for receiving a second IR receiver (not shown). Container 302 also includes a fourth molded in cavity 314 located on the second side of the container 302 for receiving an IR receiver (not shown). In addition, container 302 optionally has a plurality of grooves 320 molded in container 302 for receiving wires, not shown connected to the IR transmitter and IR receivers. Container 302 may have more or fewer molded in cavities configure for receiving IR transmitters and/or receivers.

[0083]FIG. 17 is a prospective view of reservoir 300 with IR transmitter 403 located in molded in cavity 308, IR receiver 404 located in molded in cavity 310, IR receiver 406 located in molded in cavity 312 and IR receiver 408 located in molded in cavity 314. The wires placing the IR transmitter 403, and IR receivers, 404, 406, 408 in circuit communications with a controller (not shown) are not shown for clarity.

[0084]IR transmitter 403, and IR receivers, 404, 406, 408 (and their associated wiring) are held securely in place by a wrap 420. Wrap 420 may include product labels, identifying such things as, for example, product, trademarks, manufacture, manufacturing date, expiration date, formulation components, and the like. Preferably, wrap 420 is opaque. When opaque, wrap 420 blocks extraneous light that may affect the IR receivers. Accordingly, wrap 420 increases the accuracy of the level sensing system 401. Wrap 420 may be a shrink-wrap sleeve that is placed over reservoir 302 and the IR emitter/IR receivers and heated so that it shrinks tightly around reservoir 302. Wrap 420 may be an adhesively attached wrap, preferably a wrap that extends completely around reservoir 302.

[0085]FIG. 18 is a schematic diagram of another exemplary dispenser system 400. Dispenser system 400 is similar to the dispensers disclosed above and may include any of the components disclosed above in addition to, or in leu of, those described with respect to dispenser system 400. This exemplary dispenser system 400 is filled by refill 401. Refill 401 includes a container 302. Container 302 includes a connector 404 and a wireless data tag 494. Wireless data tag 494 may be a read only or a read/write data tag. Data tag 494 may be configured to operate using radio frequency (RF), Bluetooth, ultrasonic or any other types of wireless communication.

[0086]Dispenser system 400 includes a refill connector 410, which mates with connector 404 to provide a liquid tight connection allowing liquid to flow from the refill container 402 and into refill conduit 412. Dispenser system 400 also includes a data tag reader 495. Data tag reader 495 may be a read only device that only reads information stored on data tag 494. Data tag reader 495 may be a read/write device that can both read data stored on data tag 494 and write data to data tag 494.

[0087]Dispenser system 400 includes a pumping system 330 that includes a motor 332 and a pump 333. Pump 333 is in fluid communication with refill connector 410 and with the interior of reservoir 302. As described above, a controller (not shown) receives data from data tag reader 495 and determines whether to fill reservoir 302 with the contents of refill container 402. If the controller determines that refill container 402 does not contain an authorized liquid or determines that the volume of liquid in refill container 402 has, or should have been, depleted, the controller does not operate pump 333 to pump liquid from refill container 402 to reservoir 302. If refill container 402 contains an authorized liquid and any volume of liquid previously removed from the refill container 402 does not exceed the total volume of the refill container 402, the controller causes pump 333 to operate and pump liquid from refill container 402 to reservoir 303.

[0088]Dispensing system 400 includes a level sensing system 401 as described above. In addition, reservoir 302 includes a vent 420. Vent 420 includes an air vent passageway 498 that is open to the atmosphere, a float cage 421 and a float 420. When the liquid level in the reservoir 302 is below the float 420, air vent passageway 498 is open to the atmosphere. When the liquid level in reservoir 302 rises up near the top, float 420 floats upward and seals off the air vent passageway 498, preventing liquid from flowing out of the air vent passageway 498.

[0089]A connector 430 is secured to second neck 306. Connector 430 includes a liquid feed conduit 432 that places a liquid inlet port of pump 442 in fluid communication with reservoir 302. Pump 442 is driven by motor 441. Pump 442 is a sequentially activated multi-diaphragm pump that includes a liquid outlet 446 and an air outlet 448. Sequentially activated multi-diaphragm pump 442 may be, for example, the foam at a distance sequentially activated pumps are shown and described in U.S. Non-Provisional application Ser. No. 18/159,697, which is titled Sequentially Activated Multi-Diaphragm Foam-At-A-Distance Dispenser Systems, filed on Jan. 26, 2023, and which is incorporated herein by reference in its entirety. Liquid from liquid outlet 446 flows through liquid outlet conduit 450 to foam generator 460. Air from air outlet 448 flows through air outlet conduit 452 to foam generator 460. The air and liquid mix together in foam generator 460 and are dispensed out of dispensing outlet 462 in the form of a foam.

[0090]While various inventive aspects, concepts and features of the inventions may be described and illustrated herein as embodied in combination in the exemplary embodiments, these various aspects, concepts and features may be used in many alternative embodiments, either individually or in various combinations and sub-combinations thereof. It is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Unless expressly excluded herein, all such combinations and sub-combinations are intended to be within the scope of the present inventions. Still further, while various alternative embodiments as to the various aspects, concepts and features of the inventions—such as alternative materials, structures, configurations, methods, circuits, devices and components, software, hardware, control logic, alternatives as to form, fit and function, and so on—may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Those skilled in the art may readily adopt one or more of the inventive aspects, concepts or features into additional embodiments and uses within the scope of the present inventions even if such embodiments are not expressly disclosed herein. Additionally, even though some features, concepts or aspects of the inventions may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative values and ranges may be included to assist in understanding the present disclosure; however, such values and ranges are not to be construed in a limiting sense and are intended to be critical values or ranges only if so expressly stated. Moreover, while various aspects, features and concepts may be expressly identified herein as being inventive or forming part of an invention, such identification is not intended to be exclusive, but rather there may be inventive aspects, concepts and features that are fully described herein without being expressly identified as such or as part of a specific invention. Descriptions of exemplary methods or processes are not limited to inclusion of all steps as being required in all cases, nor is the order in which the steps are presented to be construed as required or necessary unless expressly so stated.