Foam dispensing systems, pumps and refill units having high air to liquid ratios

• US 10,080,467 B2
• Filed: 11/21/2016
• Issued: 09/25/2018
• Est. Priority Date: 11/20/2015
• Status: Active Grant

• Current Assignee: GOJO Industries Incorporated
• Original Assignee: GOJO Industries Incorporated
• Inventors: Ciavarella, Nick E., Twaroski, Jacob, Jenkins, Dennis K.
• Primary Examiner(s): Buechner, Patrick M
• Application Number:
  US15/356,795
• Publication Number:
  US 20170143172A1
• Time in Patent Office: 673 Days
• CPC Class Codes: A47K 5/14 Foam or lather making devices for shaving A45D27/02
• CPC Class Codes: B05B 12/122 responsive to presence or shape of target B05B12/124 takes precedence
• CPC Class Codes: B05B 7/0018 with devices for making foam
• CPC Class Codes: B05B 7/0416 with arrangements for mixing one gas and one liquid
• CPC Class Codes: B05B 7/2402 Apparatus to be carried on or by a person, e.g. by hand; Apparatus comprising containers fixed to the discharge device B05B7/0012 takes precedence
• CPC Class Codes: F04B 13/02 of two or more fluids at the same time
• CPC Class Codes: F04B 19/06 Pumps for delivery of both liquid and elastic fluids at the same time wet gas pumps F04B37/20
• CPC Class Codes: F04B 23/04 Combinations of two or more pumps
• CPC Class Codes: F04B 23/06 the pumps being all of reciprocating positive-displacement type
• CPC Class Codes: F04B 43/026 each plate-like pumping flexible member working in its own pumping chamber
• CPC Class Codes: F04B 43/04 Pumps having electric drive
• CPC Class Codes: F04B 45/047 Pumps having electric drive

Abstract

An exemplary foam dispenser system includes a housing, a container, a motor, an air pump, a foam pump, a first mixing chamber, a second mixing chamber, a foam cartridge, and an outlet for dispensing foam. The container holds a foamable liquid. The foam pump has a liquid pump portion that pumps liquid, and an air pump portion that pumps air. The first mixing chamber is located downstream of the liquid pump portion and the air pump portion, and the liquid and the air mix in the first mixing chamber to create a first foam mixture. The second mixing chamber is located downstream of the first mixing chamber and the air pump, and the first mixture and air from the air pump mix in the second mixing chamber to create a second foam mixture. The second foam mixture travels through the foam cartridge and exits the outlet as rich foam.

Claims

1. A foam dispenser comprising:

a housing;

a container for holding foamable liquid;

a motor;

an air pump;

a foam pump having;

a liquid pump portion that pumps liquid;

an air pump portion that pumps air;

a first mixing chamber located downstream of the liquid pump portion and the air pump portion for mixing the liquid from the liquid pump portion with the air from air pump portion to create a first foam mixture;

a second mixing chamber located downstream of the first mixing chamber and the air pump for mixing the first foam mixture from the foam pump with air from the air pump to create a second foam mixture;

a foam cartridge; and

an outlet for dispensing foam.

2. The foam dispenser of claim 1 wherein the first foam mixture has an air to liquid ratio of greater than about 2 to 1.

3. The foam dispenser of claim 1 wherein the second foam mixture has an air to liquid ratio of greater than 10 to 1.

4. The foam dispenser of claim 1 wherein the second foam mixture has an air to liquid ratio greater than about 20 to 1.

5. The foam dispenser of claim 1

wherein the liquid pump portion of the foam pump includes at least one liquid pump diaphragm and

wherein the air pump portion of the foam pump includes at least two air pump diaphragms.

6. The foam dispenser of claim 1 wherein an operating cycle of the foam pump includes a shot of liquid followed by two or more shots of air.

7. The foam dispenser of claim 1 wherein the air pump portion comprises a plurality of air pump diaphragms.

8. The foam dispenser of claim 1 wherein the container and the foam pump form a refill unit and the refill unit is removable from the foam dispenser without removing the air pump.

9. The foam dispenser of claim 1 wherein the air pump includes a wobble plate and the foam pump includes a wobble plate.

10. The foam dispenser of claim 1 wherein the first foam mixture enters the second mixing chamber in a first direction and air from the air pump enters the second mixing chamber in substantially the opposite direction.

11. The foam dispenser of claim 1 wherein the first foam mixture enters the second mixing chamber in a first direction and air from the air pump enters the second mixing chamber tangentially to the first direction.

12. The foam dispenser of claim 1 wherein the first foam mixture enters the second mixing chamber in a first direction and air from the air pump enters the second mixing chamber in a direction substantially perpendicular to the first direction.

13. The foam dispenser of claim 1 wherein the motor drives the air pump and the foam pump.

14. A foam dispenser comprising:

a housing;

a motor;

an air pump secured to the housing wherein the air pump has an air pump outlet;

a removable and replaceable refill unit wherein the refill unit includes;

a container for holding a foamable liquid;

a foam pump having;

a liquid pump portion that pumps liquid;

an air pump portion that pumps air;

a first mixing chamber located downstream of the liquid pump portion and the air pump portion for mixing the liquid from the liquid pump portion with the air from air pump portion to create a first foam mixture;

an air inlet for receiving air from the air pump;

a second mixing chamber located downstream of the first mixing chamber of the foam pump and in fluid communication with the air inlet for mixing the first foam mixture with air from the air pump;

a foam cartridge; and

an outlet for dispensing foam;

wherein the refill unit is releasably attachable to the air pump in a manner that allows the air pump outlet to be in fluid communication with the second mixing chamber of the refill unit when the refill unit is inserted in the foam dispenser.

15. The refill unit of claim 14 wherein the foam pump comprises a first liquid pump diaphragm, a first air pump diaphragm and a second air pump diaphragm.

16. The refill unit of claim 15 further comprising a wobble plate connected to the first liquid pump diaphragm, the first air pump diaphragm and the second air pump diaphragm.

17. The refill unit of claim 15 further comprising a foam pump drive, wherein the foam pump drive is an eccentric drive mechanism.

18. A foam dispenser for dispensing foam having an air to liquid ratio of greater than about 15 to 1 comprising:

a housing;

a motor located within the housing

a holder for retaining a container with a foamable liquid;

a container with foamable liquid;

a foam pump;

the foam pump having

a liquid pump diaphragm, and

at least three air pump diaphragms;

a mixing chamber located downstream of the liquid pump diaphragm and the at least three air pump diaphragms; and

an outlet;

wherein the liquid pump diaphragm and the at least three air pump diaphragms are operated sequentially.

19. The dispenser of claim 18 wherein the foam pump creates a working pressure of greater than about 10 pounds per square inch.

20. The dispenser of claim 18 wherein the foam pump is connected to, and remains with, the dispenser and separates from the container when the container is removed from the dispenser.