Sequentially actuated multi-diaphragm foam pump, refill unit, and dispenser system having non-uniform wobble plates

Abstract

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

Description

[Technical field]

[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 145,025, filed February 3, 2021, the entire disclosure of which is incorporated herein by reference.

[0002] The present invention relates generally to a pump, refill unit for a dispenser system, and more particularly to a pump, refill unit, and dispenser having a sequentially actuated multi-diaphragm foam pump for mixing liquid soap, sanitizer, or lotion with air to generate and dispense a foam product, where the foam density can be controlled by a non-uniform wobble plate. [Background technology]

[0003] Liquid dispenser systems, such as liquid soap and sanitizer dispensers, dispense a predetermined amount of liquid to a user when the dispenser is actuated. In addition, it may be desirable to dispense the liquid in the form of a foam, for example, by injecting air into the liquid to create a foamy mixture of liquid and air bubbles. The foam density may vary as the type of fluid being foamed is changed. In addition, some customers prefer a thicker foam than others. The foam density may be changed by changing the ratio of air and liquid that are combined to form the foam, but changing the volume of the liquid or air chambers for sequentially actuated multi-diaphragm foam pumps. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] U.S. Provisional Patent Application No. 63 / 145,025 [Patent Document 2] U.S. Patent No. 6,871,679 [Patent Document 3] U.S. Patent No. 7,647,954 [Patent Document 4] US Patent Application Publication No. 2015 / 0266657 [Patent Document 5] U.S. Patent Application No. 2015 / 025184 [Patent Document 6] U.S. Patent Application Serial No. 14 / 811,995 [Patent Document 7] US Patent Application Publication No. 20140367419 [Patent Document 8] US Patent Application Publication No. 2014 / 0234140 [Patent Document 9] U.S. Patent No. 8,960,498 [Patent Document 10] US Patent Application Publication No. 2014 / 0054322 Summary of the Invention [Means for solving the problem]

[0005] The present application discloses exemplary embodiments of a sequentially actuated multi-diaphragm foam pump, a refill unit, and a dispenser system, wherein a refill unit, a sequentially actuated multi-diaphragm foam pump, and a wobble plate are disclosed herein. The exemplary foam dispenser includes a housing, a receptacle for receiving a container of foamable liquid, and the foam pump is in fluid communication with the container of foamable liquid when the container of foamable liquid is inserted into the receptacle. The foam pump includes a molded multi-diaphragm pump member having a housing, a liquid pump diaphragm, and one or more air pump diaphragms. One or more outlet valves are located downstream of the liquid pump diaphragm and the one or more air pump diaphragms. A mixing chamber is located downstream of the one or more outlet valves for mixing the foamable liquid from the liquid pump diaphragm with air from the one or more air pump diaphragms. A drive motor is included, and the foam pump is operably coupled to the drive motor by a wobble plate. The wobble plate has two or more vanes. The first vane has a first vane profile distance between a first surface contacting the body of the liquid pump diaphragm and a second surface contacting the retaining member of the liquid pump diaphragm. The second vane has a second vane profile distance between a first surface contacting the body of the air pump diaphragm of one of the one or more air pump diaphragms and a second surface contacting the retaining member of the air pump diaphragm of one of the one or more air pump diaphragms. The first vane profile distance is different from the second vane profile distance. An outlet for dispensing foam is also included.

[0006] An exemplary wobble plate for a sequentially acting multi-diaphragm foam pump includes three or more vanes, a wobble plate shaft, and an aperture located for each of the three or more vanes. A first vane has a first thickness that approximates the aperture in the first vane. A second vane has a second thickness that approximates the aperture in the second vane, and a third vane has a second thickness that approximates the aperture in the second vane.

[0007] An exemplary embodiment of a sequentially acting foam pump includes a housing, a liquid inlet, and a molded multi-diaphragm pump member. The molded multi-diaphragm pump member includes a liquid pump diaphragm having a first volume, and two or more air pump diaphragms each having a second volume. The first volume is smaller than the second volume. One or more outlet valves are also included. A mixing chamber is located downstream of the one or more outlet valves for mixing the foamable liquid from the liquid pump chamber with air from each of the two or more air pump chambers. A wobble plate is included. The wobble plate has two or more vanes. The first vane has a first vane profile distance and the second vane has a second vane profile distance. The first vane connects to the liquid pump diaphragm and the second vane connects to one of the two or more air pump diaphragms. The first vane profile distance is different from the second vane profile distance. An outlet for dispensing foam is also included.

[0008] Another exemplary sequentially acting foam pump includes a housing, a molded multi-diaphragm pump member having a liquid pump diaphragm and one or more air pump diaphragms, one or more outlet valves located downstream of the liquid pump diaphragm and the one or more air pump diaphragms, and a mixing chamber located downstream of the one or more outlet valves for mixing foamable liquid from the liquid pump diaphragm with air from the one or more air pump diaphragms. A drive motor and a non-uniform wobble plate are also included. The foam pump is operatively coupled to the drive motor by the non-uniform wobble plate. The non-uniform wobble plate comprises two or more vanes. The two or more vanes each have a pump diaphragm contact surface. The first vane has a first pump diaphragm contact surface that is spaced a first distance from the first pump diaphragm, and the second vane has a second pump diaphragm contact surface that is spaced a second distance from the second pump diaphragm, the first distance being greater than the second distance.

[0009] Another exemplary wobble plate for a sequentially actuated multi-diaphragm foam pump includes three or more vanes, a wobble plate shaft, and an aperture located for each of the three or more vanes. A first vane is configured to have a first distance from a first contact surface of the first pump diaphragm. A second vane is configured to have a second distance from the first contact surface on the second pump diaphragm, and a third vane is configured to have substantially the second distance from the first contact surface on the third pump diaphragm. [Brief description of the drawings]

[0010] [Figure 1] 1 is an exemplary embodiment of a refill unit for a foam dispenser.

[0011] [Diagram 2] 1 is an exemplary embodiment of a foam dispenser.

[0012] [Figure 2A] 3 illustrates the exemplary foam dispenser of FIG. 2 fitted with the exemplary refill unit of FIG. 1.

[0013] [Diagram 3] FIG. 1 is an exploded view of an exemplary embodiment of a sequentially acting multi-diaphragm foam pump and motor taken from a first perspective.

[0014] [Figure 4] FIG. 4 is an exploded view of the exemplary embodiment of the sequentially acting multi-diaphragm foam pump and motor of FIG. 3 taken from a second perspective.

[0015] [Diagram 5] FIG. 4 is a plan view of an exemplary diaphragm assembly for the exemplary embodiment of the sequentially acting multi-diaphragm foam pump of FIG.

[0016] [Figure 6] FIG. 6 is a bottom view of the exemplary diaphragm assembly of FIG. 5.

[0017] [Figure 7] FIG. 4 is a plan view of an exemplary valve seat for the exemplary embodiment of the sequentially acting multi-diaphragm foam pump of FIG.

[0018] [Figure 8] FIG. 8 is a bottom view of the exemplary valve seat of FIG.

[0019] [Figure 9] FIG. 4 is a plan view of an exemplary diaphragm assembly sheet for the exemplary embodiment of the sequentially acting multi-diaphragm foam pump of FIG.

[0020] [Figure 10A] 10 is a cross-sectional view taken along line AA in FIGS. 5-9 of the liquid pump portion of the sequentially acting multi-diaphragm foam pump of FIG. 3.

[0021] [Figure 10B] 10 is a cross-sectional view taken along line BB of FIGS. 5-9 of the first air pump portion of the sequentially acting multi-diaphragm foam pump of FIG. 3. FIG.

[0022] [Figure 10C] 10 is a cross-sectional view taken along line CC of FIGS. 5-9 of the second air pump portion of the sequentially acting multi-diaphragm foam pump of FIG. 3. FIG.

[0023] [Figure 11] FIG. 2 is a cross-sectional view of another exemplary embodiment of a sequentially acting multi-diaphragm foam pump.

[0024] [Figure 12] 1 is a perspective view of an exemplary embodiment of a refill unit having a sequentially actuated multi-diaphragm foam pump. FIG.

[0025] [Figure 13]FIG. 13 is a rear view of the exemplary embodiment of the refill unit having the sequentially acting multi-diaphragm foam pump of FIG. 12 with a rear cover.

[0026] [Figure 14] FIG. 13 is a perspective view of an exemplary embodiment of a refill unit having a sequentially acting multi-diaphragm foam pump of FIG. 12 without the rear cover.

[0027] [Figure 15] FIG. 13 is a rear view of the exemplary embodiment of the refill unit having the sequentially acting multi-diaphragm foam pump of FIG. 12 without the rear cover.

[0028] [Figure 16] 1 is an exemplary foam dispenser having a refill unit mounted thereon having a sequentially actuated multi-diaphragm foam pump.

[0029] [Figure 17] 1 illustrates an exemplary foam dispenser with the refill unit removed.

[0030] [Figure 18] 17 is an example motor and drive system for the example foam dispenser of FIG. 16.

[0031] [Figure 19A] FIG. 2 is a perspective view of another exemplary embodiment of a sequentially acting multi-diaphragm foam pump.

[0032] [Figure 19B] FIG. 19B is an exploded perspective view of the sequentially acting multi-diaphragm foam pump of FIG. 19A.

[0033] [Figure 20A] FIG. 19B is an exploded side view of the exemplary embodiment of the sequentially acting multi-diaphragm foam pump of FIG.

[0034] [Figure 20B]FIG. 19B is a cross-sectional exploded side view of the exemplary embodiment of the sequentially acting multi-diaphragm foam pump of FIG.

[0035] [Figure 21A] FIG. 19B is a top view of the exemplary embodiment of the sequentially acting multi-diaphragm foam pump of FIG.

[0036] [Figure 21B] FIG. 19B is a front view of the exemplary embodiment of the sequentially acting multi-diaphragm foam pump of FIG.

[0037] [Figure 21C] FIG. 19B is a side view of the exemplary embodiment of the sequentially acting multi-diaphragm foam pump of FIG.

[0038] [Figure 21D] 21A is a vertical cross-sectional view of the exemplary embodiment of the sequentially acting multi-diaphragm foam pump of FIG. 19A taken along line AA of FIG.

[0039] [Figure 21E] 21B is a cross-sectional view of the exemplary embodiment of the sequentially acting multi-diaphragm foam pump of FIG. 19A taken along line CC of FIG. 21B.

[0040] [Figure 22] FIG. 2 is a cross-sectional view of another exemplary embodiment of a sequentially acting multi-diaphragm foam pump.

[0041] [Figure 23] FIG. 2 is an exploded view of another exemplary embodiment of a sequentially acting multi-diaphragm foam pump.

[0042] [Figure 24] FIG. 1 is a perspective view of an exemplary embodiment of a sequentially acting four diaphragm foam pump.

[0043] [Diagram 25]FIG. 1 is a cross-sectional view of an exemplary embodiment of a sequentially operating four diaphragm foam pump.

[0044] [Figure 26] FIG. 2 is a perspective view of an exemplary outlet nozzle.

[0045] [Figure 27] FIG. 27 is a cross-sectional view of the exemplary outlet nozzle of FIG. 26.

[0046] [Figure 28] FIG. 4 is a partial cross-sectional view of a pump diaphragm.

[0047] [Figure 29] FIG. 2 is a partial cross-sectional view of a pump diaphragm having reduced volume and reduced travel or lost motion.

[0048] [Diagram 30] FIG. 29 is a partial cross-sectional view of the pump diaphragm of FIG. 28 connected to an actuator.

[0049] [Diagram 31] 30 is a partial cross-sectional view of the pump diaphragm of FIG. 29 with the actuator connected to the actuator in a first position.

[0050] [Diagram 32] 30 is a partial cross-sectional view of the pump diaphragm of FIG. 29 with the actuator connected to the actuator in a second position.

[0051] [Diagram 33] FIG. 1 is a partial cross-sectional view of a sequentially actuated foam pump having multiple pump diaphragms, one configured to have reduced volume and reduced displacement or lost motion.

[0052] [Diagram 34] FIG. 13 is a partial cross-sectional view of another exemplary pump diaphragm.

[0053] [Diagram 35] 1 illustrates an exemplary partial cross-sectional view of a sequentially acting foam pump with an exemplary non-uniform wobble plate for controlling foam density.

[0054] [Diagram 36] FIG. 36 is a plan view of the example non-uniform wobble plate of FIG. 35.

[0055] [Figure 37] 36 is a cross-sectional view of the example non-uniform wobble plate of FIG. 35.

[0056] [Figure 38] 11 is a cross-sectional view of another exemplary embodiment of a non-uniform wobble plate. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0057] The present application discloses exemplary embodiments of a foam dispenser and refill unit having a sequentially actuated multi-diaphragm foam pump. Some exemplary embodiments include a wobble plate and three or more pump diaphragms. The three or more pump diaphragms include at least one liquid pump diaphragm and at least two air pump diaphragms. Each liquid pump diaphragm has a liquid inlet for receiving a liquid, such as, for example, a soap, disinfectant, or lotion, and each air pump diaphragm has an air inlet for receiving air. The three or more pump diaphragms operate sequentially, and each pump diaphragm operates once in an operating cycle. The operating cycle begins with the operation of a liquid pump diaphragm. Additionally, the sequentially actuated multi-diaphragm foam pump includes a mixing chamber. Each liquid pump diaphragm pumps liquid into the mixing chamber, and each air pump diaphragm pumps air into the mixing chamber. The liquid mixes with the air in the mixing chamber to generate a foam mixture, and the foam mixture is dispensed from a pump outlet. In some embodiments of the present invention, the foam mixture has an air to liquid ratio of between about 7 to 1 and about 10 to 1. In some embodiments, the air to liquid ratio is greater than 10 to 1, and in some embodiments, less than 7 to 1.

[0058] The sequentially actuated multi-diaphragm foam pump may be used in a foam dispenser. An exemplary foam dispenser includes a housing, a motor, a refill unit, a sequentially actuated multi-diaphragm foam pump, and a foam cartridge. The pump receives foamable liquid from the refill unit, mixes the foamable liquid with air to generate a foam mixture, forces the foam mixture through the foam cartridge to enrich the foam, and dispenses the foam to a user.

[0059] FIG. 1 illustrates a refill unit 100 for a foam dispenser. The refill unit 100 includes a collapsible container 102. The collapsible container 102 includes a neck 103 and a drip-free quick connector 104. Exemplary drip-free quick connectors are disclosed in U.S. Pat. No. 6,871,679, entitled "Bag and Dispensing System Comprising Such A Bag," and U.S. Pat. No. 7,647,954, entitled "Connector Apparatus And Method For Connecting The Same For Controlling Fluid Dispensing," which are incorporated herein by reference in their entireties. The refill unit houses a supply of foamable liquid. In various embodiments, the contained foamable liquid can be, for example, a soap, disinfectant, cleanser, disinfectant, lotion, and the like. The container is a collapsible container and can be made of a thin plastic or flexible bag-like material. In other embodiments, the container may be a non-collapsible container formed by a rigid housing member or any other suitable configuration for containing the foamable liquid without leakage. In the case of a non-collapsible container, a venting system may be included. Exemplary venting systems are disclosed in U.S. Patent Application Publication No. 2015 / 0266657, entitled Closed system for venting a dispenser reservoir, U.S. Patent Application No. 2015 / 025184, entitled Pumps With Container Vents, and U.S. Patent Application No. 14 / 811,995, entitled Vented Refill Units And Dispensers Having Vented Refill Units, which are incorporated herein by reference.

[0060] FIG. 2 illustrates an exemplary embodiment of a touch-free foam dispenser 200. The touch-free foam dispenser 200 includes a housing 202, a motor 204, a foam pump 206, a refill unit connector 208, a foam cartridge 210, and a nozzle 212. An exemplary embodiment of the foam cartridge 210 is shown and described in U.S. Patent Application Publication No. 20140367419, which is incorporated by reference herein in its entirety. The refill unit 100 may be connected to the refill unit connector 208 as shown in FIG. 2A. The refill unit 100 contains a foamable liquid, such as soap, sanitizer, lotion, cleanser, disinfectant, etc. The touch-free foam dispenser 200 is actuated when a sensor 214 detects the presence of a user or object. Upon detecting an object or user, the sensor 214 sends a signal to a processor (not shown) in an electronic control board 216. The electronic control board 216 sends an output signal to the motor 204 that rotates the eccentric wobble plate actuator drive mechanism 301. The sensor 214 and the electronic control board 216 receive power from a power source 218. In some embodiments, the motor 204 receives power from the power source 218, and in other embodiments, the refill unit includes a power source (not shown) that provides power to a rechargeable power source (not shown). An exemplary embodiment of a refill unit with a power source that provides power to the wobble plate actuator drive mechanism 301 (FIG. 3) is shown and described in U.S. Patent Application Publication No. 2014 / 0234140, entitled Power Systems For Touch Free Dispensers And Refill Units Containing A Power Source, which is incorporated herein by reference in its entirety. Providing power to the motor 204 causes the wobble plate actuator drive mechanism 301 to rotate. Rotation of the eccentric wobble plate actuator drive mechanism 301 sequentially compresses and expands the diaphragm of the foam pump 206, pumping liquid and air into the mixing chamber 325. The liquid and air mix together to form a foamy mixture. The foamy mixture is forced through the foam cartridge 210, which strengthens the foam into a rich foam. The rich foam is dispensed from the foam dispenser 200 through the nozzle 212.

[0061] The refill unit 100 and foam dispenser 200 shown in Figures 1 and 2, respectively, are depicted generally as a variety of different components may be used in many of the refill units 100 and foam dispensers 200. The foam pump 206 is depicted generally above, which is described in detail below. Some exemplary dispenser components that may be used in accordance with the present invention are shown and described in U.S. Patent No. 8,960,498, entitled Touch-Free Dispenser With Single Cell Operation And Battery Banking, U.S. Patent Application Publication No. 2014 / 0054322, entitled Off-Axis Inverted Foam Dispensers And Refill Units, and U.S. Patent Application Publication No. 2014 / 0234140, entitled Power Systems For Touch Free Dispensers And Refill Units Containing a Power Source, which are incorporated herein by reference in their entireties.

[0062] 3 is an exploded view of an exemplary embodiment of foam pump 206. Foam pump 206 is driven by motor 204. Foam pump 206 includes pump base 324, wobble plate 314, diaphragm assembly seat 312, diaphragm assembly 310, valve seat 308, outlet valves 323A, 323B, 323C, screws 302, and cover 348. Valve seat 308, diaphragm assembly seat 312, and pump base 324 are secured together by screws 302 within threaded holes 308A, 312A, 324A. Cover 348 is attached to valve seat 308. Outlet valves 323A, 323B, 323C are secured and seated on valve seat 308.

[0063] The diaphragm assembly 310 includes three pump diaphragms 310A, 310B, 310C, each of which has a connector 311A, 311B, 311C. The diaphragm assembly 310 is mounted in a diaphragm assembly sheet 312. The pump diaphragms 310A, 310B, 310C are disposed in receiving holes 313A, 313B, 313C of the diaphragm assembly sheet 312, and the three connectors 311A, 311B, 311C are connected to the wobble plate 314 by inserting the three connectors 311A, 311B, 311C into the three wobble plate links 314A, 314B, 314C.

[0064] Air enters the foam pump 206 through pump air inlet 424B (FIG. 4), and a liquid, such as, for example, a foamable soap or disinfectant, enters the foam pump 206 through liquid inlet 352. Two of the pump diaphragms 310B, 310C receive air, and the other pump diaphragm 310A receives a foamable liquid, such as, for example, a soap or disinfectant.

[0065] FIG. 4 is another exploded view of the exemplary foam pump 206 from a different perspective. As mentioned above, the diaphragm assembly 310 includes three pump diaphragms 310A, 310B, 310C. Each pump diaphragm 310A, 310B, 310C has a corresponding inlet valve 316A, 316B, 316C (better seen in FIG. 5 and FIG. 6). FIG. 4 also provides a view of the bottom of the valve seat 308. The bottom of the valve seat 308 has three regions corresponding to the three pump diaphragms 310A, 310B, 310C. Each region has three fluid outlet openings 309A, 309B, 309C extending through the valve seat 308, valve stem retaining openings 329A, 329B, 329C (FIG. 7), and fluid inlet grooves 319A, 319B, 319C. The fluid inlet channels 319 A, 319 B, 319 C do not extend through the valve seat 308 .

[0066] 5 and 6 show top and bottom views, respectively, of an exemplary diaphragm assembly 310 for foam pump 206. In some embodiments, the diaphragm assembly is made of natural rubber, EPDM, silicone, silicone rubber TPE, TPU, TPV, vinyl, etc. The diaphragm assembly 310 includes three molded pump diaphragms 310A, 310B, 310C and three corresponding inlet valves 316A, 316B, 316C. The top of the diaphragm assembly 310 acts as a sealing gasket. The top of the diaphragm assembly 310 has a flat section 310F, and each pump diaphragm 310A, 310B, 310C has a gasket wall 327A, 327B, 327C that surrounds the respective valve 316A, 316B, 316C and pump diaphragm 310A, 310B, 310C. Gasket walls 327A, 327B, 327C seal the bottom of valve seat 308 (FIGS. 4 and 8), thereby preventing air and fluids, such as liquid soap or disinfectant, from leaking from foam pump 206 at locations other than pump outlet 350 (FIG. 3). One-way inlet valves 316A, 316B, 316C allow air, liquid soap, or disinfectant to enter pump diaphragms 310A, 310B, 310C when pump diaphragms 310A, 310B, 310C have negative pressure (i.e., when pump diaphragms 310A, 310B, 310C are expanding) and seal inlet openings 321A, 321B, 321C when pump diaphragms 310A, 310B, 310C have positive pressure (e.g., when pump diaphragms 310A, 310B, 310C are compressing). The one-way inlet valves 316 A, 316 B, 316 C are formed by flexible tabs and are made of the same material as the diaphragm assembly 310 .

[0067] 7 is a plan view of an exemplary valve seat 308 for foam pump 206. One-way liquid outlet valve 323A is shown in transparency to more clearly show the flow of liquid 331A through liquid outlet opening 309A and into mixing chamber 325. One-way liquid outlet valve 323A includes a valve stem 357A (FIG. 3) that is inserted into opening 329A to secure one-way liquid outlet valve 323A to valve seat 308. One-way liquid outlet valve 323A is normally closed to prevent air or liquid from flowing back from mixing chamber 325 through air outlet opening 309A and into liquid pump diaphragm 310A. One-way liquid outlet valve 323A opens when liquid pump diaphragm 310A is compressed to pump fluid.

[0068] Similarly, the one-way air outlet valves 323B, 323C are shown transparent to more clearly show the flow of air 331B, 331C through the air outlet openings 309B, 309C into the mixing chamber 325. The one-way air outlet valves 323B, 323C include valve stems 357B, 357C (FIG. 3), respectively, that are inserted into corresponding openings 329B, 329C to secure the one-way air outlet valves to the valve seat 308. The one-way air outlet valves 323B, 323C are normally closed to prevent air or liquid from flowing back from the mixing chamber 325 through the air outlet openings 323B, 323C into the liquid pump diaphragms 310B, 310C. The one-way air outlet valves 323B, 323C open when the corresponding air pump diaphragms 310B, 310C are compressed to pump air.

[0069] The valve seat 308 also includes a flow direction control wall 308E. The flow direction control wall 308E provides a flow path that aids in mixing of the liquid and air. In this embodiment, the flow direction control wall 308E is curved, causing the liquid and air to intersect in a tangential relationship. In some embodiments, the flow direction control wall 308E provides a flow path that aids in mixing of the liquid and air. andThe flow paths are designed and positioned to intersect the air at a desired angle, for example, each flow path may intersect at an angle of 120 degrees. In some embodiments, the flow direction control wall 308E is positioned so that the two air paths intersect the liquid flow path at approximately 180 degrees. The design of the flow path intersection may be different for different types of liquids, for example, a higher quality foam may be obtained by intersecting a liquid soap head-on (at 180 degrees) with two air flow paths, while a higher quality foam may be obtained for a foamable sanitizer by intersecting the air flow path tangentially with the liquid flow path.

[0070] 8 is a bottom view of an exemplary valve seat 308 for foam pump 206. Valve seat 308 includes three liquid outlet openings 309A that pass through valve seat 308 and a liquid outlet valve opening 329A for retaining one-way liquid outlet valve 323A. Valve seat 308 also includes a liquid inlet groove 319A that extends partially into valve seat 308 to provide a liquid path from one-way liquid inlet valve 316A to the interior of liquid pump diaphragm 310A. In addition, valve seat 308 includes a first set of three air outlet openings 309B that pass through valve seat 308 and a second set of three air outlet openings 309C that pass through valve seat 308. The valve seat 308 also includes air outlet valve openings 329B, 329C for retaining the one-way air outlet valves 323B, 323C, and air inlet grooves 319B, 319C that extend partially into the valve seat 308 to provide an air path from the one-way air inlet valves 316B, 316C to the interior of the air pump diaphragms 310B, 310C.

[0071] 9 is a plan view of an exemplary diaphragm assembly sheet 312 for an exemplary embodiment of foam pump 206. Diaphragm assembly sheet 312 includes three receiving holes 313A, 313B, 313C and three inlet openings 321A, 321B, 321C. In fluid communication with inlet opening 321A is a fluid inlet 352 that may be coupled to a liquid outlet of container 102. Each receiving hole 313A, 313B, 313C is sized to receive a diaphragm 310A, 310B, 310C. Each inlet opening 321A, 321B, 321C extends through diaphragm assembly sheet 312 to allow either air, liquid soap, or sanitizer to enter one of diaphragms 310A, 310B, 310C.

[0072] In some embodiments, the foam mixture has an air to liquid ratio between about 7 to 1 and about 10 to 1. In some embodiments, the air to liquid ratio is greater than 10 to 1, and in some embodiments, less than 7 to 1.

[0073] In some exemplary embodiments, a flow control valve (not shown) is provided between the container 102 of foamable liquid and the pump 206. The flow control valve may be used to adjust the liquid to air ratio. If a higher liquid to air ratio is required, the flow control valve is set to a lower flow rate that starves the liquid pump diaphragm 310A. Conversely, to increase the liquid to air ratio, the flow control valve may be opened wider to allow more liquid to flow into the pump 206. In some embodiments, the liquid pump diaphragm 310A may have a different volume than the air pump diaphragms 310B, 310C to adjust the liquid to air ratio. In some embodiments, the volume of the liquid pump diaphragm 310A is reduced by inserting a sponge (not shown) into the liquid pump diaphragm 310A. Not only does the sponge (not shown) reduce the volume, but in some embodiments, the sponge slows the flow of liquid through the liquid pump diaphragm 310A. In some embodiments, a restrictor comprising an orifice having a smaller diameter than the liquid inlet may be used to restrict fluid flow.

[0074] FIG. 10A is a cross-sectional view taken along line AA of FIGS. 5-9 showing the liquid pump portion of foam pump 206. In operation, liquid pump diaphragm 310A is moved downward, as indicated by reference numeral 350B, thereby expanding pump chamber 1002, thereby opening liquid inlet valve 316A and allowing liquid to be drawn into pump chamber 1002 through liquid inlet 352, inlet opening 321A, and liquid inlet groove 319A. When pump chamber 1002 is expanded, it is primed with a liquid, such as liquid soap or disinfectant, for example. When liquid pump diaphragm 310A is compressed (i.e., liquid pump diaphragm 310A moves in the direction indicated by reference numeral 350A), liquid is pumped in the direction indicated by reference numeral 340A. Liquid moves through liquid outlet opening 309A, past one-way liquid outlet valve 323A, and into mixing chamber 325. One-way liquid outlet valve 323A is normally closed, but the one-way liquid outlet valve 323A opens due to pressure caused by compressing liquid pump chamber 1002. One-way liquid outlet valve 323A prevents air or liquid from flowing back into liquid pump diaphragm 310A through liquid outlet opening 309A. Liquid pump diaphragm 310A then begins to expand, which starts the process again by causing liquid inlet valve 316A to open and liquid is drawn through liquid inlet opening 321A and liquid inlet groove 319A into liquid pump chamber 1002. The operating cycle of foam pump 206 includes one pumping of liquid from liquid pump diaphragm 310A through liquid outlet opening 309A, past liquid outlet valve 323A and into mixing chamber 325 (FIG. 7) (followed by two air pumps, as explained below).

[0075] 10B and 10C are cross-sectional views taken along lines BB and CC, respectively, of FIGS. 5-9 showing the air pump portion of foam pump 206. In operation, air pump diaphragms 310B, 310C are moved downward, as indicated by reference numeral 350B, thereby expanding air pump chambers 1004, 1006, thereby opening air inlet valves 316B, 316C and allowing air to be drawn into pump chambers 1004, 1006 through air inlet openings 321B, 321C and air inlet grooves 319B, 319C. Once pump chambers 1004, 1006 are primed with air, air pump diaphragms 310B, 310C may be compressed (moved in the direction indicated by reference numeral 350A). Compression of air pump diaphragms 310B, 310C forces air in the direction indicated by reference numeral 340A. Air travels through air outlet openings 309B, 309C, past one-way air outlet valves 323B, 323C, and into mixing chamber 325 to mix with the foamable liquid. The one-way air outlet valves 323B, 323C are normally closed, but the one-way air outlet valves 323B, 323C open due to pressure caused by compressing air pump chambers 1004, 1006. The one-way air inlet valves 323B, 323C prevent air or liquid from flowing back through the air outlet openings 309B, 309C into the air pump diaphragms 310B, 310C. Air pump diaphragms 310B, 310C then begin to expand, causing air inlet valves 316B, 316C to open, beginning the process again and air being drawn into air pump chambers 1004, 1006 through air inlet openings 321B, 321C and air inlet channels 319B, 319C. An operating cycle of foam pump 206 includes one pumping of liquid (as described above), followed by one pumping of air from air pump diaphragm 310B, through air outlet opening 309B, past air outlet valve 323B, and into mixing chamber 325 (FIG. 7). In addition, an operating cycle of foam pump 206 includes one pumping of air from air pump diaphragm 310C, through air outlet opening 309C, past air outlet valve 323C, and into mixing chamber 325 (FIG. 7).

[0076] The diaphragms 310A, 310B, 310C operate sequentially, with one operation sequence including one pumping of liquid, e.g., soap or disinfectant, or air, by each of the three pump diaphragms 310A, 310B, 310C. The order of operation of the pump diaphragms 310A, 310B, 310C depends on the configuration of the wobble plate 314 (FIG. 3). As shown in FIG. 3, each pump diaphragm 310A, 310B, 310C has a connector 311A, 311B, 311C, and the three pump diaphragms 310A, 310B, 310C connect to the wobble plate 314 by inserting the three connectors 311A, 311B, 311C into the three wobble plate links 314A, 314B, 314C. The wobble plate 314 is connected to an eccentric wobble plate actuator that causes the wobble plate 314 to ripple. As the wobble plate 314 ripples, the wobble plate links 314A, 314B, 314C move in an up and down motion. The upward motion compresses the pump diaphragms 310A, 310B, 310C and the downward motion expands the pump diaphragms 310A, 310B, 310C. The configuration of the wobble plate 314 compresses one pump diaphragm 310A, 310B, 310C at a time, which sequentially pumps the pump diaphragms 310A, 310B, 310C. The configuration of the wobble plate 314 also expands one pump diaphragm 310A, 310B, 310C at a time, which sequentially primes the pump diaphragms 310A, 310B, 310C. In an exemplary operating sequence, liquid pump diaphragm 310A pumps a shot of fluid, followed by air pump diaphragm 310B pumping a shot of air, and the operating sequence is concluded with air pump diaphragm 310C pumping a second shot of air. This sequence may be repeated any number of times depending on the desired foam output dose. The air from air pump diaphragms 310B, 310C mixes with either the liquid or sanitizer from liquid pump diaphragm 310A in mixing chamber 325 (FIG. 7), thereby creating a foam mixture. The foam mixture exits foam pump 206 through pump outlet 350.

[0077] 4 shows the liquid soap or disinfectant flow path in an exploded view. When liquid pump diaphragm 310A expands, liquid enters foam pump 206 through liquid inlet 352, which is indicated by reference numeral 330A. Liquid travels through opening 321A in diaphragm assembly seat 312, as indicated by reference numeral 330B, past liquid one-way inlet valve 316A. Inlet valve 316A opens and liquid travels through groove 319A and into liquid pump diaphragm 310A, which is indicated by reference numerals 330D and 330E.

[0078] The liquid pump diaphragm 310A compresses the liquid and pumps it through liquid outlet opening 309A, past one-way liquid outlet valve 323A, and into mixing chamber 325 (FIG. 7), which is designated by reference numeral 340A. Air follows a similar path for air pump diaphragms 310B, 310C. As air pump diaphragms 310B, 310C expand, air is drawn into air inlet 424B, travels through openings 321B, 321C (FIG. 9) in diaphragm seat assembly 312, travels through one-way air inlet valves 316B, 316C (FIGS. 5 and 6), travels into grooves 319B, 319C in the bottom of valve seat 308, and travels into air pump diaphragms 310B, 310C. As air pump diaphragms 310B, 310C compress, air is forced through openings 309B, 309C, past one-way air outlet valves 323B, 323C (FIG. 7) and into mixing chamber 325 where the air mixes with the liquid to form a foam mixture. The foam mixture is dispensed through outlet 350, which is indicated by reference numeral 304B.

[0079] 11 is a cross-sectional view of another exemplary embodiment of a sequentially actuated multi-diaphragm foam pump 1100. The sequentially actuated multi-diaphragm foam pump 1100 includes a motor 1112, a motor shaft 1113, a wobble plate 1110, a wobble plate pin 1127, an eccentric wobble plate driver 1120, a liquid pump diaphragm 1106, two air pump diaphragms 1108 (only one shown), a mixing chamber 1130, and a pump outlet 1114. The motor 1112 drives the motor shaft 1113, thereby rotating the motor shaft 1113. The rotation of the motor shaft 1113 rotates the eccentric wobble plate driver 1120, which in turn moves the wobble plate pin 1127 along a circular path, thereby causing the wobble plate 1110 to ripple. In some embodiments, the wobble plate 1110 includes a ball (not shown) that rides in a socket (not shown) on the pump housing, and a wobble plate pin 1127 extends outward and connects to an eccentric wobble plate actuator 1120, which moves the pin along a circular path, thereby rippling the wobble plate 1110. As the wobble plate 1110 rippling, the ends connected to the three pump diaphragms 1106, 1108 move in an up and down motion, causing the three pump diaphragms 1106, 1108 to compress sequentially. One operating sequence of the mixing pump 1100 includes one pumping by each of the three pump diaphragms 1106, 1108. The liquid pump diaphragm 1106 operates first in an operating cycle, followed by sequential dispersion by the two air pump diaphragms 1108.

[0080] Similar to the embodiment described above, in operation, the liquid pump diaphragm 1106 expands and contracts to pump liquid, and the air pump diaphragm 1108 (only one shown) expands and contracts to pump air. Expansion of the liquid pump diaphragm 1106 opens the liquid inlet valve 1105, allowing liquid, such as soap or disinfectant, to enter the liquid pump chamber 1124 through the liquid inlet 1102. Expansion of the air pump diaphragm 1108 opens the air inlet valve 1107 (only one shown), allowing air to enter the air pump chamber 1126 (only one shown) through the air inlet 1104. Circular motion of the wobble plate pin 1127 sequentially ripples the end of the wobble plate 1110. The ripple motion causes the liquid pump diaphragm to compress, thereby opening the liquid outlet valve 1116, allowing liquid to flow through the liquid outlet opening 1122 and into the mixing chamber 1130. One of the air pump diaphragms 1108 is then compressed by rippling the wobble plate 1110, which opens the air outlet valve 1118 and allows air to flow through the air outlet opening 1123 and into the mixing chamber 1130. The other air pump diaphragm (not shown) then compresses, forcing air into the mixing chamber 1130. The air and liquid soap or sanitizer mix in the mixing chamber 1130 to produce a foam mixture. The foam mixture exits the mixing pump 1100 through the pump outlet 1114.

[0081] 12-15 show an exemplary embodiment of a refill unit 1200. FIG. 12 is a perspective view of an exemplary embodiment of a refill unit 1200 having a sequentially actuated multi-diaphragm foam pump 1206, and FIG. 13 is another perspective view of the exemplary refill unit 1200 with the backplate 1214 removed to show multiple diaphragms 1510A, 1510B, and 1510C. FIG. 13 is a rear elevation view of the refill unit 1200, and FIG. 15 is a rear elevation view of the refill unit 1200 with the backplate 1214 removed to show multiple diaphragms 1510A, 1510B, and 1510C. The refill unit 1200 connects to a foam dispenser 1600 (FIGS. 16, 17). The refill unit 1200 includes a container 1202, a foam pump 1206, an actuation mechanism 1304 (FIG. 13), a foam cartridge 1210, and a nozzle 1212. The refill unit 1200 includes a supply of foamable liquid. In various embodiments, the foamable liquid contained therein can be, for example, a soap, a disinfectant, a cleanser, a sanitizer, a lotion, or the like. The container 1202 is a collapsible container and can be made of a thin plastic or flexible bag-like material. In some embodiments, the container 1202 is a non-collapsible container formed by a rigid or semi-rigid housing member, or any other suitable configuration for containing the foamable liquid without leaking. In the case of a non-collapsible container, a venting system can be included, for example, any of the venting systems in the patents / applications incorporated above.

[0082] The foam pump 1206 is similar to the pumps described above and includes a housing 1208, a liquid pump diaphragm 1510A (FIG. 15), air pump diaphragms 1510B, 1510C, and a mixing chamber (not shown). The liquid pump diaphragm 1510A and the air pump diaphragms 1510B, 1510C are disposed within the housing 1208. The liquid pump diaphragm 1510A receives liquid from the container 1202 through the liquid inlet 1552 and the liquid inlet opening 1509A, and the liquid pump diaphragm 1510A pumps the liquid into the mixing chamber. The air pump diaphragm 1510B, 1510C receives air through at least one air inlet (not shown) and air inlet openings 1509B, 1509C, and air pump diaphragms 1510B, 1510C pump the air into the mixing chamber. The liquid pump diaphragm 1510A and air pump diaphragm 1510B are sequentially actuated by an actuation mechanism 1304 (FIG. 13). An operating cycle of the foam pump 1206 includes one pumping of liquid from the liquid pump diaphragm 1510A into the mixing chamber 325 and one pumping of air from the air pump diaphragms 1510B, 1510C into the mixing chamber. The operating cycle begins with one shot of liquid from the liquid pump diaphragm 1510A, followed by one shot of air from the air pump diaphragm 1510B and one shot of air from the air pump diaphragm 1510C. The liquid and air mix in a mixing chamber (not shown) to form a foamy mixture which passes through foam cartridge 1210 and exits foam pump 1206 through outlet 1212. Typically, dispensing of the foam requires one or more operating cycles or revolutions. In some embodiments of the invention, the foam mixture has an air to liquid ratio of between about 7 to 1 and about 10 to 1. In some embodiments, the air to liquid ratio is greater than 10 to 1, and in some embodiments, less than 7 to 1.

[0083] In some exemplary embodiments, a flow control valve (not shown) is provided between the container 1202 of foamable liquid and the pump 1206. The flow control valve may be used to adjust the liquid to air ratio. If a higher liquid to air ratio is required, the flow control valve is set to a lower flow rate that starves the liquid pump diaphragm 1510A. Conversely, to increase the liquid to air ratio, the flow control valve may be opened wider to allow more liquid to flow into the pump 1206. In some embodiments, the liquid pump diaphragm 1510A may have a different volume than the air pump diaphragms 1510B, 1510C to adjust the liquid to air ratio. In some embodiments, the volume of the liquid pump diaphragm 1510A is reduced by inserting a sponge (not shown) into the liquid pump diaphragm 1510A. Not only does the sponge (not shown) reduce the volume, but in some embodiments, the sponge slows the flow of liquid through the liquid pump diaphragm 1510A.

[0084] Foam pump 1206 may include some or all of any of the embodiments described herein, and may have two or more liquid pump diaphragms and one or more air pump diaphragms.

[0085] The actuation mechanism 1304 (FIG. 13) releasably connects to the drive system of a motor 1706 (FIG. 17) that is permanently attached to the foam dispenser 1600. The actuation mechanism 1304 is covered by the backplate 1214.

[0086] In some embodiments, the actuation mechanism 1304 does not include a wobble plate 1405, but may include a circular plate (not shown) and one or more springs (not shown). The circular plate is connected to the liquid pump diaphragm 1510A and the air pump diaphragms 1510B, 1510C. The one or more springs urge the circular plate outward, thereby urging the liquid pump diaphragm 1510A and the air pump diaphragms 1510B, 1510C to their extended positions. A drive system (not shown) on the dispenser includes a wheel that travels around the periphery of the circular plate. The contact point between the wheel and the circular plate pushes that portion of the circular plate downward. As the wheel rotates around, the wheel sequentially compresses the liquid pump diaphragm 1510A and the air pump diaphragms 1510B, 1510C. As the wheel moves past the diaphragms 1510A, 1510B, 1510C, the diaphragms 1510A, 1510B, 1510C expand to draw in fluid as they are biased toward their extended positions by the diaphragm material as well as one or more springs. In some embodiments, springs are not required and the diaphragm material is sufficient to bias the diaphragms 1510A, 1510B, 1510C to their extended positions.

[0087] The above-described embodiments are merely exemplary, and the actuation mechanism 1304 may be configured in any manner that causes sequential movement of the liquid pump diaphragm 1510A and the air pump diaphragms 1510B, 1510C of the foam pump 1206.

[0088] Figure 13 is a rear view of an exemplary embodiment of a refill unit 1200 having the sequentially acting multi-diaphragm foam pump 1206 of Figure 12 with a backplate 1214. The backplate 1214 has an opening 1301. The refill unit 1200 is attached to the foam dispenser 1600 (Figure 16) by connecting an attachment mechanism 1304 to the drive system of a motor 1706 through the opening 1301 in the backplate 1214.

[0089] 14 and 15 are diagrams of an exemplary embodiment of a refill unit 1200 having a sequentially actuated multi-diaphragm foam pump 1206 with the backplate 1214 removed. The actuation mechanism 1304 includes a wobble plate 1405, a wobble plate connecting link 1407, and a pin 1409. Each wobble plate link 1407 connects to a pump diaphragm 1510A, 1510B, 1510C. In this exemplary embodiment, the pin 1409 of the actuation mechanism 1304 releasably connects the actuation mechanism 1304 to an eccentric drive system 1707 (FIGS. 17 and 18) of the motor 1706. With reference to FIGS. 17 and 18, a portion of the pump 1206 of the refill unit 1200 is received in a socket 1701 of the foam dispenser 1600, and the actuation mechanism 1304 releasably connects to the eccentric drive system 1707. The eccentric drive system 1707 is attached to the shaft 1809 of the motor 1706. The pin 1409 of the actuation mechanism 1304 releasably engages the pin 1409 of the eccentric drive system 1707 which engages the notch 1811. In some embodiments, the eccentric drive system 1707 is connected to the actuation mechanism 1304, is part of the refill unit 1200, and releasably connects to the shaft 1809 of the motor 1706. The above-described embodiments are merely exemplary. The refill unit 1200 and motor 1706 may be configured in any manner that allows the refill unit 1200 to be releasably attached to the motor 1706 and that allows the motor 1706 to operate the foam pump 1206.

[0090] 14 and 15, the eccentric drive system 1707 (FIGS. 17 and 18) ripples the wobble plate 1405, thereby causing the continuous movement of the liquid pump diaphragm 1510A and the air pump diaphragms 1510B, 1510C. As the liquid pump diaphragm 1510A expands, liquid moves from the container 1202 through the liquid inlet 1552 and the liquid inlet opening 1509A into the liquid pump diaphragm 1510A. The liquid pump diaphragm 1510A is in a primed position when it is filled with liquid. As the air pump diaphragms 1510B, 1510C expand, air moves through at least one air inlet (not shown) and through the air inlet openings 1509B, 1509C into the respective air pump diaphragms 1510B, 1510C. The air pump diaphragms 1510B, 1510C are in a primed position when they are filled with air. An exemplary operating cycle includes one pump of liquid from the liquid pump diaphragm 1510A, followed by one pump of air from the air pump diaphragm 1510B, followed by one pump of air from the air pump diaphragm 1510C.

[0091] In some embodiments, each pump diaphragm 1510A, 1510B, 1510C has a volume between about 0.1 and 1.0 ml. The pump diaphragms 1510A, 1510B, 1510C pump liquid and air into a mixing chamber (not shown) where the liquid and air mix to form a foamy mixture. The foamy mixture passes through the foam cartridge 1210 to form a rich foam, and the rich foam exits the refill unit 1200 through the nozzle 1212. In some embodiments, the liquid pump diaphragm 1510A has a volume between about 0.1 and 1.0 ml.

[0092] In some embodiments, the foam dose dispensed by the foam dispenser comprises between about 0.3 ml and about 7.0 ml of liquid. In some embodiments, the foam dose comprises between about 3 and 10 revolutions, including between about 3 and 7 revolutions, including between about 5 and 10 revolutions per dispense. In some embodiments, the foam dose is about 0.3 ml for highly concentrated lightweight soaps. In some embodiments, the foam dose is about 7.0 ml of liquid for heavy-duty soaps such as grease cleaning soaps.

[0093] In some embodiments, the dispenser operates at a voltage between about 3 volts and 10 volts, including between about 3 volts and about 5 volts, including between about 4 volts and about 6 volts, including between about 4 volts and about 8 volts, including between about 6 volts and about 9.5 volts.

[0094] In some embodiments, the pump continues for about 0.3 seconds to 2 seconds to dispense a dose of foam, including between about 0.5 seconds to 1.5 seconds, including between about 0.5 seconds to 1 second. In some embodiments, the dispense time is about 0.6 seconds, such as dispensing a foam sanitizer having about 1.2 ml of liquid. In some embodiments, the dispense time is less than 1.50 seconds, such as dispensing a light-duty soap and heavy-duty soap having between about 0.3 ml of liquid and about 7.0 ml of liquid.

[0095] In some embodiments, the wobble plate drive actuator rotates between about 120 and about 480 revolutions per minute.

[0096] In some embodiments, there are multiple liquid pump diaphragms, for example, two liquid pump diaphragms, three liquid pump diaphragms, four liquid pump diaphragms, etc. In some embodiments, there are multiple air pump diaphragms, for example, two air pump diaphragms, three air pump diaphragms, four air pump diaphragms, five air pump diaphragms, six air pump diaphragms, seven air pump diaphragms, and eight air pump diaphragms, In some embodiments, the number of air pump diaphragms to liquid pump diaphragms is 1:1, 2:1, 3:1, 4:1, 5:1, 6:1, 7:1, and 8:1.

[0097] 19A-19B, 20A-20B, and 21A-21E show various views of another exemplary embodiment of a sequentially actuated multi-diaphragm foam pump 1900. The foam pump 1900 is coupled to a foam cartridge housing 1902 and a container receiver 1904, with the foam cartridge housing 1902 coupled to a nozzle 1906. The foam pump 1900 includes a housing 1908, a diaphragm assembly 1910, a pump outlet 1912, and a pump cover 1914. The diaphragm assembly 1910 includes three pump diaphragms 1916a, 1916b, 1916c. The three pump diaphragms 1916a, 1916b, 1916c include one liquid pump diaphragm 1916a and two air pump diaphragms 1916b, 1916c. Diaphragm assembly 1910 is exemplary only and may include four or more pump diaphragms. Additionally, diaphragm assembly may include one or more liquid pump diaphragms and / or one or more air pump diaphragms.

[0098] A container (not shown) is connected to the container 1904 with a closure to allow liquid to enter the liquid inlet 1918. In operation, as the liquid pump diaphragm 1916a expands, liquid is drawn through the liquid channel 1920, past the liquid inlet valve 1922a, and into the liquid pump diaphragm 1916a. Similarly, as the air pump diaphragms 1916b, 1916c expand, air is drawn through the openings, past the air inlet valves 1922b, 1916c, and into the air pump diaphragms 1916b, 1916c, respectively. When the liquid pump diaphragm 1916a compresses, liquid is forced out of the liquid pump diaphragm 1916a, deflecting the wall of the normally closed liquid outlet valve 1923 away from the side wall 1927 due to the natural elasticity of the material, and liquid flows into the mixing chamber 2132 (FIG. 21E). Similarly, when the air pump diaphragms compress, air is forced out of air pump diaphragms 1916b, 1916c, deflecting the walls of liquid outlet valve 1923 away from side wall 1927 and air flows into mixing chamber 2132. When pressure from the liquid or air is removed, for example when liquid pump diaphragm 1916a or air pump diaphragms 1916b, 1916c expand, liquid outlet valve 1923 seals against side wall 1927, sealing off diaphragms 1916a, 1916b, 1916c from outlet nozzle 1906.

[0099] The liquid and air mix in the mixing chamber 2132 to generate a foam mixture, which exits through the pump outlet 1912. After the foam mixture exits the pump outlet 1912, the foam mixture travels through a foam cartridge 1924. In this particular embodiment, the foam cartridge 1924 includes screens 1926a, 1926b and a sponge 1928. The foam cartridge 1924 may include a variety of components, for example, the components of the foam cartridge 1924 may include one or more screens 1926 and / or one or more sponges 1928. The foam exits the foam cartridge 1924 and is dispensed from the outlet nozzle 1906 as a rich foam.

[0100] The pump diaphragms 1916a, 1916b, 1916c operate sequentially, and the operation of the pump diaphragms 1916a, 1916b, 1916c can take any form as described for the various embodiments of the foam pump described herein. In one embodiment, the liquid pump diaphragm 1916a operates first during an operating cycle, followed by sequential operation by the two air pump diaphragms 1916b, 1916c.

[0101] 22 is a cross-sectional view of another exemplary embodiment of a sequentially acting multi-diaphragm foam pump 2200. The sequentially acting multi-diaphragm foam pump 2200 is driven by a motor 2212 having a motor shaft 2213. The foam pump 2200 includes a wobble plate 2210, a wobble plate pin 2227, an eccentric wobble plate driver 2220, a liquid pump diaphragm 2206, two air pump diaphragms 2208 (only one shown), a mixing chamber 2230, a liquid inlet 2202, a liquid inlet valve 2205, an air pump chamber 2226, an air inlet 2204, an air inlet valve 2207, an outlet valve 2216, the mixing chamber 2230, and an outlet 2214.

[0102] The motor 2212 drives the motor shaft 2213, which rotates the motor shaft 2213. The rotation of the motor shaft 2213 rotates the eccentric wobble plate driver 2220, which in turn moves the wobble plate pin 2227 along a circular path, causing the wobble plate 2210 to ripple. In some embodiments, the wobble plate 2210 includes a ball (not shown) that rides in a socket (not shown) on the pump housing, and the wobble plate pin 2227 extends outward and connects to the eccentric wobble plate actuator 2220, which moves the pin along a circular path, thereby ripples the wobble plate 2210. As the wobble plate 2210 ripples, the ends connected to the three pump diaphragms 2206, 2208 move in an up and down motion, causing the three pump diaphragms 2206, 2208 to expand and compress sequentially.

[0103] Expansion of the liquid pump diaphragm 2206 causes the liquid inlet valve 2205 to open, drawing liquid, such as, for example, soap or disinfectant, through the liquid inlet 2202 and into the liquid pump chamber 2224. Expansion of the air pump diaphragms 2208 (only one shown) causes the air inlet valve 2207 to open (only one shown), drawing air through the air inlet 2204 (only one shown) and into the air pump chamber 2226. Compression of the liquid pump diaphragm 2206 causes the liquid pump chamber 2224 to compress, thereby deflecting the outlet valve 2216 open, allowing liquid to flow into the mixing chamber 2230. Compression of one of the air pump diaphragms 2208 causes the air pump chamber 2226 to compress, thereby deflecting the outlet valve 2216 open away from the sidewall, thereby allowing air to flow into the mixing chamber 2230. A second air pump diaphragm similarly pumps air into the mixing chamber. The air and liquid soap or sanitizer mix in mixing chamber 2230 to produce a foam mixture. The foam mixture travels through foam cartridge 2232 and exits foam pump 2200 through pump outlet 2214.

[0104] One sequence of operation of the foam pump 2200 involves one pumping by each of the three pump diaphragms 2206, 2208. The liquid pump diaphragm 2206 operates first in an operating cycle, followed by sequential dispersion by the two air pump diaphragms 2208.

[0105] 23 is an exploded view of another exemplary embodiment of a sequentially acting multi-diaphragm foam pump 2300. The foam pump 2300 is driven by a motor 2304. The foam pump 2300 includes a pump housing 2324, a wobble plate 2314, a diaphragm assembly seat 2312, a diaphragm assembly 2310, a valve seat 2308, inlet valves 2323a, 2323b, 2323c, a gasket 2306, and a cover 2348. The cover 2348 is attached to the valve seat 2308 and the gasket 2306 is located between the cover 2348 and the gasket 2306 to form a seal around the air inlet opening 2325, the liquid inlet 2352, and the foam outlet 2350 to prevent fluid leakage. Inlet valves 2323 a , 2323 b , 2323 c are secured to and seated within valve seat 2308 .

[0106] The diaphragm assembly 2310 includes three pump diaphragms 2311a, 2311b, 2311c, each pump diaphragm 2311a, 2311b, 2311c having a connector 2315. The diaphragm assembly 2310 is seated in a diaphragm assembly seat 2312. The pump diaphragms 2311a, 2311b, 2311c are disposed in receiving holes 2313a, 2313b, 2313c, respectively, of the diaphragm assembly seat 2312, and the three connectors 2315 connect to the wobble plate 2314 by inserting the three connectors 2315 into three respective wobble plate links 2317.

[0107] The bottom of the valve seat 2308 has three cylindrical projections 2351a, 2351b, 2351c corresponding to the three pump diaphragms 2311a, 2311b, 2311c, respectively. The three pump diaphragms 2311a, 2311b, 2311c fit snugly over the three cylindrical projections 2351a, 2351b, 2351c and act as one-way liquid outlet valves. When the pump diaphragms 2311a, 2311b, 2311c expand and the interiors of the pump diaphragms 2311a, 2311b, 2311c are under negative pressure, the pump diaphragms 2311a, 2311b, 2311c seal against the walls of the cylindrical protrusions 2351a, 2351b, 2351c, respectively, preventing the flow of fluid between the pump diaphragms 2311a, 2311b, 2311c and the walls of the cylindrical protrusions 2351a, 2351b, 2351c to the pump diaphragms 2311a, 2311b, 2311c. When pump diaphragms 2311a, 2311b, 2311c compress and the interior of pump diaphragms 2311a, 2311b, 2311c is under positive pressure, pump diaphragms 2311a, 2311b, 2311c bend away from the walls of cylindrical projections 2351a, 2351b, 2351c, respectively, allowing fluid to flow out of pump diaphragms 2311a, 2311b, 2311c. When the positive pressure stops or is below the cracking pressure of pump diaphragms 2311a, 2311b, 2311c, pump diaphragms 2311a, 2311b, 2311c move back to their normal positions and form a seal against the walls of cylindrical projections 2351a, 2351b, 2351c. Additionally, each cylindrical projection 2351a, 2351b, 2351c has one or more fluid inlet openings 2309a, 2309b, 2309c that extend through the valve seat 2308 and the stem retaining openings 2329a, 2329b, 2329c, respectively.

[0108] Similar to the embodiment described above, in operation, when liquid pump diaphragm 2311a expands, a vacuum is created and liquid is drawn through liquid inlet 2352, through fluid inlet opening 2309a, past fluid inlet valve 2323a, and into liquid pump diaphragm 2311a. Similarly, when air pump diaphragms 2311b, 2311c expand, air is drawn through air inlet 2325, through air inlet openings 2309b, 2309c, past fluid inlet valves 2323b, 2323c, and into air pump diaphragms 2311b, 2311c.

[0109] As the liquid pump diaphragm 2311a contracts, a positive pressure is created within the diaphragm 2111, and once the positive pressure reaches a selected cracking pressure, the diaphragm 2311a bends away from the cylindrical wall 2351a and flows into the mixing chamber 2372. As the air pump diaphragms 2311b, 2311c contract, a positive pressure is created, and once the positive pressure reaches a selected cracking pressure, the diaphragms 2311b, 2311c bend away from the cylindrical walls 2351b, 2351c, respectively, and air flows into the mixing chamber 2372. The air and liquid mix together to form a foamy mixture, which is forced out of the outlet 2350. The foam mixture may be dispensed as is, or may be further refined using foam cartridges, sponges, screens, baffles, etc., and combinations thereof (not shown).

[0110] In some embodiments, the liquid pump diaphragm 2311a includes a sponge (not shown) to limit the amount of liquid that can be retracted or expanded to create different air to liquid mixture ratios. In some embodiments, a flow control valve (not shown) is attached to the liquid inlet 2352, which allows the flow rate of liquid to be controlled to adjust the air to liquid ratio.

[0111] The pump diaphragms 2311a, 2311b, 2311c are expanded and compressed by the movement of the wobble plate 2314. The shaft 2303 of the motor 2304 is connected to an eccentric wobble plate driver 2326. A wobble plate pin 2327 connects to the eccentric wobble plate driver 2326 in a region that is offset from the centerline of the motor shaft 2303. Offsetting the wobble plate pin 2327 from the motor shaft 2303 causes a circular motion of the wobble plate pin 2327, which sequentially ripples the ends of the wobble plate 2314. The ripples cause the pump diaphragms 2311a, 2311b, 2311c to sequentially compress and expand to pump liquid and air.

[0112] 24 and 25 show another exemplary embodiment of a sequentially actuated multi-diaphragm foam pump 2400. The foam pump 2400 includes a pump housing 2402, a liquid inlet valve 2528, three air inlet valves 2538 (only one shown), a wobble plate 2504, a liquid pump diaphragm 2506, three air pump diaphragms 2508 (only one shown), a mixing chamber 2510, and a foam pump outlet 2412. The foam pump 2400 is coupled to and in fluid communication with a foam cartridge housing 2514, which houses a foam cartridge 2516. The foam cartridge 2516 is in fluid communication with an outlet nozzle 2518. The foam pump 2400 also includes a liquid inlet 2420 in fluid communication with a container (not shown) that holds a foamable liquid. Liquid inlet 2420 is coupled to foam pump 2400 such that foamable liquid is directed to liquid pump diaphragm 2506 .

[0113] 24 is a perspective view of a foam pump 2400 showing a liquid inlet housing 2422 upstream of a liquid pump diaphragm 2506 and three air inlet regions 2424A, 2424B, and 2424C upstream of and corresponding to three air pump diaphragms 2508. In some embodiments of the pumps described herein, multiple pump chambers, e.g., a liquid pump chamber and two or more air pump chambers, are formed by a molded multi-chamber diaphragm.

[0114] The liquid pumping section includes a pump diaphragm 2506, a liquid pump diaphragm inlet 2526, a liquid inlet valve 2528, a liquid pump diaphragm chamber 2530, a liquid pump diaphragm outlet 2532, and an outlet valve 2534. In this embodiment, the outlet valve 2534 is integrally molded with the liquid pump diaphragm 2506 and the air pump diaphragm 2508. The liquid pump diaphragm 2506, the liquid pump diaphragm inlet 2526, the liquid inlet valve 2528, the liquid pump diaphragm chamber 2530, the liquid pump diaphragm outlet 2532, and the liquid outlet valve 2534 can take any form described herein. Each air pumping section includes an air pump diaphragm 2508, an air pump diaphragm inlet 2536, an air inlet valve 2538, an air pump diaphragm chamber 2540, an air pump diaphragm outlet 2542, and an outlet valve 2534. Outlet valve 2534 is a cylindrical member that deflects away from the sealing wall when the pump diaphragm is under positive pressure to allow air or liquid to enter the mixing chamber. Air pump diaphragm 2508, air pump diaphragm inlet 2536, air inlet valve 2538, air pump diaphragm chamber 2540, air pump diaphragm outlet 2534, and outlet valve 2544 can take any form described herein.

[0115] In operation, the liquid pump diaphragm 2506 expands and contracts to pump liquid, and the three air pump diaphragms 2508 expand and contract to pump air. Expansion of the liquid pump diaphragm 2506 opens the liquid inlet valve 2528, drawing liquid through the liquid inlet 2526 and into the liquid pump diaphragm chamber 2530. Expansion of each air pump diaphragm 2508 opens a corresponding air inlet valve 2538, drawing air into a corresponding air pump diaphragm chamber 2540. Air enters each air pump diaphragm 2508 through a corresponding air inlet 2536 (only one shown). The wobble plate 2504 is connected to a motor (not shown), which may take any form described herein. The motor sequentially wobbles the ends of the wobble plate 2504. The wave-like motion causes the liquid pump diaphragm 2506 to compress, which forces the outlet valve 2534 open by the liquid flowing into the mixing chamber 2510. The outlet valve 2534 is made of a flexible material, such as the same material as the pump diaphragms 2506, 2508, and in some cases, the pump diaphragms 2506, 2508 and the outlet valve 2534 are formed as one piece. The flexible material allows the outlet valve 2534 to remain closed during expansion of the liquid pump diaphragm 2506 and when the liquid pump diaphragm 2506 is in a primed state. However, during compression of the liquid pump diaphragm 2506, the flexible material of the outlet valve 2534 is forced open to allow liquid to flow into the mixing chamber 2510.

[0116] Subsequently, one of the air pump diaphragms 2508 is compressed by the rippling wobble plate 2504, thereby opening the outlet valve 2534 and allowing air to flow through the mixing chamber 2510. The flexible material allows the outlet valve 2534 to remain closed during expansion of the corresponding air pump diaphragm 2508 and when the air pump diaphragm 2508 is in a primed state. However, similar to the liquid, during compression of the air pump diaphragm 2508, the flexible material of the outlet valve 2534 is forced open to allow air to enter the mixing chamber 2510. Similarly, the remaining air pump diaphragms 2508 sequentially compress and pump the air into the mixing chamber 2510. The air and liquid mix in the mixing chamber 2510 to produce a foam mixture. The foam mixture exits the foam pump 2400 through the pump outlet 2412.

[0117] As can be seen, liquid is pumped directly from the liquid pump diaphragm 2506 into the mixing chamber 2510. In other words, liquid does not have to travel through an additional conduit or channel after leaving the liquid pump diaphragm 2506 and before entering the mixing chamber 2510. In some embodiments, a shorter distance between the liquid pump diaphragm outlet 2532 and the mixing chamber 2510 improves the efficiency of the foam pump 2400.

[0118] After the foam mixture exits the foam pump 2400, it travels through a conduit 2546 in the foam cartridge housing 2514 and enters the foam cartridge 2516. The foam cartridge housing 2514 is an elbow component that directs the foam mixture to flow downward. The downward flow of the foam mixture improves the output efficiency of the foam mixture. However, the foam cartridge housing can take any form that allows the foam mixture to exit through the outlet nozzle 2518.

[0119] In any of the above described embodiments, the size of the liquid path relative to the air path may vary. In certain embodiments, the liquid path is between about 20 and 40 times larger than the air path. Also, in certain embodiments, the liquid inlet and / or outlet valves have a higher cracking pressure than the air inlet and / or outlet valves.

[0120] Exemplary embodiments of foam pumps may be used in soap or sanitizer dispensers. The refill units described herein include at least one container for holding liquid. The refill units are removable from the dispenser and can be replaced with a new refill unit. In some embodiments, the foam pump is a permanent part of the dispenser and the refill unit includes a container and a fitting for connecting to a fitting (not shown) on the foam pump. In some embodiments, the refill unit includes a foam pump secured to the container, which releasably connects to a drive unit, such as a motor, that is permanently secured to the dispenser. In some embodiments, the refill unit includes a container, a foam pump, and a motor. In some embodiments, the refill unit includes a power source, such as a battery.

[0121] In some embodiments, the dispenser includes a direct current (DC) power source. V From 9 V For example, the voltage is about 5 V From about 9 V , for example about 6 to about 8 V , for example about 3 V , for example about 4.5 V , for example about 6 V , for example about 7.5 V , for example about 8 V , and for example about 9 V has.

[0122] In some embodiments, the dispenser dispenses at about 1 to about 2.5 milliliters / second of foam, such as about 1.9 to 2.5 milliliters / second of foam, such as about 1.9 milliliters / second of foam, such as about 2.0 milliliters / second of foam, such as about 2.1 milliliters / second of foam, such as about 2.2 milliliters / second of foam, such as about 2.3 milliliters / second of foam, such as about 2.4 milliliters / second of foam, and such as about 2.5 milliliters / second of foam.

[0123] A conventional mechanical piston foam pump required 1.8 Joules per 12 ml of dispensed foam, resulting in 0.15 Joules per milliliter of foam. The liquid volume was 0.9, resulting in an air to liquid ratio of 11 to 1. An exemplary pump constructed in accordance with an embodiment of the present invention required only 0.6 Joules per 12 ml of dispensed foam, resulting in 0.05 Joules per milliliter of foam. The liquid volume was 0.5, resulting in an air to liquid ratio of 24 to 1.

[0124] In some exemplary embodiments, the motor used to drive the foam pump consumes about 0.4 to about 1.5 Joules / 12 milliliters of foam output, such as about 0.6 to 1.5 Joules / 12 milliliters of foam output, such as about 0.5 to 1.3 Joules / 12 milliliters of foam output, such as about 0.0 to 1.3 Joules / 12 milliliters of foam output, such as about 0.9 to 1.3 Joules / 12 milliliters of foam output, such as about 0.5 Joules / 12 milliliters of foam output. Torr, for example about 0.6 Joules / 12 ml of foam output, for example about 0.7 Joules / 12 ml of foam output, for example about 0.8 Joules / 12 ml of foam output, for example about 0.9 Joules / 12 ml of foam output, for example about 1.0 Joules / 12 ml of foam output, for example about 01.1 Joules / 12 ml of foam output, for example about 1.2 Joules / 12 ml of foam output, for example about 1.3 Joules / 12 ml of foam output.

[0125] In some embodiments, the output foam volume is about 60 to 130 milliliters of foam, such as about 100 to 120 milliliters of foam, such as about 80 milliliters of foam, such as about 90 milliliters of foam, such as about 100 milliliters of foam, such as about 110 milliliters of foam, and such as about 120 milliliters of foam.

[0126] In some embodiments, the output foam volume has a foam density of about 0.08 to about 0.125 grams per milliliter of foam, such as a foam density of about 0.08 grams per milliliter of foam, such as a foam density of about 0.09 grams per milliliter of foam, such as a foam density of about 0.1 grams per milliliter of foam, such as a foam density of about 0.11 grams per milliliter of foam, and such as a foam density of about 0.12 grams per milliliter of foam.

[0127] In some embodiments, the foam pump is configured to produce a foam having an air ratio of about 10 to 1. In some embodiments, the foam pump is configured to produce a foam having an air ratio of about 9 to 1. In some embodiments, the foam pump is configured to produce a foam having an air ratio of about 8 to 1. In some embodiments, the foam pump is configured to produce a foam having an air ratio of about 7 to 1. In some embodiments, the foam pump is configured to produce a foam having an air ratio of about 6 to 1.

[0128] While the embodiments described above generally include pumps having one liquid pump chamber and multiple air chambers, in some embodiments, the pump has two or more liquid pump chambers. In some embodiments, the pump has two or more liquid pump chambers. In some embodiments, the two or more liquid pump chambers pump two or more different liquids.

[0129] 26 is a perspective view of an exemplary foam outlet nozzle 2600 that provides extra high volume foam soap. In this exemplary embodiment, the outlet nozzle 2600 is connected to a four-chamber sequentially actuated diaphragm foam pump 2602 described herein, although the outlet nozzle 2600 may be used with other pumps. The pump 2602 includes a liquid inlet 2604, three air inlets 2624 (only two are visible), and an outwardly flared outlet nozzle 2650.

[0130] Figure 27 is a cross-sectional view of the exemplary foam outlet nozzle 2600 of Figure 26. The foam outlet nozzle 2600 includes a fluid inlet 2702. 2702receives the liquid / air mixture from the foam pump 2602. The fluid travels through a passageway and passes through a mixing medium 2704, which can be, for example, a screen that creates turbulence in the mixture to generate foam. The foamy mixture passes through a second mixing medium 2708, which can also be, for example, a screen. While this exemplary embodiment includes two mixing mediums 2704, 2708, it has been discovered that just one mixing medium 2708 results in high quality foam in a novel design of the outlet nozzle 2600. The foamy mixture passes through a passageway having an inner diameter 2720 and into a second passageway having an inner diameter 2722. In some embodiments, the inner diameters 2720 and 2722 have an inner diameter between about 0.2 inches and about 0.35 inches. The foam outlet nozzle 2600 includes a flared tip 2710. In some embodiments, the flared tip 2710 has an inner diameter between about 0.5 inches and about 0.7 inches. Additionally, it has been discovered that the length 2730 of the port 2709 affects the quality of the foam output through the foam outlet nozzle 2600. In some embodiments, the port length 2730 is between about 0.3 inches and about 1.25 inches. Exemplary embodiments of the foam outlet port 2600 have provided foam densities as low as 0.04 grams / cubic cm, as low as 0.04 grams / cubic cm, as low as 0.03 grams / cubic cm, and as low as 0.02 grams / cubic cm. Without limiting effects, it is believed that the high foam volume is due to the large diameter port 2709 and flared tip 2710. The hold to the tube cannot be too small or the foam will break.

[0131] In some exemplary embodiments, the liquid cylinder (not shown) of the foam pump 2602 utilizes a mechanism to throttle the liquid flow entering the foam pump 2602, such as, for example, lost motion, a smaller diameter liquid diaphragm, a restrictor valve, a restrictor inlet, a sponge located within the liquid diaphragm, etc. In some embodiments, depending on the soap formulation level of alcohol and surfactant type, the nozzle 2600 of the foam pump 2602 may differ in design. A larger diameter nozzle with a single screen will lather soap formulations that are more difficult to lather, such as soaps with alcohol or non-ideal surfactants, and produce a foam with large bubbles. A better foaming formulation, when coupled with a smaller nozzle diameter and a dual screen, can produce a high volume foam with consistent small bubbles.

[0132] As mentioned above, in some instances, it is desirable to adjust the volume for one or more of the pump diaphragms to control the ratio of liquid to air that combine to form a foam. The system and method described below may be applied to any of the exemplary embodiments disclosed herein. For example, the system and method may be applied to a three-diaphragm foam pump, a four-diaphragm foam pump, a five-diaphragm foam pump, etc. In some exemplary embodiments, the volume of the liquid pump diaphragm is reduced. In some embodiments, the liquid pump diaphragm moves a shorter distance than the corresponding air pump diaphragm due to "lost motion." That is, the mechanism (in this case, the wobble plate) moves the same distance for both the air pump diaphragm and the liquid pump diaphragm, but due to intentional lost motion in the connection between the liquid pump diaphragm and the wobble plate, the liquid pump diaphragm does not move the entire course of the wobble plate's travel, but rather only moves a portion of the distance the wobble plate moves, while the air pump diaphragm moves substantially the same distance as the wobble plate moves. While the above description is directed to lost motion in a liquid pump diaphragm, the concepts of the present invention work equally well with one or more air pump diaphragms. In some exemplary embodiments, lost motion occurs between the wobble plate and one or more air pump diaphragms, whether or not lost motion occurs between one or more liquid pump diaphragms.

[0133] 28 is a cross-sectional view of an exemplary embodiment of a pump diaphragm 2800. The pump diaphragm 2800 includes a stem 2802, a retaining member 2804, a base 2806, a pump chamber 2810, and a top surface 2812 of the pump chamber 2810. In this exemplary embodiment, the stem 2802 has a length 2808 and the pump chamber 2810 has a pump chamber depth 2814. The stem 2802 is sized such that when the pump diaphragm 2800 is connected to the wobble plate 3000 (FIG. 30), there is little to no gap between the wobble plate 3000 and the top of the base 2803 and the bottom of the retaining member 2804. Thus, when the wobble plate 3000 moves in an upward direction, the pump diaphragm 2800 moves substantially the same distance as the wobble plate 3000. Similarly, when the wobble plate 3000 moves in a downward direction, the pump diaphragm 2800 moves substantially the same distance as the wobble plate 3000 .

[0134] 29 is a cross-sectional view of an exemplary embodiment of a pump diaphragm 2900 configured for lost motion. The pump diaphragm 2900 includes a stem 2902, a retaining member 2904, a base 2906, a pump chamber 2910, and a top surface 2912 of the pump chamber 2910. In this exemplary embodiment, the stem 2902 has a length 2908. The length 2908 is greater than the length 2808 of the pump diaphragm 2800. The pump chamber 2910 has a pump chamber depth 2914. In this exemplary embodiment, the pump chamber depth 2914 is reduced to ensure that the pump chamber 2910 is fully compressed with each stroke, eliminating or substantially eliminating the possibility of air remaining in the pump chamber 2910 during operation of the pump. In some embodiments, the depth of the pump chamber 2910 does not need to be reduced.

[0135] The stem 2902 is sized such that when the pump diaphragm 2900 is connected to the wobble plate 3100 (FIG. 31), there is a gap between the wobble plate 3100 and the top of the base 2903 and / or between the wobble plate 3100 and the bottom of the retaining member 2904. Thus, when the wobble plate 3100 moves in an upward direction from the base 2906, the pump diaphragm 2900 does not move upwards initially. After the wobble plate 3100 contacts the bottom surface of the retaining member 2904, the pump diaphragm 2900 moves the remaining distance that the wobble plate 3100 travels. Thus, the pump diaphragm 2900 does not move as far as the wobble plate 3100. When the wobble plate 3100 moves in a downward direction, the pump diaphragm 2900 does not move until the wobble plate 3100 contacts the base 2906. After the wobble plate 3100 contacts the base 2906 , continued movement in a downward direction causes the pump diaphragm 2900 to move the remaining distance that the wobble plate 3100 travels, fully compressing the pump chamber 2910 .

[0136] When comparing pump diaphragm 2800 with pump diaphragm 2900, preferably the length of stem 2902 is increased by lowering base 2906 so that retaining member 2904 is positioned in substantially the same location as retaining member 2804 while base 2906 is lower than base 2806.

[0137] 33 is a partial cross-sectional view of an exemplary embodiment of a pump 3300 having two air pump chambers and a single liquid pump chamber with lost motion and reduced pump diaphragm volume. Although the exemplary embodiment shows two air pump diaphragms and one liquid pump diaphragm, the concepts of the present invention may be applied to pumps having more than one air pump diaphragm and / or more than one liquid pump diaphragm.

[0138] The pump 3300 includes a liquid inlet 3302, a first liquid inlet valve 3304, a second liquid inlet valve 3306, a fluid outlet valve 3320, and a liquid pump diaphragm 3305. The liquid pump diaphragm 3305 includes a liquid pump chamber 3307, a base 3308, a stem 3310, and a retaining member 3312. In addition, the pump 3300 includes two air pump diaphragms 3320 having two air pump chambers 3316, a stem 3326, a base 3324, and a retaining member 3328. The air pump chambers 3322 and the liquid pump chambers 3307 are in fluid communication with the fluid outlet valve 3320. Downstream of the fluid outlet valve 3320 are a fluid passageway 3332, a first porous foam member 3334, a foam region 3336, a second porous foam member 3338, and a second porous foam member 3339. 3338 , and a bubble outlet 3340 .

[0139] The liquid pump chambers 3307 are smaller than the corresponding air pump chambers 3322. Additionally, the stem 3310 of the liquid pump diaphragm 3305 is longer than the stem 3326 of the air pump diaphragm. The retaining members 3312 and 3326 are all substantially the same size and lie in substantially the same plane. Thus, as described above with respect to the wobble plate, when an actuator such as a wobble plate actuates the liquid pump diaphragm 3305 and the air pump diaphragm 3320, the base 3308 of the liquid pump diaphragm 3305 moves less than the wobble plate due to lost motion caused by the increased length of the stem 3310.

[0140] 34 is a cross-sectional view of another exemplary embodiment of a pump diaphragm 3400. The pump diaphragm 3400 is similar to the pump diaphragm 2800 and includes a stem 3402, a retaining member 3404, a base 3406, a pump chamber 3410, and a top surface 3412 of the pump chamber 3410. In this exemplary embodiment, the stem 3402 has a length 3408 and the pump chamber 3410 has a pump chamber depth 3414. The stem 3402 is sized such that when the pump diaphragm 3400 is connected to a wobble plate (not shown), there is little to no gap between the wobble plate and the top of the base 3403 and the bottom of the retaining member 3404. Thus, when the wobble plate moves in an upward direction, the pump diaphragm 3400 moves substantially the same distance as the wobble plate. Similarly, when the wobble plate moves in a downward direction, pump diaphragm 3400 moves substantially the same distance as the wobble plate. The difference between pump diaphragm 3400 and pump diaphragm 2800 is that the volume of pump chamber 3410 has been reduced by reducing width 3450 of pump diaphragm 3400. Thus, pump diaphragm 3400 is a liquid pump diaphragm and two air pumps where the pump is similar to pump diaphragm 2800. Diaphragm If including, each revolution of the wobble pump Every , Being pumped Volume of liquid of More than twice as much A large volume of air is pumped .

[0141] While changing the volume of one or more pump chambers in a multi-diaphragm foam pump is effective, it may not be feasible to have multiple pump lines with slightly different liquid-to-air volume ratios. Furthermore, there is often some "guesswork" involved in adjusting the volume size to reach the desired liquid-to-air ratio. In addition, different formulations may require slight fine-tuning to the liquid-to-air ratio. Making small changes or fine-tuning by changing the volume of the pump chambers can be time-consuming and cost-prohibitive.

[0142] In some embodiments, the wobble plate is modified so that one or more of the pump diaphragms do not move the same distance as one or more other pump diaphragms and / or do not move as far as the wobble plate vanes. For example, the wobble plate vanes may be thinner (relative to the other wobble plate vanes) at the connection points to the liquid pump diaphragm, resulting in a greater degree of movement of the wobble plate relative to the liquid pump diaphragm. Although this description is directed to a liquid pump diaphragm, the concepts may be used for one or more of the air pump diaphragms as well.

[0143] 35 is a partial cross-sectional view of an example sequentially actuated foam pump 3500 having an example non-uniform wobble plate 3550 for controlling and / or fine-tuning the liquid to air ratio to adjust foam density. By "non-uniform" wobble plate, we mean that one or more of the wobble plate vanes have one or more contact surfaces that are positioned differently than one or more other contact surfaces of another wobble plate vane.

[0144] The use of a non-uniform wobble plate allows the foam density of a liquid to air mixture to be controlled, altered, and / or fine-tuned by varying the liquid to air ratio without requiring a change in volume for one or more of the pump chambers. In some exemplary embodiments, the liquid pump chamber has a different volume than the air pump chamber, and a non-uniform wobble plate can be used to fine-tune the sequentially actuated foam pump for a desired formulation and / or desired foam density. However, in some embodiments, the liquid pump chamber has the same volume as one or more of the air pump chambers, and a non-uniform wobble plate can be used to change, alter, and / or fine-tune the liquid to air ratio of the sequentially actuated foam pump.

[0145] The sequentially actuated foam pump 3500 is similar to the sequentially actuated foam pumps described above, and the same components may not be re-described with respect to the foam pump 3500. In this exemplary embodiment, the sequentially actuated foam pump 3500 includes three air pump chambers and one liquid pump chamber. In some embodiments, two or fewer air pump chambers are used. In some embodiments, four or more air pump chambers are used. In some embodiments, two or more liquid pump chambers are used. The inventive concepts disclosed herein may be used with any number of liquid pump chambers and any number of air pump chambers, provided that the pump includes at least one liquid pump chamber and at least one air pump chamber.

[0146] The sequentially acting foam pump 3500 includes a liquid inlet 3502 and a liquid pump chamber 3506. The liquid inlet 3502 is configured to connect to a container (not shown) and may be located within a foam dispenser (not shown). The liquid pump chamber 3506 is formed in part by a flexible liquid pump diaphragm 3570. When the liquid pump chamber 3506 expands, liquid flows through the liquid inlet 3502, past the one-way liquid inlet check valve 3504, and into the liquid pump chamber 3506. The flexible liquid pump diaphragm 3570 includes a body 3571. The body 3571 has a tail 3574 that includes a reduced engagement section 3572 and an enlarged retention member 3573.

[0147] The sequentially acting foam pump 3500 also includes one or more air inlets (not shown), and three air pump chambers. As the air pump chamber 3512 expands, air flows through the one or more air inlets (not shown), past a one-way air inlet check valve 3510, and into the air pump chamber 3512 (this exemplary embodiment includes two additional air pump chambers similarly configured). The air pump chamber 3512 is formed in part by a flexible air pump diaphragm 3575. The flexible air pump diaphragm 3575 has a body 3576 including a tail 3579 having a reduced engagement section 3577 and an enlarged retention member 3578.

[0148] The sequentially acting foam pump 3500 also includes an exemplary non-uniform wobble plate 3550. The wobble plate 3550 is a four-blade wobble plate. The wobble plate 3550 includes a first vane 3552, a second vane 3554, a third vane 3602 ( FIG. 36 ), and a fourth vane 3604. The first vane 3552 includes an aperture 3558, the second vane 3554 includes an aperture 3560, the third vane 3602 includes an aperture 3603, and the fourth vane 3604 includes an aperture 3605.

[0149] The flexible liquid pump diaphragm 3570 is secured to the wobble plate 3550 by pulling the liquid pump diaphragm tail 3574 through the opening 3558 in the vane 3552. The enlarged retaining member 3573 stretches, is pulled through the opening 3558, and returns to its enlarged shape. When the flexible liquid pump diaphragm 3570 is connected to the wobble plate 3550, the engagement section 3572 sits in the opening 3558 and connects the wobble plate 3550 to the liquid pump diaphragm 3570. The vane 3552 contacts and exerts a force on the enlarged retaining member 3573 as the liquid pump chamber 3506 expands and exerts a force on the body 3571 compressing the liquid pump chamber. In some embodiments, the liquid pump chamber 3506 expands on its own due to the elastic nature of the liquid pump diaphragm 3570. In some embodiments, the liquid pump chamber 3506 expands in part on its own due to the elastic nature of the liquid pump diaphragm 3570 .

[0150] The flexible air pump diaphragm 3575 is connected to the wobble plate 3550 by pulling the air pump diaphragm tail 3579 through the opening 3560 in the vane 3554. The enlarged retaining member 3578 stretches and is pulled through the opening 3560. As the enlarged retaining member 3578 passes through the opening 3560 it expands to its original enlarged size. When the flexible air pump diaphragm 3575 is connected to the wobble plate 3550, the engagement section 3577 sits in the opening 3560 and the wobble plate 3550 is connected to the air pump diaphragm 3575. The remaining air pump chambers are similarly connected to the wobble plate 3550.

[0151] Figure 36 is a top view of an exemplary non-uniform wobble plate 3550 and Figure 37 is a cross-sectional view of an exemplary wobble plate 3550. The wobble plate 3550 includes an annular extension 3554 for receiving the wobble plate shaft 3564.

[0152] In this exemplary embodiment, vane 3552 has a reduced cross-section and surface 3600 is located inward of surfaces 3610 on second vane 3554 , third vane 3602 , and fourth vane 3604 .

[0153] A motor 3580 is connected to the sequentially actuated multi-diaphragm foam pump 3500. The motor 3580 has a motor shaft 3582 connected to an eccentric gear 3590. The eccentric gear 3590 connects to the wobble plate shaft 3564. As the motor shaft 3582 rotates, the wobble plate 3550 sequentially moves each of the vanes 3552, 3602, 3554, and 3604 toward and away from the sequentially actuated multi-diaphragm foam pump 3550.

[0154] When the liquid pump chamber 3506 compresses, liquid therein flows from the liquid pump chamber 3506, past the outlet valve 3508, and into the mixing chamber 3520. Similarly, when the air pump chamber 3572 compresses, air flows from the air pump chamber 3572, past the outlet valve 3508, and into the mixing chamber 3520. Sequential compression of the remaining air pump chambers (not shown) causes additional air to flow past the outlet valve 3508 and into the mixing chamber 3520. The air / liquid mixture flows through the outlet conduit 3522, through the first screen 3524, into the foaming chamber 3523, past the second screen 3525, and out the outlet 3526, where it is dispensed as a foam having the desired density.

[0155] In this exemplary embodiment, since the contact surface 3600 is undercut or located further away from the pump diaphragm, movement of the first distance in the inward direction may not cause the liquid pump chamber 3506 to compress because the surface 3600 is undercut or thinned as described in more detail below. Thus, until the surface 3600 contacts the body 3571, the vane 3552 moves the first distance, resulting in no compression of the liquid pump chamber 3506. Further movement of the second distance in the first direction causes compression of the liquid pump chamber 3570. Thus, the first portion of the inward movement of the vane 3552 towards the liquid pump chamber 3506 does not compress the liquid pump chamber 3506. In some embodiments, the liquid pump chamber 3506 does not compress completely due to the undercut contact surface.

[0156] As the vanes 3552 of the wobble plate 3550 move in the second direction, the vanes 3552 push against the enlarged retaining member 3573, expanding the liquid pump chamber 3570. In this exemplary embodiment, the bottom surface 3702 of the vanes 3552 is symmetrical to the bottom surfaces of the remaining vanes. By changing the position of the contact surface 3600, the amount of compression of the liquid pump chamber 3506 can be changed without changing the overall motion of the wobble plate 3550. In this exemplary embodiment, the liquid pump chamber 3506 does not compress completely during a compression cycle.

[0157] For the air pump diaphragm 3575, when the wobble plate 3550 moves in a first direction, the vane 3554 pushes against the body 3576, compressing the air pump chamber 3512. When the wobble plate 3550 moves in a second direction, the vane 3554 pulls against the enlarged retaining member 3578, expanding the air pump chamber. In this exemplary embodiment, the movement of the vane 3610 (and the other two air pump chambers) results in substantially the same compression or expansion movement of the air pump diaphragm.

[0158] As a result, the volume of liquid pumped during operation may be adjusted without changing the size or volume of the liquid pump chamber. The liquid to air ratio may be changed, tweaked, or adjusted by modifying or changing the position of one or more contact surfaces of the wobble plate to adjust the amount of compression (or expansion, as described in more detail below) of one or more of the liquid or air pump chambers. As a result, by providing non-uniform wobble plates with different contact surface positions of one or more vanes, different formulations of fluids may be pumped through the same multi-diaphragm foam pump and dispensed at different desired foam densities. Additionally, by providing non-uniform wobble plates with various non-uniform wobble plate configurations, a single formulation may be dispensed at different foam densities.

[0159] Although the exemplary embodiment discloses modifying only vane 3552, one or more of the other vanes that compress and expand the air pump diaphragm may be similarly modified to fine-tune the liquid to air ratio.

[0160] In this exemplary embodiment, engagement section 3558 and engagement section 3577 have the same length. Similarly, the remaining two air pump diaphragms (not shown) and their respective engagement sections (not shown) have the same length.

[0161] The term vane profile may be used to describe some embodiments herein. As described above, the wobble plate 3550 has a plurality of vanes. In this exemplary embodiment, the wobble plate 3550 has a first vane 3552. The first vane 3552 has a first surface 3600 for contacting a portion of the body 3571 of the liquid pump diaphragm 3570 to compress the liquid pump diaphragm 3570. In this exemplary embodiment, the first surface 3600 at least partially surrounds an upper portion of the opening 3558. The first vane 3552 has a second surface 3702 for contacting the enlarged retention member 3573 to expand the liquid pump diaphragm 3570. In this exemplary embodiment, the second surface 3702 at least partially surrounds a lower portion of the opening 3558. The distance between the portion of the first surface 3600 and the second surface 3702 may be referred to herein as a first vane profile distance.

[0162] In this exemplary embodiment, the wobble plate 3550 also has a second vane 3554. The second vane 3554 has a first surface 3610 for contacting a portion of the body 3576 of the air pump diaphragm 3575. In this exemplary embodiment, the first surface 3610 at least partially surrounds an upper portion of the opening 3560. The second vane 3554 has a second surface 3704 for contacting the enlarged retaining member 3578. In this exemplary embodiment, the second surface 3704 at least partially surrounds a lower portion of the opening 3560. The distance between at least a portion of the first surface 3610 and the second surface 3704 may be referred to herein as a second vane profile distance.

[0163] In some embodiments, one or more of the lower vane surfaces may be undercut (or thinned) relative to one or more of the remaining lower vane surfaces, as described in more detail below. Undercutting the lower vane surfaces reduces the amount of expansion caused by the vanes expanding the pump chamber. FIG. 38 shows an exemplary embodiment of a non-uniform wobble plate 3800 with an undercut or reduced lower vane surface. The non-uniform wobble plate 3800 is similar to the non-uniform wobble plate 3550, and the same components are not described again herein. The non-uniform wobble plate 3800 has a vane 3810. The lower surface 3802 of the vane 3810 is undercut or thinned relative to the lower surface 3804 of the remaining vane 3812. In this exemplary embodiment, the entire upper surface of the vane is symmetrical. In some embodiments, one or more upper surfaces are undercut or thinned to reduce the amount of compression with respect to one or more pump diaphragms.

[0164] In this exemplary embodiment, as the vane 3810 moves inward, contact occurs with the diaphragm (not shown) and the pump chamber (not shown) compresses. As the vane 3810 moves outward, it moves a first distance without contacting the enlarged retaining member (not shown). As the vane 3810 moves further outward, the contact surface 3802 contacts the enlarged retaining member (not shown) and begins to expand the pump chamber (not shown). In this exemplary embodiment, the pump chamber (not shown) does not have to fully expand. In this exemplary embodiment, because the top surface of the vane 3810 is symmetrical with the top surface of the vane 3812, the pump chamber (not shown) compresses fully (or at least as much as the other pump chamber (not shown)).

[0165] In some embodiments, material is removed from one or more vanes to create a non-uniform wobble plate having one or more vanes with a reduced profile as shown herein. In some embodiments, material is added to one or more vanes to create a non-uniform wobble plate having one or more vanes with a different thickness than one or more other vanes. In some embodiments, a separate piece of material, such as a washer or O-ring, is added to one or more vanes to create a wobble plate having one or more vanes with a different thickness than one or more other vanes.

[0166] While the present invention has been illustrated by describing its embodiments, and the embodiments have been described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such details. Further advantages and modifications will be readily apparent to those skilled in the art. Also, elements described in one embodiment may be readily adapted for use with other embodiments. Thus, the invention in its broader aspects is not limited to the specific details, representative apparatus, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant's general inventive concept.

Claims

1. Housing and a receptacle for receiving a container of foamable liquid; a foam pump in fluid communication with the container of foamable liquid when the container of foamable liquid is inserted into the receptacle; A drive motor; an outlet for dispensing foam; 1. A foam dispenser comprising: The foam pump comprises: Housing and a molded multi-diaphragm pump member having a liquid pump diaphragm and one or more air pump diaphragms; one or more outlet valves located downstream of the liquid pump diaphragm and the one or more air pump diaphragms; a mixing chamber located downstream of the one or more outlet valves for mixing foamable liquid from the liquid pump diaphragm with air from one or more air pump diaphragms; the foam pump is operably coupled to the drive motor by a wobble plate; The wobble plate has two or more blades, a first vane having a first vane profile distance between a first surface contacting the body of the liquid pump diaphragm and a second surface contacting a retaining member of the liquid pump diaphragm, and a second vane having a second vane profile distance between a first surface contacting the body of one of the one or more air pump diaphragms and a second surface contacting the retaining member of the one of the one or more air pump diaphragms; The first blade profile distance is different from the second blade profile distance. Dispenser.

2. The dispenser of claim 1 , wherein the first flight profile distance is less than the second flight profile distance.

3. 2. The dispenser of claim 1, wherein the first surface of the first vane is farther away from the molded multi-diaphragm pump member than the first surface of the second vane.

4. 2. The dispenser of claim 1, wherein the first surface of the first vane is closer to the molded multi-diaphragm pump member than the first surface of the second vane.

5. The dispenser of claim 1 , wherein the wobble plate comprises three vanes.

6. The dispenser of claim 1 , wherein the wobble plate comprises four vanes.

7. A dispenser as described in claim 1, wherein the wobble plate has three or more vanes, the first vane having the first vane profile distance and the remaining vanes having the second vane profile distance.

8. The dispenser of claim 1 , wherein a volume of the liquid pump diaphragm is less than a volume of the one or more air pump diaphragms.

9. Housing and A liquid inlet; 1. A molded multi-diaphragm pump component comprising: a liquid pump diaphragm having a first volume; two or more air pump diaphragms, each having a second volume; the first volume is smaller than the second volume; a molded multi-diaphragm pump member; one or more outlet valves; a mixing chamber downstream of the one or more outlet valves for mixing foamable liquid from the liquid pump diaphragm with air from each of two or more air pump diaphragms; A wobble board having two or more wings, the first blade has a first blade profile distance and the second blade has a second blade profile distance; the first vane connects to the liquid pump diaphragm; the second vane connects to one of the two or more air pump diaphragms; the first blade profile distance is different from the second blade profile distance; A wobble board, An outlet for dispensing foam; 1. A sequentially acting foam pump comprising:

10. 10. The sequentially actuated foam pump of claim 9, wherein the first vane profile distance is less than the second vane profile distance.

11. 10. The sequentially actuated foam pump of claim 9, wherein the first vane profile distance is defined by a thinner portion of the first vane.

12. 10. The sequentially actuated foam pump of claim 9, wherein the second vane profile distance is defined by a thicker surface of the second vane.

13. 10. The sequentially acting foam pump of claim 9, further comprising one or more screens located downstream of the liquid pump diaphragm and the two or more air pump diaphragms.

14. A housing, a molded multi-diaphragm pump member having a liquid pump diaphragm and one or more air pump diaphragms; one or more outlet valves located downstream of the liquid pump diaphragm and the one or more air pump diaphragms; a mixing chamber downstream of the one or more outlet valves for mixing foamable liquid from the liquid pump diaphragm with air from the one or more air pump diaphragms; A drive motor; Uneven wobble plate and 1. A sequentially acting foam pump comprising: the non-uniform wobble plate is operably coupled to the drive motor; the non-uniform wobble plate comprises two or more vanes; the two or more vanes each have a pump diaphragm contact surface; the first vane has a first pump diaphragm contact surface spaced a first distance from the first pump diaphragm; the second vane has a second pump diaphragm contact surface spaced a second distance from the second pump diaphragm; The first distance is greater than the second distance.

15. 15. The sequentially acting foam pump of claim 14, wherein the first pump diaphragm is a liquid pump diaphragm.

16. 15. The sequentially acting foam pump of claim 14, wherein the second pump diaphragm is an air pump diaphragm.

17. The sequentially acting foam pump of claim 14, wherein the non-uniform wobble plate further comprises a third vane, the third vane having a third pump diaphragm contact surface spaced a third distance from the third pump diaphragm.

18. The sequentially acting foam pump of claim 14, wherein the first blade has a first blade profile distance and the second blade has a second blade profile distance, the first blade profile distance being different from the second blade profile distance.

19. The sequentially acting foam pump of claim 14, wherein the wobble plate is asymmetric.

20. The sequentially acting foam pump of claim 14, wherein one of the first blade and the second blade is thicker than the other.

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