Dispensers and dispenser systems for precisely controlled output dosing of soap or sanitizer

Abstract

[0003] An exemplary power system for dynamically controlling a dispenser drive motor for dispensing soap, disinfectant, or lotion. A typical soap, disinfectant, or lotion dispenser includes a housing, a receptacle for receiving a container for holding the soap, disinfectant, or lotion, the soap, disinfectant, or lotion container, and a pump secured to the container. The typical soap, disinfectant, or lotion dispenser includes a power source, a motor, and an actuator coupling the motor to the pump. The typical soap, disinfectant, or lotion dispenser further includes a pulse-width modulation circuit in circuit communication with the power source and the motor. One actuation cycle of the actuator dispenses one dose of soap, disinfectant, or lotion. The pulse-width modulation circuit provides a plurality of voltage pulses to the motor to move the actuator through one actuation cycle.

Description

[Technical field]

[0001] Related Applications This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 033,892, filed June 3, 2020, entitled "DISPENSERS AND DISPENSER SYSTEMS FOR PRECISELY CONTROLLED OUTPUT DOSING OF SOAP OR SANITIZER," which is incorporated herein by reference in its entirety.

[0002] The present invention relates generally to a touchless soap and sanitizer dispenser system, and more particularly to a dispenser with precisely controlled output dosage of soap or sanitizer. [Background technology]

[0003] In hands-free (or touch-free) dispensers, the liquid or foam pump is typically actuated by an actuator that drives the pump through a drive cycle to dispense a dose of fluid. The liquid and foam pumps primarily used in soap and sanitizer dispensers today are dome pumps and piston pumps. Some dispensers have utilized rotary positive displacement pumps.

[0004] Rotary positive displacement pumps, which are pumps with multiple rollers on a wheel that rotate and compress a dispensing tube (these pumps are often used in devices such as intravenous drip systems), have fairly accurate dose sizes, but the dispensing speeds are not practical for dispensing a single dose of soap or disinfectant. Furthermore, creating foam soap or disinfectant with a rotary positive displacement pump is not feasible due to the dispensing speed required.

[0005] Some prior art dispensers deliver a dose of fluid based on a time, such as, for example, a one second "on time" that results in the dispensing of a dose. As a result, the battery voltage at the dispenser affects the amount of liquid dispensed. As the battery voltage decreases, the pump motor rotates slower, thereby dispensing less fluid as the battery deteriorates.

[0006] Most prior art dispensers dispense a single "shot" of liquid and / or a single shot and a single shot of liquid that are mixed together to form a foam. In other words, a single liquid pump chamber is filled with liquid and dispensed for each dose of soap or sanitizer in liquid or foam form. When the dispenser dispenses a dose of soap or sanitizer, the single liquid pump chamber may not be completely filled or completely emptied. Thus, a single liquid pump chamber that dispenses a single shot of liquid often has an inconsistent liquid dispense dose size.

[0007] In prior art dispensers, the "average dose" size dispensed over a given number of dispenses in these pumps is fairly consistent, but the individual amounts or dose sizes of each individual dispense often vary. For example, the average dispensed dose may be, for example, 1.2 milliliters per dispense over 10 dispenses, but the individual doses that make up that average may vary, for example, from 1.0 to 1.4 milliliters per dispensed dose. There are a variety of factors that can lead to dose inconsistencies, such as, for example, different vacuum pressures in the container holding the fluid, the pump not being fully primed, manufacturing variances between individual pumps, the level of fluid in the refill, the length of time between dispenses, motor overrun, battery charge, pump life cycle, etc.

[0008] To overcome dosing inconsistencies, one may decide to set the dispense amount to a higher dispense amount to ensure that at least the selected minimum amount is dispensed every time. This approach generally results in dispensing more fluid than is actually needed over many individual dispensing cycles. This approach is sometimes referred to as overdosing. Overdosing reduces the number of dispenses per refill unit (or per full container), increasing operational costs and the costs associated with replacing refills or refill containers. Furthermore, many people have their dispensers dispense multiple doses of fluid per use, resulting in further increased costs and frequent replacement of refill units. Thus, there is a need for dispensers with more accurately or precisely controlled dispense amounts and dispensers that dispense selected amounts of fluid in a short period of time. Summary of the Invention [Means for solving the problem]

[0009] Exemplary soap, disinfectant, and lotion dispensers are disclosed herein. The exemplary soap or disinfectant dispenser includes a housing, a container for holding a fluid, a pump in fluid communication with the interior of the container, a dispenser processor, a power source, a motor, an encoder, a pulse width modulation circuit in circuit communication with the power source and the motor, and a brake. The encoder provides a number of signals to the processor for each revolution of the motor. The processor determines the speed of the motor multiple times through each revolution of the motor. The pulse width modulation circuit adjusts the duty cycle to maintain the selected speed. Additionally, the processor causes the brake to be applied after a set number of revolutions of the motor.

[0010] Another typical soap or sanitizer dispenser includes a housing, a container for holding a fluid, a pump in fluid communication with the interior of the container, a dispenser processor, a power source, and a stepper motor. Each full revolution of the stepper motor is divided into a number of equal steps. The processor determines the number of revolutions of the stepper motor according to the steps. The processor determines the speed of the stepper motor according to the steps. A pulse width modulation circuit is also included. The pulse width modulation circuit adjusts the duty cycle to maintain a selected speed, and the processor causes the motor to stop at a set number of revolutions of the motor.

[0011] Another exemplary soap or sanitizer dispenser includes a housing and a receptacle for receiving a container having soap or sanitizer located at least partially within the housing. The pump is in fluid communication with the interior of the container. The dispenser further includes a dispenser processor, a power source, a motor, an encoder, and a pulse width modulation circuit in circuit communication with the processor, the power source, and the motor.

[0012] A typical methodology for dispensing soap or disinfectant includes providing a dispenser having a container for holding a fluid, a motor, a pump driven by the motor, a power source, an object sensor, a processor, an encoder, and a pulse width modulation circuit. The methodology further includes detecting the presence of an object with the object sensor, causing the pulse width modulation circuit to output a power signal with a first duty cycle to the motor, receiving a plurality of signals from the encoder indicative of the speed of the motor, and varying the first duty cycle to one or more second duty cycles to cause the speed of the motor to approach a selected motor speed. When the pump is driven by the motor, liquid is pumped from the dispenser. The methodology further includes determining a number of revolutions of the motor, and causing the pulse width modulation circuit to stop powering the motor upon determining that the selected number of revolutions of the motor has occurred. In some embodiments, the typical methodology further includes causing a brake to be set to stop rotation of the motor and / or the pump.

[0013] These and other features and advantages of the present invention will become better understood with regard to the following description and accompanying drawings. [Brief description of the drawings]

[0014] [Figure 1] 1 is a general illustrative schematic diagram of a typical dispenser having a removable refill unit.

[0015] [Diagram 2] FIG. 1 illustrates an exemplary removable refill unit.

[0016] [Diagram 3-4] FIG. 2 is an exemplary illustration of a pulse width modulated duty cycle for driving a dispenser motor.

[0017] [Diagram 5]FIG. 1 is an exemplary methodology or logic flow diagram for precisely controlling the dosage of a fluid to be dispensed.

[0018] [Figure 6] FIG. 11 is another exemplary methodology or logic flow diagram for precisely controlling the dosage of a fluid to be dispensed.

[0019] [Figure 7] FIG. 11 is yet another exemplary methodology or logic flow diagram for precisely controlling the dosage of a fluid to be dispensed.

[0020] [Figure 8-10] FIG. 2 is a diagram of a typical brake circuit for stopping the dispenser motor.

[0021] [Figure 11] FIG. 11 is yet another exemplary methodology or logic flow diagram for precisely controlling the dosage of a fluid to be dispensed. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] The following includes definitions of exemplary terms used throughout this disclosure. Both the singular and plural forms of all terms are included with their respective meanings. Unless otherwise stated, both capitalized and non-capitalized forms of all terms are included with their respective meanings.

[0023] "Circuit communication" as used herein refers to a communication relationship between devices. Direct electrical, electromagnetic, and optical connections and indirect electrical, electromagnetic, and optical connections are examples of circuit communication. Two devices are in circuit communication if a signal from one device is received by the other device regardless of whether the signal is modified by any other device. For example, two devices separated by one or more of the following: amplifiers, filters, transformers, opto-isolators, digital or analog buffers, analog integrators, other electronic circuits, fiber optic transceivers, or satellites are in circuit communication if a signal from one device is communicated to the other device even if the signal is modified by an intermediate device. As another example, an electromagnetic sensor is in circuit communication with a signal if it receives electromagnetic radiation from the signal. As a final example, two devices that are not directly connected to each other but either can interface with a third device, such as a CPU, are in circuit communication.

[0024] Also, as used herein, a voltage and a value representing a digitized voltage are considered equivalent for purposes of this application, and thus the term "voltage" as used herein refers to either a signal, or a value in a processor that represents a signal, or a value in a processor that is determined from a value that represents a signal.

[0025] As used herein, a "signal" includes, but is not limited to, one or more electrical signals, analog or digital signals, one or more computer instructions, bits or bitstreams, and the like.

[0026] As used herein, "logic," synonymous with "circuitry," includes, but is not limited to, hardware, firmware, software, and / or combinations of each to perform a function or execute an action. For example, based on a desired application or need, logic may include discrete logic, such as a software-controlled microprocessor or microcontroller, an application specific integrated circuit (ASIC) or other programmed logic device. Logic may also be embodied entirely as software. The circuits identified and described herein may have many different forms to perform a desired function.

[0027] The values ​​specified in the detailed description are exemplary and are determined as necessary for a particular dispenser and / or refill format. Accordingly, the inventive concepts disclosed and claimed herein are not limited to the specific values ​​or ranges of values ​​used to describe the embodiments disclosed herein.

[0028] 1 illustrates a dispenser 100 having a precisely controlled output dosage. The dispenser 100 includes a housing 102. The housing 102 can completely surround the components installed within the dispenser and a refill unit 110 as shown. In some embodiments, the housing 102 only partially surrounds the refill unit 110. In some embodiments, the housing 102 surrounds an occlusion 116. The refill unit 110 is removable and replaceable. The refill unit 110 is shown in dashed lines to indicate an installed position and in solid lines to indicate the refill unit 110 is removed from the dispenser 100.

[0029] Located within the housing 102 is system circuitry 130. The system circuitry 130 may be on a single circuit board or may be on multiple circuit boards. Additionally, portions of the system circuitry 130 may not be on a circuit board, but rather may be individually mounted and electrically connected or coupled to other components as desired. In this embodiment, the system circuitry 130 includes a processor 132, a memory 133, an optional header 134, an optional permanent power source 136, an optional voltage regulator 138, an optional door switch circuit 140, an object sensor 142, a motor 150, an optional capacitor bank 145, an optional capacitor control circuit 146, an optional replaceable power interface receptacle 144, an optional pulse width modulation circuit 180, and a switching device 182, a motor encoder 150, and an optional brake 150.

[0030] The motor 148 drives the pump 190. In this exemplary embodiment, the pump 190 is a sequentially actuated rotary diaphragm foam pump, such as those identified below and incorporated herein. In this exemplary embodiment, the pump 190 is a permanent pump, remaining fixed to the dispenser housing 102 when the refill unit 110 is removed from the dispenser 100.

[0031] In this exemplary embodiment, the pump 190 is a foam pump that draws air through an air inlet 192 (when the refill unit 110 is attached to the dispenser 100) and liquid through a liquid inlet 191. The pump 190 has a foam outlet 196 for dispensing foam from the dispenser 100. In some embodiments, the pump 190 is a liquid pump and does not require the optional air inlet 192. In some embodiments, the pump 190 is part of the refill unit 110 or is fixed to the refill unit 110 and is removed and replaced with the refill unit. In some embodiments, the refill unit 110 is replaced with a permanent or semi-permanent container that is periodically refilled and not removed or replaced. In this exemplary embodiment, the dispenser 100 includes an encoder 152 and an optional brake 154, as described in more detail below. The pump 190 is a direct drive pump, where each revolution of the motor 150 correlates to one revolution of the pump.

[0032] Sequentially acting foam pumps have multiple small diaphragms, for example, three or four diaphragms that expand and contract sequentially. These pumps generally have one liquid pump diaphragm and two or more air pump diaphragms. The diaphragms are small. In some embodiments, each pump diaphragm needs to expand and compress 10-30 times to produce one dose of foam soap or disinfectant. In some embodiments, the pump diaphragm needs to expand and compress 12-28 times to produce one dose of foam soap or disinfectant. In some embodiments, the pump diaphragm needs to expand and compress 14-26 times to produce one dose of foam soap or disinfectant. In some embodiments, the pump diaphragm needs to expand and compress 16-24 times to produce one dose of foam soap or disinfectant. In some embodiments, the pump diaphragm needs to expand and compress 16-20 times to produce one dose of foam soap or disinfectant. In some embodiments, approximately 18 expansions and compressions of the pump diaphragm are required to produce one dose of foam soap or sanitizer.

[0033] Having a small liquid pump chamber that must expand and compress multiple times during a single dispense of fluid helps increase the accuracy of the output volume. For example, variables such as time between dispenses, vacuum pressure, fill level in the refill container, etc. are minimized by using multiple liquid pump compressions and expansions per dose of fluid. In some embodiments, the liquid pump chamber is compressed at least about 5 times for each dispense of fluid. In some embodiments, the liquid pump chamber is compressed at least about 8 times for each dispense of fluid. In some embodiments, the liquid pump chamber is compressed at least about 10 times for each dispense of fluid. In some embodiments, the liquid pump chamber is compressed at least about 12 times for each dispense of fluid. In some embodiments, the liquid pump chamber is compressed at least about 14 times for each dispense of fluid. In some embodiments, the liquid pump chamber is compressed at least about 16 times for each dispense of fluid. In some embodiments, the liquid pump chamber is compressed at least about 18 times for each dispense of fluid. In some embodiments, the liquid pump chamber is compressed at least 5 times for each dispense of fluid, but not more than about 30 times for each dispense of fluid. In some embodiments, the liquid pump chamber is compressed at least 10 times for each dispense of fluid, but not more than about 25 times for each dispense of fluid. In some embodiments, the liquid pump chamber is compressed at least 10 times for each dispense of fluid, but not more than about 22 times for each dispense of fluid. In some embodiments, the liquid pump chamber is compressed at least 10 times for each dispense of fluid, but not more than about 20 times for each dispense of fluid.

[0034] Exemplary sequentially acting diaphragm pumps and associated dispensers are shown and described in U.S. Pat. Nos. 9,943,196, 10,065,199, 10,080,466, 10,080,467, 10,143,339, and 10,080,468, which are incorporated herein by reference in their entireties.

[0035] Additionally, typical components in a touch-free dispenser are disclosed in U.S. Pat. No. 7,837,066, entitled "Electronically Keyed Dispensing System And Related Methods Utilizing Near Field Response," U.S. Pat. No. 9,172,266, entitled "Power Systems For Touch-Free Dispensers and Refill Units Containing a Power Source," U.S. Pat. No. 7,909,209, entitled "Apparatus for Hands-Free Dispensing of a Measured Quantity of Material," U.S. Pat. No. 7,611,030, entitled "Apparatus for Hands-Free Dispensing of a Measured Quantity of Material," and U.S. Pat. No. 7,611,030, entitled "Electronically Keyed Dispensing Systems and Related Methods Utilizing Near Field Response." No. 7,621,426, entitled "Touch-Free Dispenser with Single Cell Operation and Battery Banking," and U.S. Patent Publication No. 8,960,498, entitled "Touch-Free Dispenser with Single Cell Operation and Battery Banking," all of which are incorporated herein by reference in their entireties. Various one or more of the disclosed features or components may be used in dispenser 100.

[0036] The processor 132 may be any type of processor, such as, for example, a microprocessor or microcontroller, discrete logic such as an application specific integrated circuit (ASIC), or other programmed logic device. The processor 132 is in circuit communication with an optional header 134. The header 134 is a circuit connection port that allows a user to connect to the system circuitry 130 to program the circuitry, run diagnostics on the circuitry, and / or retrieve information from the circuitry. In some embodiments, the header 134 includes wireless transmit / receive circuitry, such as wireless RF, Bluetooth, ANT, etc., configured to perform the functions identified above without a hard connection, and in some embodiments, remotely.

[0037] Processor 132 is in circuit communication with memory 133. Memory 133 may be any type of memory, such as, for example, random access memory (RAM), read-only memory (ROM), programmable read-only memory (PROM), electrically programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), flash, ROM, etc., or a combination of different types of memory. In some embodiments, memory 133 is separate from processor 132, and in some embodiments, memory 133 is present on or within processor 132.

[0038] An optional permanent power source 136, such as, for example, one or more batteries, is also provided. The permanent power source 136 is preferably designed such that the permanent power source 136 does not need to be replaced over the life of the dispenser 100. The permanent power source 136 is in circuit communication with a voltage regulation circuit 138. In one exemplary embodiment, the voltage regulation circuit 138 provides regulated power to the processor 132, the object sensor 142, and any other components that require regulated power. The permanent power source 136 may be used to power other circuits that require a small amount of power and will not prematurely deplete the permanent power source 136. If a permanent power source is not used, or even if optionally accompanied by a permanent power source, the voltage regulation circuit 138 is connected to a separate power source.

[0039] The processor 132 is also in circuit communication with an optional door circuit 140 so that the processor 132 knows when a door (not shown) of the dispenser 100 is closed. In some embodiments, the door is a conventional door or dispenser cover that opens to allow a user to remove and replace a refill or refill a container. In some embodiments, the "door" is simply a part of the dispenser that can be opened to access the electronics and / or to allow the refill unit to be removed and replaced. In some embodiments, the processor 132 does not allow the dispenser 100 to dispense a dose of fluid if the door is open. The door circuit 140 may be any type of circuit, such as, for example, a mechanical switch, a magnetic switch, a proximity switch, etc.

[0040] The processor 132 is also in circuit communication with an object sensor 142 to detect whether an object is present in the dispensing area. The object sensor 142 may be any type of passive or active object sensor, such as, for example, infrared sensors and detectors, proximity sensors, imaging sensors, thermal sensors, etc.

[0041] Additionally, the processor 132 is in circuit communication with an optional pulse width modulation circuit 180. The pulse width modulation circuit 180 is in circuit communication with a switching device 182. In this exemplary embodiment, the switching device 182 is in circuit communication with the bank of capacitors 145 and the motor 150. In some embodiments, the switching device 182, alone or in combination with the optional bank of capacitors 145, is in circuit communication with a different power source (not shown). In some embodiments, the bank of capacitors 145 is replaced with one or more batteries and / or one or more rechargeable batteries. In operation, the processor 132 provides one or more signals to the pulse width modulation circuit 180, which in turn controls the switching device 182 to modulate the power provided by the capacitors 145 to drive the motor 150. A more detailed description of the modulated power signals is provided below. The motor 148 (and any associated gearing) operates a foam pump 190, which in some embodiments may be a liquid pump.

[0042] In this exemplary embodiment, the dispenser 100 includes an encoder 152. The encoder 152 may be, for example, an optical encoder. In some embodiments, the encoder 152 provides an output to the processor 132 at least about 4 times per revolution of the motor 150. In some embodiments, the encoder 152 provides an output to the processor 132 at least about 8 times per revolution of the motor. In some embodiments, the encoder 152 provides an output to the processor 132 at least about 16 times per revolution of the motor. In some embodiments, the encoder 152 is a 4-slot optical encoder. In some embodiments, the encoder 152 is an 8-slot optical encoder. In some embodiments, the encoder 152 is a 16-slot encoder. The encoder 152 is used to precisely count revolutions and / or portions thereof of the motor 150. In some embodiments, the encoder 152 is used to precisely count revolutions and / or portions thereof of the pump 190.

[0043] In this exemplary embodiment, the dispenser 100 also includes an optional brake 154. The optional brake 154 can be used to stop the motor 150 and / or pump 190 after the required number of revolutions and / or a fraction thereof has been reached, indicating that the correct dosage size / volume has been dispensed. Without the brake 154, the motor 150 can continue to rotate (or freewheel) and dispense more fluid than necessary. Additionally, various factors can affect the amount of freewheel rotation, such as, for example, motor speed, vacuum pressure in the fluid container 112, drive voltage, etc. Thus, the amount of freewheel movement may vary from dispense to dispense and may differ from time to time based on drive voltage, vacuum pressure in the container, etc. The use of the optional brake 154 is one way to mitigate and / or prevent dosage size variations between individual dispenses due to freewheel movement. In some embodiments, the freewheel movement is consistent and can be taken into account in determining the number of revolutions and / or a fraction thereof required for the correct dosage, and in such embodiments, the optional brake 154 may not be required.

[0044] In some embodiments, brake 154 is a mechanical brake. A conventional brake may include, for example, a rotor (not shown) on a motor shaft (not shown) that is gripped by one or more brake pads (not shown) to stop the motor. In some embodiments, brake 154 is an electric brake or a dynamic brake. Exemplary embodiments of electric or dynamic brakes are shown and described in connection with Figures 7-9.

[0045] In this exemplary embodiment, the refill unit 110 is shown in phantom lines inserted into the dispenser 100 in FIG. 1 and in solid lines in FIG. 2. This therefore illustrates that the refill unit 110 may be easily inserted into the dispenser 100 and removed from the dispenser 100 as a unit. The refill unit 110 includes a container 112 and a closure 116. In some embodiments, the container 112 is a non-collapsible container and a vent (not shown) is included in the closure 116 to allow air to flow into the container and prevent collapse of the container 112. In some embodiments, the container 112 is a collapsible container and collapses when fluid is removed from the container 112. In some embodiments, the refill unit 110 also includes a foamable liquid 113, such as a foamable soap, disinfectant, lotion, moisturizer, or other foamable liquid used for personal hygiene. In some embodiments, the refill unit 110 is for use in a liquid dispenser rather than a foam dispenser, and is filled with a non-foaming or non-foamable liquid, such as, for example, a soap, disinfectant, lotion, moisturizer, or other liquid used for personal hygiene.

[0046] Additionally, in some embodiments, the refill unit 110 includes an optional replaceable energy source 120. The replaceable energy source 120 may be any power source, such as a battery, e.g., a single "AA" battery, a coin cell, a 9 volt battery, etc. In some embodiments, the replaceable energy source 120 does not include sufficient power to directly power the motor 150 (and any associated gearing) to dispense the contents of the refill unit 110.

[0047] The replaceable energy source 120 is inserted into the dispenser 100 along with the refill unit 110 and removed from the dispenser 100 along with the refill unit 110. Preferably, the refill unit 110 is attached to the replaceable energy source 120, but in some embodiments, the replaceable energy source 120 is provided separately from the refill unit 110. In either case, however, the replaceable energy source 120 is generally removed with or simultaneously with the refill unit 110. In some embodiments, the refill unit 110 does not have a replaceable power source, and the dispenser 100 receives sufficient power to dispense the contents of the refill unit 110 without receiving power from the refill unit 110.

[0048] In this exemplary embodiment, the system circuitry 130 also includes a bank of capacitors 145 and a capacitor control circuit 146 that is in circuit communication with the processor 132. The bank of capacitors 145 and the capacitor control circuit 146 are in circuit communication with a replaceable energy source interface receptacle 144 and a PWM switch 182. The replaceable energy source interface receptacle 144 is configured to receive and / or otherwise electrically couple with the replaceable energy source 120 when the refill unit 110 is inserted into the dispenser 100. In some embodiments, the capacitors and capacitor circuitry are replaced with one or more batteries.

[0049] In some embodiments, during operation, when the refill unit 110 is inserted into the dispenser 100, the processor 132 and capacitor control circuit 146 cause the bank of capacitors 145 to charge in parallel. In some exemplary embodiments, there are two or more capacitors. In some embodiments, the capacitors are too large to power the motor 150 and associated gearing required to dispense a dose of foam. Capacitors that are too large are preferably charged to a level lower than the rated voltage of the capacitor. Because the bank of capacitors 145 is charged to less than full capacity, there is less discharge in the capacitors when they are idle for a period of time. In some embodiments, the capacitors are charged to less than about 50% of their full capacity. In some embodiments, the capacitors are charged to less than about 75% of their full capacity. In some embodiments, the capacitors are charged to less than about 90% of their full capacity.

[0050] When processor 132 determines via object sensor 142 that an object is within the dispensing zone, processor 132 causes capacitor control circuit 146 to place capacitor 145 in series and power switching device 182, which in cooperation with pulse width modulation circuit 180 provides modulated power to power motor 150 to operate foam pump 190. Once a dose is dispensed, processor 132 checks the charge on capacitor 145. If the charge is below a threshold, processor 132 causes capacitor control circuit 146 to charge capacitor 145. Capacitors 145 are charged in parallel.

[0051] In some embodiments, the processor 132 monitors the amount of fluid remaining in the refill unit 110. The processor 132 can monitor the amount of fluid by counting motor revolutions, detecting the fluid level using, for example, a level sensor, a proximity sensor, infrared detection, etc., so that it can determine the exact amount of fluid that has been removed from the refill unit 110 and compare it to the total amount of fluid in the refill unit, etc. In some embodiments, a value indicative of the amount of fluid removed from the refill unit is stored in the refill unit 110 so that if the refill unit is moved to a different dispenser, the dispenser can determine the amount of fluid remaining in the refill unit 110.

[0052] In some embodiments, when the processor 132 determines that the refill unit 110 is empty or close to empty, the processor 132 causes the replaceable energy source 120 to charge the capacitors 145 to their maximum charge, or alternatively, to charge the capacitors 145 until the replaceable energy source 120 is completely drained or as drained as possible. Thus, when the refill unit 110 and replaceable energy source 120 are removed, as much energy as possible is removed from the replaceable energy source 120.

[0053] Although the exemplary dispenser 100 is shown and described with a capacitor as the power source, other types of power sources may be used, such as, for example, a rechargeable battery. Further exemplary dispensers and more details regarding the circuitry for the touch-free dispensers described above are more fully described and shown in U.S. patent application Ser. No. 13 / 770,360, entitled "Power Systems for Touch Free Dispensers and Refill Units Containing a Power source," filed Feb. 19, 2013, which is incorporated herein by reference in its entirety.

[0054] FIG. 3 illustrates a typical waveform output by the pulse width modulation circuit 180 and the switching device 182. In this typical embodiment, the voltage is 5 volts and one cycle is 0.2 seconds. The waveform represents a 25% duty cycle, meaning that the motor receives a voltage pulse at about 5 volts and about 0.05 seconds long, followed by 0.15 seconds of substantially no voltage. Similarly, FIG. 4 illustrates another typical waveform output by the pulse width modulation circuit 180 and the switching device 182. In this typical embodiment, the voltage is 5 volts and one cycle is 0.2 seconds. The waveform represents a 50% duty cycle, meaning that the motor receives a voltage pulse at about 5 volts and about 0.1 seconds long, followed by 0.1 seconds of substantially no voltage. Any suitable duty cycle can be used. Generally, the duty cycle is greater than a 10% duty cycle. Furthermore, the duty cycle does not need to be constant throughout the dispensing cycle. For example, if the dispense cycle is 1 second, the waveform may start out with a 25% duty cycle, increase to a 90% duty cycle as the load increases, and drop back to 25% duty cycle as the load decreases.

[0055] A typical duty cycle can be between a 10% duty cycle and a 100% duty cycle. Preferably, the duty cycle is between about 40% and about 95%.

[0056] The pulse width or duty cycle can be rapidly changed by the processor 132 to control the speed of the motor 150. In this exemplary embodiment, the pump 190 is a sequentially acting diaphragm pump. In this exemplary embodiment, the pump 190 has four diaphragms. One diaphragm pumps liquid and the other three diaphragms pump air. The air and liquid mix together to form a foam that exits the dispenser.

[0057] In this particular embodiment, the motor 150 directly drives the pump 192. Thus, the speed of the motor 150 is the same as the speed of the pump. In some embodiments, one or more gears or the like can be used to increase or decrease the speed of the pump relative to the motor.

[0058] In some exemplary embodiments, it may be desirable to control the speed of the motor to a set or selected speed. The set or selected speed may be, for example, a speed between about 1300 revolutions per minute ("RPM") and about 2200 RPM. In some embodiments, the set speed may be, for example, a speed between about 1300 RPM and about 2100 RPM. In some embodiments, the set speed may be, for example, a speed between about 1400 RPM and about 2000 RPM. In some embodiments, the set speed may be, for example, a speed between about 1500 RPM and about 1900 RPM. In some embodiments, the set speed may be, for example, a speed between about 1600 RPM and about 1800 RPM.

[0059] In the following exemplary embodiment, the set speed is selected to be approximately 1700 RPM (or approximately 28.3 revolutions per second). The pulse width signal is selected to drive the motor 150 at 1700 RPM, which drives the pump 190 at 1700 RPM for a sufficient time to deliver the desired dose of fluid. In this exemplary embodiment, the pump 190 delivers the desired dose of fluid in 18 revolutions of the pump 190 and motor 150. In this exemplary embodiment, the pulse width signal is set at 90% for the first 1 / 2 to 5 / 8 revolutions of the motor 190. After the motor begins to rotate, the pulse width is adjusted based on the actual speed of the motor. The encoder 152 provides feedback to the processor 132 indicative of the speed and cumulative number of revolutions of the motor 150. In this particular embodiment, the encoder 152 is an 8-slot optical encoder and provides feedback to the processor 8 times per revolution of the motor 150. If the motor speed is greater than 1700 RPM, the pulse width is reduced. If the motor speed is less than 1700 RPM, the pulse width is increased. In some embodiments, the feedback signal is delivered to the processor 132 four or more times per revolution. By receiving motor speed feedback and controlling the speed, the processor 132 can provide a more consistent output.

[0060] Additionally, processor 132 can use the signal received from encoder 152 to precisely control the amount of output by ensuring that motor 150 and / or pump 190 rotate a precise number of revolutions and / or fractions thereof. Thus, pump 190 dispenses substantially exactly the same amount of fluid every time. As used herein, the term "substantially" means about + / - 0.1 milliliters of fluid. In a preferred embodiment, both the motor speed and motor / pump revolutions are utilized to obtain a very precise dispense output.

[0061] This exact amount of output is dispensed regardless of factors such as battery voltage, motor speed, vacuum pressure within the refill unit, etc. The length of time of dispense may vary, but the number of revolutions remains constant. In some embodiments, the pump speed is a number selected between 8 and 30 RPM. In some embodiments, the pump speed is a number selected between 10 and 28 RPM. In some embodiments, the pump speed is a number selected between 12 and 26 RPM. In some embodiments, the pump speed is a number selected between 14 and 24 RPM. In some embodiments, the pump speed is a number selected between 16 and 22 RPM. In some embodiments, the pump speed is a number selected between 16 and 20 RPM. In some embodiments, the pump speed is 18 RPM.

[0062] By receiving the motor RPM (or a portion thereof) and controlling the RPM (or a portion thereof), the processor 132 can provide a more precise amount of power. Further, in some embodiments, by controlling both the motor speed and RPM, the processor 132 can deliver a precise amount of power in a precise time.

[0063] In some embodiments, a stepper motor (not shown) is used. When a stepper motor is used, an encoder is not required. The structure of a stepper motor breaks down one full revolution into an equal number of "steps." Thus, the processor 132 can determine the speed and / or RPM of the motor as a function of the steps without the need for an encoder. Additionally, the processor 132 can determine the number of rotations of the motor and / or pump based on the number of steps. As a result, regardless of whether a stepper motor or an encoder is used, the processor 132 receives speed and / or position feedback that allows it to control the speed and / or number of rotations of the motor.

[0064] Exemplary methodologies and logic diagrams are provided herein, and unless otherwise noted, additional blocks or steps may be included, fewer blocks or steps may be used, blocks or steps may be performed in a different order, and one or more blocks from one methodology or logic diagram may be combined with other methodologies or block diagrams.

[0065] FIG. 5 is an exemplary methodology or logic diagram 500 for controlling a dispenser. The exemplary methodology 500 begins at block 502. At block 504, an object is detected in a detection zone. The object is detected by an object sensor, such as an infrared ("IR") object sensor, which includes an IR transmitter and an IR receiver. Upon detecting the object, at block 506, the dispenser processor causes a PWM circuit to transmit power to the motor. The power transmitted by the PWM circuit to the motor is a pulsed voltage, such as a voltage of about 5 volts. In some embodiments, the voltage is initially pulsed according to a selected duty cycle. Preferably, the selected duty cycle is greater than 90%. In this embodiment, for example, the initial duty cycle may be set to about 95%. Once the motor is energized at block 506, the processor begins receiving signals from a motor encoder connected to the motor. The motor encoder begins providing the processor with multiple signals per full rotation of the motor. In some embodiments, the motor encoder provides the processor with four or more signals per full rotation. In some embodiments, the motor encoder provides the processor with 8 or more signals per full revolution. In some embodiments, the motor encoder provides the processor with 12 or more signals per full revolution. In some embodiments, the motor encoder provides the processor with 16 or more signals per full revolution. Preferably, before a full revolution, more preferably before three-quarters of a revolution, the processor begins to control the speed of the motor in response to the signals provided by the encoder. At block 510, the processor determines the speed of the motor and compares the motor speed to a set or selected speed. In this exemplary embodiment, the selected speed may be, for example, 1800 RPM. If at block 508, the processor determines that the measured speed is greater than 1800 RPM, then at block 512, the width or duty cycle of the voltage pulse is reduced or decreased. If at block 508, the processor determines that the measured speed is less than 1800 RPM, then at block 508, the width or duty cycle of the voltage pulse is increased or increased.At block 512, a determination is made as to whether a desired or set number of revolutions or turns of the motor and / or pump have been completed. In this exemplary embodiment, the desired or set number of revolutions or turns of the motor is, for example, 18 full revolutions. If the set number, 18 in this exemplary embodiment, has not been reached, the logic or methodology loops back to block 508 where the speed of the motor is determined. In this manner, the processor may adjust the width of the voltage pulse multiple times during each revolution of the motor. If the set number has been reached, the methodology proceeds to block 514 where the processor causes the PWM circuit to stop or de-energize the motor and the methodology ends at block 518 or loops back to block 504.

[0066] FIG. 6 is an exemplary methodology or logic diagram 600 for controlling a dispenser. The exemplary methodology 600 begins at block 602. At block 604, an object is detected in a detection zone. The object is detected by an object sensor, such as, for example, an infrared ("IR") object sensor, which includes an IR transmitter and an IR receiver. Upon detecting the object, at block 606, the dispenser processor causes a PWM circuit to transmit power to the motor. The power transmitted by the PWM circuit to the motor is a pulsed voltage, such as, for example, a voltage of about 5 volts. Initially, the voltage is pulsed according to a selected duty cycle. In this embodiment, for example, the initial duty cycle may be set to about 95%. Once the motor is energized at block 606, the processor begins receiving signals from a motor encoder connected to the motor. The motor encoder begins providing the processor with multiple signals per full rotation of the motor. In some embodiments, the motor encoder provides the processor with four or more signals per full rotation. In some embodiments, the motor encoder provides the processor with 8 or more signals per full revolution. In some embodiments, the motor encoder provides the processor with 12 or more signals per full revolution. In some embodiments, the motor encoder provides the processor with 16 or more signals per full revolution. Preferably, before a full revolution, more preferably before three-quarters of a revolution, the processor begins to control the speed of the motor in response to the signals provided by the encoder. At block 608, the processor determines the speed of the motor and compares the motor speed to a set or selected speed. In this exemplary embodiment, the selected speed may be, for example, 1800 RPM. If at block 608, the processor determines that the measured speed is greater than 1800 RPM, then at block 610, the width or duty cycle of the voltage pulse is reduced or decreased. If at block 608, the processor determines that the measured speed is less than 1800 RPM, then at block 610, the width or duty cycle of the voltage pulse is increased or increased.At block 612, a determination is made as to whether a desired or set number of revolutions of the motor or pump have been completed. In this exemplary embodiment, the desired or set number of motor revolutions is, for example, 18 full revolutions. If the set number, 18 in this exemplary embodiment, has not been reached, the logic or methodology loops back to block 608 where the speed of the motor is determined. In this manner, the processor can adjust the width of the voltage pulse multiple times during each revolution of the motor. If the set number of revolutions or revolutions has been reached, the methodology proceeds to block 614 where the processor causes the PWM circuit to stop powering or de-energize the motor. At block 616, the brake is applied, either manually or via an electric brake circuit. The brake stops the motor and associated pump very quickly. Thus, the brake ensures that the pump rotates a precise number of revolutions and therefore dispenses a precisely controlled dose of fluid. The exemplary embodiment ends at block 618 or loops back to block 604.

[0067] FIG. 7 is an exemplary methodology or logic diagram 700 for controlling a dispenser. The exemplary methodology 700 begins at block 702. At block 704, an object is detected in a detection zone. The object is detected by an object sensor, such as an infrared ("IR") object sensor, which includes an IR transmitter and an IR receiver. Upon detecting the object, at block 706, the dispenser processor causes the drive circuit to send power to the motor. The motor encoder begins providing multiple signals to the processor per full rotation of the motor. In some embodiments, the motor encoder provides four or more signals to the processor per full rotation (four signals being, for example, one signal per quarter rotation). In some embodiments, the motor encoder provides eight or more signals to the processor per full rotation. In some embodiments, the motor encoder provides twelve or more signals to the processor per full rotation. In some embodiments, the motor encoder provides sixteen or more signals to the processor per full rotation. At block 712, a determination is made as to whether a desired or set number of revolutions or turns of the motor and / or pump have been completed. In this exemplary embodiment, the desired or set number of revolutions or turns of the motor is, for example, 18 full revolutions. If the set number, 18 in this exemplary embodiment, has not been reached, the logic or methodology loops back to block 706 and the motor continues to be energized. If the set number has been reached, the methodology proceeds to block 714 where the processor causes the drive circuit to stop powering or de-energize the motor and the methodology ends at block 718 or loops back to block 704. In some embodiments, the motor brake or dynamic brake is applied to stop the motor.

[0068] FIG. 8 is an exemplary embodiment of an electronic braking circuit 800. This exemplary embodiment includes a motor 810 and a bi-pole switch 850. The bi-pole switch 850 is controlled by a processor (not shown) via a control signal 860. When the switch 850 is in position "a" (shown in solid lines) and the motor 810 is energized, the positive voltage of the power line 852 is connected to terminal 1 of the motor 810 and the negative (or neutral) voltage of the power line 854 is connected to terminal 2 of the motor 810. When the motor 810 has rotated a set number of revolutions, the processor (not shown) momentarily moves the switch 850 to position "b". In addition, the processor (not shown) turns off the power to lines 852, 854. Momentarily moving the switch to position "b" momentarily applies a positive voltage to terminal 2 of the motor 810 and a negative (or neutral) voltage to terminal 1. Switch 850 is in the "b" position long enough to stop the motor, but not long enough for motor 810 to start rotating in reverse. Once motor 810 has stopped, the switch is returned to the "a" position.

[0069] FIG. 9 is an exemplary embodiment of an electronic braking circuit 900. This exemplary embodiment includes a motor 910 and a transistor 950. The transistor 950 is controlled by a processor (not shown) via a control signal 960. When the motor 910 is energized, a positive voltage on a power line 952 is connected to terminal 1 of the motor 910 and a negative (or neutral) voltage on a power line 954 is connected to terminal 2 of the motor 910. Once the motor 910 has rotated a set number of revolutions, the processor (not shown) turns off the power to lines 852 and 854 and momentarily turns on the transistor 950. Turning on the transistor 950 creates a short circuit between motor terminals 1 and 2, causing the motor 910 to stop. Once the motor 910 has stopped, the transistor 950 turns off.

[0070] FIG. 10 is an exemplary embodiment of an electronic braking circuit 1000. This exemplary embodiment includes a motor 1010, a two-pole switch 1050, and a resistor 1070. The two-pole switch 1050 is controlled by a processor (not shown) via a control signal 1060. When the switch 1050 is in position "a" (shown in solid lines) and the motor 1010 is energized, a positive voltage on a power line 1052 is connected to terminal 1 of the motor 1010 and a negative (or neutral) voltage on a power line 1054 is connected to terminal 2 of the motor 1010. When the motor 1010 has rotated a set number of revolutions, the processor (not shown) moves the switch 1050 to the "b" position. In addition, the processor (not shown) turns off the power to the lines 1052 and 1054. Moving the switch 1050 to the "b" position places the resistor 1070 between terminals 1 and 2 of the motor 1010, causing the motor 1010 to stop. Once the motor 1010 has stopped, the switch 1050 returns to the "a" position.

[0071] FIG. 11 is an exemplary methodology or logic diagram 1100 for controlling a dispenser. The exemplary methodology 1100 begins at block 1102. At block 1104, an object is detected in a detection zone. The object is detected by an object sensor, such as, for example, an infrared ("IR") object sensor, which includes an IR transmitter and an IR receiver. Once an object is detected, at block 1106, the dispenser processor causes a drive circuit to send power to the motor. At block 1108, a counter is reset. At block 1110, the value of the counter 1110 is incremented. At block 1112, a determination is made as to whether the set number of revolutions has been met. If at block 1112, it is determined that the set number of revolutions has not been met, then once a full revolution has been made, the methodology loops back to block 1110, the value of the counter is incremented, and the methodology proceeds to block 1112. At block 1112, a determination is made as to whether the set number of revolutions has been met. If the set number of revolutions has been met, the motor is de-energized at block 1114. The brake is applied at block 1116. In some embodiments, the motor is stopped by applying the brake, which may be a mechanical brake or an electric brake.

[0072] Although various inventive aspects, concepts, and features of the present invention may be described and illustrated herein as being embodied in combination in exemplary embodiments, these various aspects, concepts, and features may be used individually or in various combinations and subcombinations thereof in many alternative embodiments. It is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such details. Unless expressly excluded herein, all such combinations and subcombinations are intended to be within the scope of the present invention. Furthermore, although various alternative embodiments of the various aspects, concepts, and features of the present invention, such as alternative materials, structures, configurations, methods, circuits, devices, and components, software, hardware, control logic, alternatives in terms of formation, suitability, and functionality, may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether currently known or developed in the future. Those skilled in the art may readily adopt one or more of the inventive aspects, concepts, or features for additional embodiments and uses within the scope of the present invention, even if such embodiments are not expressly disclosed herein. Furthermore, even if some features, concepts, or aspects of the invention are described herein as being preferred configurations or methods, such description is not intended to imply that such features are required or necessary unless expressly stated. Furthermore, typical or representative values ​​and ranges may be included to aid in the understanding of the present disclosure. However, such values ​​and ranges should not be construed in a limiting sense, and are intended to be critical values ​​or ranges only when expressly stated. Furthermore, although various aspects, features, and concepts may be expressly identified herein as inventive or forming part of the invention, such identification is not intended to be exclusive, and rather, inventive aspects, concepts, and features fully described herein may exist without being expressly identified as such or as part of a particular invention.The description of an exemplary method or process is not limited to the inclusion of every step as necessary in every instance, nor should the order in which the steps are presented be construed as required or essential, unless explicitly stated.

Claims

1. Housing and a container for holding a fluid; a pump in fluid communication with an interior of the vessel and operable sequentially, the pump comprising at least one liquid pump diaphragm and at least two air pump diaphragms; A dispenser processor; Power supply, A motor; An encoder; a pulse width modulation circuit in circuit communication with the power supply and the motor; Equipped with the encoder provides a plurality of signals to the processor for each revolution of the motor; the pulse width modulation circuitry supplies power to the motor in a first duty cycle for at least a portion of a revolution of the motor; the processor measures the speed of the motor multiple times during each revolution of the motor; the pulse width modulation circuit adjusts the first duty cycle to maintain a selected speed responsive to the measured speed of the motor after the at least a portion of a revolution of the motor; the processor utilizing the signals from the encoder to determine whether the motor has reached a selected number of revolutions; the processor causes the pulse width modulation circuit to stop supplying power to the motor when the pump reaches a selected RPM; The number of revolutions is greater than 5. Soap or sanitizer dispensers.

2. 10. The soap or sanitizer dispenser of claim 1, further comprising a brake.

3. 3. The soap or sanitizer dispenser of claim 2, wherein the brake is an electric brake.

4. 4. The soap or sanitizer dispenser of claim 3, wherein the brake comprises a transistor that shorts terminals of the motor to stop the motor.

5. 4. The soap or sanitizer dispenser of claim 3, wherein the brake comprises a switch, the switch switching voltage polarity across terminals of the motor.

6. 4. The soap or sanitizer dispenser of claim 3, wherein the brake comprises a switch and a resistor, the switch placing the resistor across terminals of the motor to stop the motor.

7. 3. The soap or sanitizer dispenser of claim 2, wherein the brake is set when the pulse width modulation circuit stops supplying power to the motor.

8. 10. The soap or sanitizer dispenser of claim 1, wherein the encoder provides at least four signals to the processor for each revolution of the motor.

9. 10. The soap or sanitizer dispenser of claim 1, wherein the encoder provides at least eight signals to the processor for each revolution of the motor.

10. Housing and A container of liquid; a pump in fluid communication with the reservoir, the pump having a plurality of pump diaphragms, each of the pump diaphragms compressing and expanding during one revolution of the pump; A dispenser processor; Power supply, A motor; An encoder; a pulse width modulation circuit in circuit communication with the power supply and the motor; Equipped with the encoder is configured to provide a plurality of signals to the processor indicative of a speed of the motor for each revolution of the motor; the pulse width modulation circuit provides a first duty cycle of at least 80% for at least a partial revolution of the motor; the processor measures the speed of the motor multiple times during each revolution of the motor; the pulse width modulation circuit adjusts the first duty cycle to maintain a selected speed of at least 1200 revolutions per minute after rotating at least a portion of a revolution of the motor; the processor causes the pulse width modulation circuit to stop supplying power to the motor after five revolutions of the pump and before thirty revolutions of the motor. Soap or sanitizer dispensers.

11. 11. The soap or sanitizer dispenser of claim 10, further comprising a brake.

12. 12. The soap or sanitizer dispenser of claim 11, wherein the brake is a mechanical brake.

13. 12. The soap or sanitizer dispenser of claim 11, wherein the brake is an electric brake.

14. 14. The soap or sanitizer dispenser of claim 13, wherein the brake comprises a transistor that shorts terminals of the motor to stop the motor.

15. 14. The soap or sanitizer dispenser of claim 13, wherein the brake comprises a switch, the switch switching voltage polarity across terminals of the motor.

16. 14. The soap or sanitizer dispenser of claim 13, wherein the brake comprises a switch and a resistor, the switch placing the resistor across terminals of the motor to stop the motor.

17. 11. The soap or sanitizer dispenser of claim 10, wherein the first duty cycle is at least 90%.

18. 11. The soap or sanitizer dispenser of claim 10, wherein the selected speed is at least 1700 revolutions per minute.

19. 11. The soap or sanitizer dispenser of claim 10, wherein the pulse width modulation circuitry cuts off power to the motor before 25 revolutions of the motor.

20. 11. The soap or sanitizer dispenser of claim 10, wherein the encoder provides at least four signals to the processor for each revolution of the motor.

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