Aerosol Dispensing Apparatus

Abstract

A dispensing system adapted for repeated activation of an aerosol can is described. The dispensing system includes components that improve the ability to receive and secure aerosol cans of different sizes within the dispensing system as well as improving the reliability and energy efficiency of the system.

Claims

1-17. (canceled)

18. An aerosol can dispenser for determining if an aerosol can is authorized for use with the aerosol can dispenser wherein the aerosol can dispenser comprises: a. a controller having means for activation of the aerosol can dispenser for repeated activation of the aerosol can nozzle by an aerosol can dispensing mechanism; b. a mount for mounting an aerosol can to the aerosol can dispenser to engage the aerosol can nozzle with the aerosol can dispensing mechanism; c. at least one LED emitter/receiver pair operatively connected to the controller, the LED emitter/receiver pair configured to emit LED light against an outer surface of an aerosol can and to receive reflected light from the outer surface of the aerosol can; wherein the controller is configured such that, if the reflected light signal pattern is authorized, the aerosol can dispensing mechanism is enabled to dispense a quantity of aerosol can contents and, if the reflected light signal pattern is not authorized, activation of the aerosol can dispensing mechanism is prevented.

19. The aerosol can dispenser according to claim 18, wherein the emitter and receiver of the emitter/receiver pair are positioned at different levels within the dispenser so as to operatively connect with a single photoreflective band at a specific height.

20. The aerosol can dispenser according to claim 18, wherein the aerosol can dispenser comprises multiple emitter/receiver pairs.

21. The aerosol can dispenser according to claim 18, wherein the controller is configured to implement a predetermined dispensing cycle.

22. The aerosol can dispenser according to claim 18, wherein the aerosol can dispenser comprises multiple emitter/receiver pairs arranged at different heights.

23. The aerosol can dispenser according to claim 18, wherein the emitter/receiver pair is positionable at different levels relative to the dispenser.

24. The aerosol can dispenser according to claim 18, wherein the aerosol can dispenser is battery powered.

25. The aerosol can dispenser according to claim 18, wherein the aerosol can dispenser forms part of an air freshener system.

26. The aerosol can dispenser according to claim 18, wherein the aerosol can dispenser is configured to initiate a dispense cycle based on a time signal.

27. The aerosol can dispenser according to claim 18, wherein the aerosol can dispenser is configured to dispense according to a dispensing schedule.

28. The aerosol can dispenser according to claim 18, wherein the aerosol can dispenser is configured adjust dispensing frequency based on the time of day.

29. A method for operating an aerosol can dispenser wherein method comprises: mounting an aerosol can to an aerosol can dispenser to engage a nozzle of the aerosol can with an dispensing mechanism, the dispensing mechanism being configured to allow repeated activation of the aerosol can nozzle by the aerosol can dispenser; emitting LED light from an LED emitter mounted on the aerosol can dispenser against an outer surface of an aerosol can; receiving reflected light at an LED receiver mounted on the aerosol can dispenser from the outer surface of the aerosol can; determining if the reflected light signal pattern is authorized; if the reflected light signal pattern is authorized, enabling the aerosol can dispensing mechanism to dispense a quantity of aerosol can contents and, if the reflected light signal pattern is not authorized, preventing activation of the aerosol can dispensing mechanism.

30. The method according to claim 29 wherein the LED light is emitted onto at least one photoreflective surface on the aerosol can, the photoreflective surface being configured to receive light from the LED emitter and reflect the received light towards the LED receiver.

31. The method according to claim 29, wherein the method comprises: activating the LED emitter such that LED light is emitted against the outer surface of the aerosol can in response to the controller initiating a dispensing cycle.

32. The method according to claim 29, wherein the method comprises: activating the LED emitter pair such that LED light is emitted against the outer surface of the aerosol can in response to detecting that the dispenser cabinet has been opened.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0048] The invention is described with reference to the accompanying figures in which:

[0049] FIG. 1 is a schematic diagram showing a typical aerosol can valve mechanism in accordance with the prior art in a sealed (A) and dispensing (B) position.

[0050] FIG. 2 is a schematic view of a dispenser showing an aerosol can support in accordance with one embodiment of the invention.

[0051] FIG. 3 is a sketch of an actuator mechanism and support system in accordance with one embodiment of the invention.

[0052] FIG. 4 is a perspective view of an actuator mechanism in accordance with one embodiment of the invention.

[0053] FIG. 4A is a sketch of an actuator mechanism in accordance with one embodiment of the invention.

[0054] FIG. 5 is a perspective view of an aerosol can adaptor in accordance with one embodiment of the invention.

[0055] FIG. 5A is a sketch of an aerosol can adaptor in accordance with one embodiment of the invention.

[0056] FIG. 6 is a graph comparing average energy per dispense for an actuation system in accordance with the invention (SS) and prior art systems at a 7 pound load.

[0057] FIG. 6A is a graph comparing average energy per dispense for an actuation system in accordance with the invention (SS) and prior art systems at a 5 pound load.

[0058] FIG. 7 is a graph comparing battery life for an actuation system in accordance with the invention (SS) and prior art systems at a 7 pound load.

[0059] FIG. 7A is a graph comparing battery life for an actuation system in accordance with the invention (SS) and prior art systems at a 5 pound load.

[0060] FIG. 8 is a schematic diagram of a keying system in accordance with one embodiment of the invention.

[0061] FIG. 9 is a perspective view of dispenser system with mounted aerosol can in accordance with one embodiment of the invention.

[0062] FIG. 10 is a schematic diagram of a programming interface in accordance with one embodiment of the invention.

[0063] FIG. 11 is a schematic diagram showing possible dispensing schedules for different installations.

[0064] FIG. 12 is a perspective view of dispenser system with a lower battery drawer in accordance with one embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0065] With reference to the Figures, an improved dispensing apparatus for holding and securing an aerosol can or the like and automatically activating the aerosol can to dispense a volume of the aerosol can contents is described. As shown in the FIGS. 2-5, the apparatus generally includes a can support and securing system 10 as shown in FIGS. 2, 3 and 5 and a drive mechanism as shown in FIGS. 3 and 4. Collectively, the apparatus enables aerosol cans having different sizes to be effectively secured to a dispensing apparatus and thereafter allow the dispensing of the contents of the aerosol can with improved reliability and power consumption in comparison to past systems.

Can Support and Securing System

[0066] As shown in FIGS. 2, 3, 5 and 5A, a can support and securing system 10 (CSSS) is described. The CSSS includes a base 12, frame 14 and can top adaptor 16.

[0067] As shown schematically in FIG. 3, the base 12 operatively supports a spring 12a and a can support 12b telescopically received in the base. The can support 12b will preferably include a convex surface 12d for engagement with the underside of an aerosol can 18 as shown in FIG. 3.

[0068] The frame 14 connects the base to the can top adaptor 16 as shown in FIG. 2. As shown schematically in FIG. 5A, the can top adaptor includes a recess 16a and slot 16b adapted for receiving the upper surfaces of an aerosol can 18. The recess 16a is generally a cylindrical recess for receiving the upper lip 18a of an aerosol can. The recess 16a is generally dimensioned to have a diameter greater than the normal range in sizes from different manufacturers of aerosol cans. The slot 16b receives the nozzle 18b of the aerosol can as also shown in FIG. 5. Above the can top adaptor is compartment 17 that supports a motor assembly and system electronics as described below and includes a cover 17a for covering the motor assembly and electronics.

[0069] In operation, an aerosol can 18 is positioned within the frame 14 such than the lower concave surface 18c of the aerosol can is over the convex surface 18c of the base 12. In installing the AC, the user pushes down gently against the can support 12b such that the spring is depressed thereby allowing the upper end of the AC to move with respect to the can top adaptor 16 and allow the upper lip 18a and nozzle 18b to be inserted into the recess 16a and slot 16b. As the upper lip and nozzle are seated, the upward pressure of the spring 12a biases the AC upwardly within the can top adaptor 16.

[0070] Thereafter, a dispenser cover (not shown) is closed such that the aerosol can is covered and locked to prevent unauthorized removal of the aerosol can. In addition, prior to closing the dispenser cover, the support lock 12c is activated if present. As a result, the AC is centered and locked in the ideal position for actuation. In one embodiment, the lock support 12c is a sliding member that is secured to the base 12 that can engage with the can support 12b so as to secure the can support at a specific level with respect to the base.

[0071] In order to remove an AC when the refill is empty, the service person opens the dispenser cover and unlocks the support lock (if present) to release the can support allowing the empty can to be depressed downwardly and allowing the empty to be pulled out of the dispenser. The components of the mechanism are generally configured such that a refill can only be inserted in the correct configuration for operation.

Actuation Mechanism

[0072] As discussed above, the importance of a linear actuator that is well centered on the valve stem was not widely recognized in previous designs. That is, the failures discussed above do not occur immediately after installation and are otherwise relatively infrequent. Thus, periodic problems with the aerosol can have often been blamed on random valve component failure as opposed to a fundamental problem with the way the aerosol can is operated within the dispenser.

[0073] The actuation mechanism in accordance with the invention is illustrated in FIGS. 4 and 4a and utilizes a scotch yoke mechanism 25 to convert rotary motion of an electric motor 25 to linear motion to actuate a lever 27 against the nozzle 18b of the AC.

[0074] As shown, the motor 25 is mounted and secured within the can top adaptor 16. The motor includes a gear train (not shown, optional) that is connected to torque arm 25a having an offset spindle 25b for engagement with a slot 27a within the lever 27. The lever 27 has a first end 27b having the slot 27a and a second end 27c. The first and second ends are angularly connected to one another at pivot point P such that movement of one end causes movement of the other end in a different direction as determined by the angle between the two ends. Pivot point P is secured within compartment 17 such that the pivot point is stationary with respect to the housing.

[0075] As such, rotary motion of the spindle within the slot causes substantially linear motion of the second end as shown in FIG. 4A. That is, as the motor 25 is operated, the torque arm 25a is rotated. The offset spindle 25b moves in a circular motion with the torque arm. The lever 27 is secured at pivot point P and rotates about an axis parallel to the axis of rotation of the motor spindle. As a result, the circular motion of the offset spindle causes a reciprocating motion of the first end 27a of the lever. This causes the second end of the lever arm 27c which is perpendicular to the axis of rotation to also move in a reciprocating motion. The relative lengths of the first and second ends of the lever, the offset length of the offset spindle relative to the motor axis and the angle between the two ends will determine the relative linear displacement of each end and the relative direction of movement.

[0076] Preferably, the lever is designed and positioned within the compartment 17 such that the motion of the second end of the lever is substantially linear (i.e. a controlled tangent vector) to and against the nozzle of an AC positioned with the can top adaptor and specifically the slot 16b of the can top adaptor. In other words, the second end with move in a reciprocating arcuate motion; however, the arc is sufficiently short and has a radius sufficiently large such that the movement relative to the AC stem is substantially parallel.

[0077] Preferably, the gear train (if required) includes metal gears in order to improve the life of the gear train. In a typical deployment, a cycle life greater than one million cycles can be achieved with a metal gear train.

[0078] Importantly, the scotch yoke provides improved power consumption while minimizing the risk of stalling the motor while providing consistent actuation forces against the AC nozzle. In particular, the scotch yoke is configured such that the two inflection points that provide maximum mechanical advantage of the scotch yoke cycle coincide with the two points of maximum valve actuation force namely at a) seal break (i.e. at the top of stroke) and b) at the point of maximum valve compression (i.e. where spring compression will be greatest). Applying maximum force at the top of stroke is particularly important for new aerosol cans in that new cans often start their life cycle with dry, sticky valves that may require additional force to actuate (up to 7 pounds of force).

[0079] Further still, the scotch yoke provides a parabolic increase in available actuation force as the torque arm moves towards the inflection points which correlates well with the force displacement requirements of the aerosol can valve.

[0080] Further still, as the scotch yoke is a rotating system, the system provides a fixed and repeatable stroke. As such, a degree of stroke compensation is required due to the potential variations in aerosol can height and valve geometries as discussed above. That is, slight variations in the position of the nozzle relative to the second end of the pivot arm will not affect the actual distance that the nozzle is displaced.

[0081] In order to minimize the risk of over-driving the valve (i.e. in situations where the nozzle/valve height is higher than usual), the lever arm is preferably designed with a stiffness so that a valve stem of maximum height geometry will not be damaged by over driving the valve at bottom of dispenser stroke. In other words, it is preferred that the lever arm (and in particular the second end 27c) is sufficiently flexible to moderately flex in the event that an excessive resistive force is being applied by the valve.

[0082] An additional benefit of the design is that the actuation mechanism is more compact than traditional designs. This allows for sufficient space to incorporate an additional battery within the control system without increasing the overall footprint of the housing. The extra battery may be used to extend battery life well beyond comparable products in the market. FIG. 12 (described below) shows an embodiment with one configuration for additional batteries.

Power Consumption and Energy Analysis

[0083] Different dispenser designs were tested to evaluate the energy efficiency of each design under simulated operating conditions. That is, a series of experiments were designed to simulate the normal operating conditions of a dispenser as well as compromised operating conditions. The first test conditions (Group I) represented the compromised operating conditions where the valve spring of an aerosol can requires an increased force to activate the valve which may have been caused by the valve becoming contaminated with contents such that the activation mechanism must provide an increased force to open the valve. In this group, dispensers operated against a spring having a 7 pound activation force. The second test conditions represented the normal operating conditions where the normal valve opening force is all that is required. In this group, dispensers operated against a spring having a 5 pound activation force.

[0084] Energy consumption measurements were made at these two levels as representing the typical range of force that may be required. As is understood, the activation force will usually vary over the life the can regardless of leakage as metered valves will stiffen over time due to the swelling of the stem gasket. This gasket swelling is a function of the gasket material, its reactivity with the solvents used in the formulation, ambient temperature and the length exposure of the solvents to the gasket (dispensing period). The solvents used in low VOC formulations are particularly reactive, which create challenges for US formulations compared to formulas used for Europe or Asia. By testing the dispenser with a 7 lb load, the worst case performance can be estimated.

[0085] As shown in FIGS. 6, 6A, 7 and 7A, the differences in the energy consumed per cycle at different loads (FIGS. 6 and 6A) and total number of cycles at different loads for equivalent batteries (FIGS. 7 and 7A) are shown for the subject system (SS) as compared to 8 or 9 prior art products. As shown, the subject system consumes less energy per cycle than other systems at the higher load and has substantially equal power consumption to other systems at the lower load. Importantly, as shown in FIGS. 7 and 7A, this translates into a significant improvement in battery life since the subject design makes much better use of the available energy in the batteries (1.4 V vs. 0.4 V usable) compared to other designs by eliminating current spikes that are common in past systems. This is achieved by the lever arm flexibility as described above which minimizes peak apparent load as well as the parabolic power profile of the scotch yoke.

[0086] In a typical operating scenario, a dispenser will provide approximately 3,000 dispenses per month. As such, it is predicted that the subject design will achieve a 35 month battery life under full load conditions which represents 2.5 times the battery life of other dispensers (for comparable batteries). When compared to some dispensers that will typically only provide 5 months of battery life under these conditions, this means that the batteries would have to changed 7 times more often in these dispensers as compared to the subject system.

[0087] As shown in Table 1, the estimated battery cost and service cycle for different systems is shown below. While the total cost savings appear relatively small, importantly, it is the service cycle that indicates the most significant costs associated with inefficient dispensers. For example, in large properties with multiple dispensers, if it takes on average 30 minutes to recognize a battery failure and organize and change the batteries in a dispenser, the true cost of changing batteries at a labor cost of $20/hour may cost $10 per battery change. As such, if a property has many hundreds of dispensers, the annual cost of changing batteries is very high. Thus, the subject system can provide significant labor savings associated with changing batteries.

TABLE-US-00001 TABLE 1 Estimated Annual Battery Cost and Service Cycle Service Annual Battery cycle Design cost (Months) Subject $0.78 38 System System 1 $1.40 15 System 2 $1.40 17 System 3 $0.92 24 System 4 $3.94 2 System 5 $1.32 7

[0088] Based on published costs for Duracell Procell of: [0089] AA cell =$0.39 [0090] C cell =$0.82 [0091] D cell =$0.92

[0092] Table 2 shows the effect of battery voltage on time to dispense for the subject scotch yoke dispenser. As known, the voltage of a typical alkaline battery will decrease over the life of the battery where for a single battery, the voltage will decrease from an initial value to a lower value where the battery has no usable capacity. By way of example, in a typical C cell battery, the usable voltage range is approximately 1.6 volts down to 0.9 volts. As noted above, the scotch yoke system of the subject system completes a single rotation of the offset spindle for each dispense, preferably using a time signal to initiate dispensing and a limit switch to turn off the system upon completion of one rotation. As shown in Table 2 for a system having 3 C size batteries, when the batteries are fresh, the voltage is higher and the time to dispense (Td) a fixed quantity of aerosol fluid is shorter. As the battery voltage decreases over the life of the battery, the time to dispense will increase for the minimum or threshold energy output required to complete a dispense cycle. As shown, an average of 0.62 joules is required to complete a dispense cycle whereas the time to dispense increases from 0.95 seconds to 1.79 seconds as the battery voltage drops from 4.5 volts to 2.8 volts. Importantly, and in contrast to prior art systems, when the voltage is high the energy consumed for a dispense cycle is substantially the same (or slightly lower) than the energy consumed when the voltage is low. Thus, as the energy consumed per cycle is consistent regardless of voltage, battery life is substantially improved.

[0093] It should be noted that while the time to dispense increases, this does not mean an increase in the quantity of material being dispensed if the aerosol can has a dose valve.

TABLE-US-00002 TABLE 2 Battery voltage vs. Time to Dispense for 7 pound and 5 pound valve loads 7 pound load Battery Format 3xC Vps (V) J (Ws) Td (sec)* 4.5 0.58 0.95 4.3 0.58 1.01 4.1 0.58 1.07 4.0 0.58 1.09 3.8 0.6 1.19 3.6 0.62 1.31 3.4 0.63 1.39 3.2 0.65 1.51 3.0 0.68 1.65 2.8 0.69 1.79 Average 0.62 1.30 5 lb load Battery Format 3xC Vps (V) J (ws) Td (sec)* 4.5 0.5 0.86 4.3 0.49 0.89 4.1 0.48 0.95 4.0 0.47 0.98 3.8 0.46 1.01 3.6 0.46 1.1 3.4 0.46 1.15 3.2 0.45 1.24 3.0 0.45 1.33 2.8 0.47 1.47 Average 0.47 1.10

[0094] In one embodiment as shown in FIG. 12, a dispenser having a lower battery drawer 70 is provided to enable rapid replacement of the batteries. In particular, as in most installations, the base of the dispenser is installed on a wall at a height of at least 7 feet, this embodiment provides an advantage over other systems that are mounted in this manner by providing a lower access point for the batteries. As such, as compared to prior art systems where the batteries are located adjacent the dispensing mechanism and may be at a height of 8+ feet, the lower battery drawer provides lower access for battery replacement.

Keying

[0095] In one embodiment, the dispenser is provided with a keying system to prevent unauthorized aerosol cans from being used in the dispenser as shown in FIGS. 8 and 9 and described in Applicant's copending application PCT/CA2011/001008, entitled Signal and Detection System for Keying Applications incorporated herein by reference. In this embodiment, an aerosol can 18 is provided with one or more photoreflective bands (PRB) 50a-50f surrounding the circumference of the aerosol can. A corresponding LED emitter/receiver pair 50 is operatively oriented with respect to one or more PRBs and connected to the dispenser's controller. In operation, at the time that the controller initiates a dispensing cycle and/or detects that the dispenser cabinet has been opened, the controller activates the LED emitter/receiver pair such that LED light is emitted against the outer surface of the aerosol can. The LED emitter/receiver pair is oriented such that emitted light is reflected off the outer surface of the aerosol can to the receiver. The received light signal will have characteristics corresponding to the PRB such that distinct reflected light patterns can be analyzed by the controller and compared to authorized patterns. Generally, the keying system can be used to enable a manufacturer to ensure that only authorized product is utilized within the dispenser 10.

[0096] Various coding scenarios, as described in the copending application can be employed including jurisdictional codes that enable the use of particular product in specific jurisdictions only.

[0097] The PRB may be visible, not visible or not noticeably visible to the naked eye on the exterior of the AC while remaining visible to the emitter/receiver pair. The PRB may also be visible to the emitter/receiver pair beneath overlying graphics that may be on the AC. The PRB can be applied to directly to the metal surface of the AC or to a paper label.

[0098] The emitter/receiver pair may be positioned at different levels within the dispenser so as to operatively connect with a single PRB at a specific height. In this case, for example, a dispenser intended for a specific jurisdiction would include an emitter/receiver at one height and be programmed to interpret a PRB at a corresponding height. For example, as shown in FIG. 8, the emitter/receiver pair will engage with the third PRB 50d from the bottom and will only operate with ACs that include a specific PRB at the third level. Alternatively, a dispenser intended for another jurisdiction could have the emitter/receiver pair at a different height and only operate with ACs that include a specific PRB at that other level. Various combinations of emitter/receiver pairs may also be provided to increase the number of coding options.

Touch Programming

[0099] In one embodiment, the dispenser is provided with a programming interface 60 as shown in FIGS. 9 and 10. In this embodiment, in order to minimize the need and time for programming individual dispensers at the time of installation (or thereafter), the dispenser includes a series of application specific software that provide dispensing routines applicable to a number of common installations.

[0100] As shown in FIGS. 9 and 10, an interface 60 with application graphics representing for example, an airport 60a, hospital 60b, restaurant 60d, and office 60d are displayed. The interface includes an actuation switch (not shown) beneath the outer surface wherein user-depression of the application graphic will initiate actuation of a corresponding program that has a dispensing schedule corresponding to the installation. In each case, the dispensing schedule has been pre-determined by anticipated traffic for that type of installation.

[0101] FIG. 11 shows a typical dispensing schedule for the above installations. As can be seen, over a 24 hour period for each of an airport, restaurant, office and medical facility, each installation will have different dispensing frequencies for various times of day. For example, each of heavy, normal, light or very light dispensing frequencies may be provided for different times of day in these different installations. Other graphics such as indicator 60c may be provided to give an installer or technician a visual warning that the system is about to initiate a dispensing cycle.

[0102] Further still, the controller will preferably include a factory set time within the controller such that the installer simply selects the appropriate program and does not have to program the time into each unit. In this case, as units are being manufactured for a specific jurisdiction (for example, North America), the factory would set the time of day for the median North American time (for example, Central Standard Time) thus allowing no more than a 2 hour error in the time of day setting for North American units. In another embodiment, the display interface would include a time display and a plus or minus button that allows the installer to adjust the hour setting on the time display in 1 hour increments to provide an accurate time of day. Preferably, the system clock is independent of the dispensing power supply such that regular replacement of the dispensing batteries will not necessitate resetting the system clock.

[0103] Importantly, the simple programming feature simplifies installation by allowing the installer to simply select the appropriate program for the installation, thus enabling time-efficient installation as well as an efficient dispensing schedule for that installation. In addition, this feature also provides an improved ability to predict service intervals based on the power consumption for a specific installation which overcomes the problem of past dispensing devices that may rely strictly on traffic which then results in effectively random service requirements.

[0104] Although the present invention has been described and illustrated with respect to preferred embodiments and preferred uses thereof, it is not to be so limited since modifications and changes can be made therein which are within the full, intended scope of the invention as understood by those skilled in the art.