TOP-FILL COUNTER-MOUNT SOAP DISPENSERS

Abstract

According to one embodiment, a soap dispenser includes a nozzle, a pump operable to dispense soap through the nozzle and to be positioned above a surface of a counter, a push rod having a pivot arm aperture. The push rod is coupled to the pump and movement of the push rod in a direction toward the pump activates the pump. The soap dispenser further includes a pivot arm having a lift end disposed within the pivot arm aperture, and a motor assembly. The motor assembly is operable to rotate to pivot the pivot arm and lift the lift end such that the push rod activates the pump to dispense soap through the nozzle.

Claims

1. A soap dispenser comprising: a nozzle; a pump operable to dispense soap through the nozzle and to be positioned above a surface of a counter; a push rod comprising a pivot arm aperture, wherein the push rod is coupled to the pump and movement of the push rod in a direction toward the pump activates the pump; a pivot arm comprising a lift end disposed within the pivot arm aperture; and a motor assembly, wherein the motor assembly is operable to rotate to pivot the pivot arm and lift the lift end such that the push rod activates the pump to dispense soap through the nozzle.

2. The soap dispenser of claim 1, further comprising a down tube comprising an aperture, wherein the push rod is disposed within the down tube and the lift end of the pivot arm is positioned through the aperture.

3. The soap dispenser of claim 2, further comprising: a refill locking dock having a threaded tube that is operable to extend through an opening in the counter; and a coupling nut coupled to the threaded tube, the coupling nut comprising a shaft, wherein the down tube is coupled to the shaft of the coupling nut.

4. The soap dispenser of claim 3, further comprising: a swivel coupler nut coupled to the threaded tube; an anti-swivel grip coupled to the threaded tube; and a grip plate assembly comprising teeth and disposed within a recess of the anti-swivel grip, wherein the teeth are operable to engage and undersurface of the counter when the anti-swivel grip is tightened on the threaded tube.

5. The soap dispenser of claim 2, further comprising a soap reservoir bag assembly, the soap reservoir bag assembly comprising a reservoir bag and a reservoir coupler, wherein: the reservoir bag is coupled to the reservoir coupler; and the reservoir coupler is coupled to an end of the down tube.

6. The soap dispenser of claim 5, further comprising a soap tube coupled to the pump and a soap reservoir sleeve disposed within the reservoir bag, wherein the soap tube is partially disposed within the soap reservoir sleeve.

7. The soap dispenser of claim 5, further comprising a soap reservoir, wherein the soap reservoir is coupled to the reservoir coupler and the reservoir bag is within the soap reservoir.

8. The soap dispenser of claim 5, wherein the reservoir coupler is permanently coupled to the end of the down tube.

9. The soap dispenser of claim 2, further comprising a soap tube coupled to the pump, wherein: the push rod comprises one or more groove features for holding the soap tube, an upper flange and a lower flange; and the upper flange and the lower flange engage an interior surface of the down tube.

10. The soap dispenser of claim 2, wherein: the motor assembly comprises a motor, a gear coupled to the motor, and a cam coupled to the gear; and the cam comprise a sloped surface operable to pivot the pivot arm when the motor rotates the cam.

11. A soap dispenser comprising: a nozzle; a pump operable to dispense soap through the nozzle and to be positioned above a surface of a counter; a pivot arm comprising a lift end and a cam engagement surface; and a motor assembly comprising a motor, a gear coupled to the motor, and a cam coupled to the gear, wherein: the cam comprise a sloped surface that varies a height of the cam; the cam engagement surface of the pivot arm contacts the sloped surface; actuation of the motor is operable to rotate the gear and the cam to pivot the pivot arm when the motor rotates the cam; and pivoting the pivot arm activates the pump to dispense soap through the nozzle.

12. The soap dispenser of claim 11, further comprising a push rod coupled to the pump, wherein the pivot arm contacts the push rod and lifts the push rod to activate the pump when the motor rotates the gear and the cam.

13. The soap dispenser of claim 11, further comprising an electronics assembly comprising a housing and the motor assembly disposed within the housing, wherein the pivot arm comprises a pair of pivot protrusions that are rotatably coupled to an interior surface of the housing.

14. The soap dispenser of claim 13, wherein: the pivot arm comprises a spring hole operable to receive a first end of a spring; a second end of the spring is operable to be coupled to an interior of the housing; and the spring is operable to return the pivot arm to a home position when the cam completes a revolution.

15. The soap dispenser of claim 11, further comprising: a down tube; a refill locking dock having a threaded tube that is operable to extend through an opening in the counter; and a coupling nut coupled to the threaded tube, the coupling nut comprising a shaft, wherein the down tube is coupled to the shaft of the coupling nut.

16. The soap dispenser of claim 15, further comprising: a swivel coupler nut, coupled to the threaded tube; an anti-swivel grip coupled to the threaded tube; and a grip plate assembly comprising teeth and disposed within a recess of the anti-swivel grip, wherein the teeth are operable to engage and undersurface of the counter when the anti-swivel grip is tightened on the threaded tube.

17. The soap dispenser of claim 11, further comprising a soap reservoir bag assembly, the soap reservoir bag assembly comprising a reservoir bag and a reservoir coupler, wherein: the reservoir bag is coupled to the reservoir coupler; and the reservoir coupler is coupled to an end of the down tube.

18. The soap dispenser of claim 17, further comprising a soap reservoir, wherein the soap reservoir is coupled to the reservoir coupler and the reservoir bag is within the soap reservoir.

19. The soap dispenser of claim 17, further comprising a soap tube coupled to the pump and a soap reservoir sleeve disposed within the reservoir bag, wherein the soap tube is partially disposed within the soap reservoir sleeve.

20. The soap dispenser of claim 11, further comprising a refill locking dock, wherein the nozzle is removably coupled to the refill locking dock and the pump is positioned within the nozzle.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0010] To easily identify the discussion of any particular element or act, the most significant digit or digits in a reference number refer to the figure number in which that element is first introduced.

[0011] FIG. 1 illustrates an example soap dispenser according to one or more embodiments described and illustrated herein.

[0012] FIG. 2 illustrates a partially assembled perspective view of the soap dispenser shown in FIG. 1 according to one or more embodiments described and illustrated herein.

[0013] FIG. 3 illustrates an exploded view of an example soap dispenser according to one or more embodiments described and illustrated herein.

[0014] FIG. 4 illustrates a perspective view of an example dip tube and push rod according to one or more embodiments described and illustrated herein.

[0015] FIG. 5 illustrates a side view of the example dip tube and push rod of FIG. 4 according to one or more embodiments described and illustrated herein.

[0016] FIG. 6 illustrates a front view of the example push rod of FIG. 4 according to one or more embodiments described and illustrated herein.

[0017] FIG. 7 illustrates a back view of the example push rod of FIG. 4 according to one or more embodiments described and illustrated herein.

[0018] FIG. 8 illustrates a close-up view of the example push rod of FIG. 4 according to one or more embodiments described and illustrated herein.

[0019] FIG. 9 illustrates an exploded view of an example motor assembly according to one or more embodiments described and illustrated herein.

[0020] FIG. 10 illustrates an assembled view of the example motor assembly of FIG. 9 according to one or more embodiments described and illustrated herein

[0021] FIG. 11 illustrates a perspective view of the example pivot arm according to one or more embodiments described and illustrated herein.

[0022] FIG. 12 illustrates a top view of an example cam according to one or more embodiments described and illustrated herein.

[0023] FIG. 13 illustrates a perspective view of the example cam of FIG. 12 according to one or more embodiments described and illustrated herein.

[0024] FIG. 14 illustrates a front view of the example cam of FIG. 12 according to one or more embodiments described and illustrated herein.

DETAILED DESCRIPTION

[0025] Embodiments of the present disclosure are directed to counter-mount, top-fill automatic foam soap dispensers. The soap reservoir of the dispenser is filled from the top at the counter surface, which eliminates the need to crawl under the counter to refill the soap reservoir. This saves on labor costs and reduces strain and time. The pump is located within the nozzle above the counter surface, while the motor, electronics and soap reservoir remain below the counter surface. A quiet, battery-powered motor offers quick dispensing, while sealed, sanitary refill bags used to fill the soap reservoir eliminates contamination. The design ensures no messy spills or wasted product that can occur with bulk pour refills.

[0026] As described in more detail below, a push rod interacts with a motor assembly to activate the pump to dispense foam soap in a consistent manner. The design ensures that the pump remains primed and therefore soap is dispensed each and every time an infrared sensor detects a user's hand.

[0027] Referring now to FIG. 1, an example soap dispenser 102 is illustrated according to embodiments described herein. The soap dispenser 102 includes a nozzle 104 having a pump 101 enclosed therein. The pump 101 may be any known or yet-to-be-developed pump for dispensing foam soap. The nozzle 104 may be fabricated from any suitable rigid material, such as plastic or metal. In some embodiments, the nozzle 104 includes one or more status LEDs 124 to provide status indications, such as low soap, low battery power, maintenance required, or any other status indication. The nozzle 104 is coupled to a locking refill dock 108 (e.g., by a screw cap) that allows the nozzle 104 to be removed for top-filling of a soap reservoir 120 using a soap refill bag 354 of a soap refill bag assembly 350 (see FIG. 3). The soap reservoir 120 is made of a rigid material, such as molded plastic, and is operable to receive a soap refill bag 354 that is filled with soap.

[0028] The locking refill dock 108 is accessible on a top surface of the counter 106. The locking refill dock 108 further includes a threaded tube 126 that couples the locking refill dock 108 to the soap reservoir 120 for receiving soap to refill the soap reservoir 120. The placement of the locking refill dock 108 at the top of the surface of the counter 106 provides a person with easy access to the soap refill bag so that the person may quickly and easily refill the soap refill bag from the top of the counter 106 as opposed to below the counter where space is cramped and light is limited.

[0029] A swivel coupler nut 110 couples an electronics assembly 122, which is further coupled to the soap reservoir 120, to the threaded tube 126 of the locking refill dock 108. The electronics assembly 122 includes a battery pack 118 to provide electrical power to the motor (not shown) within the electronics assembly 122. As described in more detail below, the motor is operable to dispense soap from the soap refill bag assembly 330 through the nozzle 104. A sensor power cable 112 provides power and/or data to the status indicator LEDs 124. A power cable 116 may be provided to connect the electronics assembly 122 to the battery pack 118 or other AC or DC power source. The battery pack 118 may include rechargeable batteries (e.g., lithium ion batteries) or non-rechargeable batteries.

[0030] FIG. 2 illustrates the example soap dispenser 102 with the nozzle 104 removed. FIG. 3 illustrates an exploded view of the example soap dispenser 102 shown in FIG. 2.

[0031] Referring to both FIG. 2 and FIG. 3, a grip plate assembly 344 engages the bottom surface of a counter 106. The grip plate assembly 344 is disposed within a recess of an anti-swivel grip 204 such that the grip plate assembly 344 is positioned between the bottom surface of the counter 106 and a surface of the anti-swivel grip 204. The grip plate assembly 344 has teeth 348 that engage the bottom surface of the counter 106 so that the nozzle 104 does not swivel back and forth on the top surface of the counter 106 as do many soap dispensers sold today. In some embodiments, the teeth 348 are provided on a metal plate that attaches to a plastic grip plate 349 that define the grip plate assembly 344. In other embodiments, the grip plate assembly 344 is a unitary component made of metal. The grip plate assembly 344 may further include a channel 347 for receiving the sensor power cable 112 and allow the sensor power cable 112 to pass through the grip plate assembly 344.

[0032] As stated above, the swivel coupler nut 110 threadedly engages the threaded tube 126 of the locking refill dock 108. An anti-cross-thread plate 320 may be seated within a recess of the swivel coupler nut 110. The swivel coupler nut 110 further includes a shaft 130 that slidably receives a down tube 322. As described in more detail below, the down tube 322 is operable to, among other things, couple the soap reservoir bag assembly 350 and the soap reservoir 120 to the nozzle 104. One or more gaskets may be provided on the shaft 130 to prevent soap leakage between the shaft 130 and an inner surface of the down tube 322.

[0033] A housing 338 of the electronics assembly 122 includes a tube receiving opening 336 for receiving the down tube 322. The housing 338 of the electronics assembly 122 may comprise two halves that are secured together by screws such that the down tube 322 and the shaft 130 are captured by the housing 338 within the tube receiving opening 336.

[0034] The reservoir bag assembly 350 comprises a reservoir bag 354, a reservoir coupler 352 and a soap reservoir sleeve 356. The reservoir bag 354 is permanently affixed to the reservoir coupler 352, such as by a snap fit, for example. However, other coupling methods may be used. The soap reservoir sleeve 356 may be provided to prevent a soap tube 342 running from the nozzle 104 to the reservoir bag 354 from becoming bent within the soap reservoir 120. The reservoir bag assembly 350 may be coupled to a bottom end of the down tube 322 by a snap feature between the bottom end of the down tube 322 and the reservoir coupler 352.

[0035] A push rod 332 for providing the dispensing of soap is disposed within the down tube 322 and coupled to the pump 101. The down tube 322 has an aperture 334 for receiving a pivot arm 328 that pushes the push rod 332 up and down to activate the pump to dispense foam soap, as described in more detail below. The soap tube 342 is held by the push rod 332 and extends into the soap reservoir 120.

[0036] FIGS. 4-8 illustrate various views of the push rod 332, which may be fabricated from molded plastic. The push rod 332 both maintains the soap tube 342 and pushes the pump within the nozzle 104. As best shown in FIGS. 6 and 7, the push rod 332 rod includes groove features 604 that hold the soap tube 342 in place next to the push rod 332. The soap tube 342 may fit within the groove features 604 by an interference fit, for example. The push rod 332 further includes an upper flange 608 and a lower flange 610 that engage an interior surface of the down tube 322.

[0037] An arm aperture 602 is positioned between the upper flange 608 and the lower flange 610 of the push rod 332 that receives the pivot arm 328 (see FIGS. 3 and 11). As shown in FIG. 8, the arm aperture 602 is shaped to receive the pivot arm 328. In the example embodiment, the arm aperture 602 includes a first opening 802 and a second opening 804, wherein the first opening 802 is wider than the second opening 804 to allow the pivot arm 328 to be easily disposed within the arm aperture 602.

[0038] The pivot arm 328 is operable to lift the push rod 332 from within the arm aperture 602. When the push rod 332 is lifted, it activates the pump 101 and dispenses foam soap through the nozzle 104. In embodiments of the present disclosure, the pivot arm 328 is raised and lowered by a motor assembly 910 and a cam 906.

[0039] Referring now to FIG. 9, an exploded view of an example motor assembly 910 is illustrated. FIG. 10 illustrates an assembled view of the motor assembly 910. The motor assembly 910 includes a base housing 902, a cam 906, a gear 904 and a motor 914. The motor 914 is disposed within a motor frame 912 of the cover housing 908. The gear 904 is coupled to the cam 906. The motor has a small gear (not shown) that turns the gear 904 when the motor is activated. The gear 904 then turns the cam 906.

[0040] FIG. 11 illustrates an example pivot arm 328. The pivot arm 328 has two pivot protrusions 1104 on each side, a lift end 1106 and a cam engagement surface 1108. The two pivot protrusions 1104 are rotatably coupled to recesses (not shown) of an interior surface of the housing 338 of the electronics assembly 122 such that the pivot arm 328 may pivot up and down along an axis of rotation defined by a line through the two pivot protrusions 1104. The lift end 1106 is disposed through the aperture 334 of the down tube 322 (FIG. 3) and into the arm aperture 602 of the push rod 332 (FIG. 8). The cam engagement surface 1108 rests on a cam surface 1308 of the cam 906, which actuates the pivot arm 328 as it rotates.

[0041] When the sensor detects the hands of a user, a signal is generated, which passes through the sensor power cable 112 to the motor assembly 910. Receipt of the signal causes the motor 914, and thus the cam 906, to rotate and cause the pump 101 to dispense soap.

[0042] The pivot arm 328 may also include a spring hole 1110 for receiving an end of a spring (not shown). The spring is operable to return the pivot arm 328 back to a home position each time the cam 906 as completed a revolution. Over time, the pump located above the counter within the nozzle 104 may wear in a way that prevents the pivot arm 328 from returning to the home position, which can cause the pivot arm 328 to become stuck. The spring ensures that the pivot arm 328 returns to the home location so that it can perform its intended function of lifting the push rod 332.

[0043] FIG. 12, FIG. 13 and FIG. 14 illustrate an example cam 906. The cam 906 has two holes 1304 for receiving fasteners to secure the cam 906 to the gear 904. The cam 906 further includes a sloping cam surface 1308 that varies a height of the cam along its circumference. The cam engagement surface 1108 of the pivot arm 328 rests on the cam engagement surface 1108. As the cam 906 rotates, the cam engagement surface 1108 pivots the lift end 1106 up and down to lift and lower the push rod 332, which further activates the pump 101 within the nozzle 104. Thus, rotation of the cam 906 by the motor 914 causes the nozzle to dispense foam soap.

[0044] To refill the soap dispenser 102, the user will remove the nozzle 104 from the locking refill dock 108 (e.g., by rotating or pushing down and rotating the nozzle 104), which provides access to the soap tube 342. The user then disconnects the soap tube 342 from the pump 101. Additional soap may be provided to the reservoir bag 354 through the soap tube 342, for example. When the reservoir bag 354 is refilled, the user may reconnect the soap tube 342 to the pump 101, and then reconnect the nozzle 104 onto the refill dock 108.

[0045] It should now be understood that embodiments of the present disclose allow for a soap reservoir of a soap dispenser to be refilled from above the surface of a counter. This is enabled by a push rod that is activated by a pivot arm that is raised and lowered by a cam and a motor. The pivot arm is positioned through an aperture of a down tube that maintains the push rod. An end of the pivot arm is disposed within an arm aperture of the push rod, and is operable to lift and lower the push rod. The cam surface is sloped to raise and lower the pivot arm as the motor rotates.

[0046] As used herein, the singular forms a, an and the include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a component includes aspects having two or more such components unless the context clearly indicates otherwise.

[0047] While particular embodiments have been illustrated and described herein, it should be understood that various other changes and modifications may be made without departing from the spirit and scope of the claimed subject matter. Moreover, although various aspects of the claimed subject matter have been described herein, such aspects need not be utilized in combination. It is therefore intended that the appended claims cover all such changes and modifications that are within the scope of the claimed subject matter.

[0048] It will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments described herein without departing from the scope of the claimed subject matter. Thus, it is intended that the specification cover the modifications and variations of the various embodiments described herein provided such modification and variations come within the scope of the appended claims and their equivalents.