Sequentially activated multi-diaphragm foam pumps, refill units and dispenser systems

Abstract

A foam dispenser includes a housing, a drive motor, and a foam pump. The foam pump includes a pump housing, and a molded multi-chamber diaphragm. The molded multi-chamber diaphragm includes a liquid pump diaphragm having a liquid pump stem and two or more air pump chambers each having an air pump stem. The length of the liquid pump stem is longer than the air pump stem. The foam pump further includes one or more outlet valves, a mixing chamber, an outlet for dispensing foam wherein the outlet is in fluid communication with the foam cartridge; and an actuator for sequentially actuating the liquid pump chamber and the two or more air pump chambers, wherein there is lost motion between the actuator and the liquid pump diaphragm.

1 -. 20  (canceled) 
     
     
         21 . A foam dispenser comprising:
 a housing;   a refill unit connector for placing a refill unit in fluid communication a foam pump;   wherein the refill unit connector is a drip free connector;   a drive motor;   the foam pump coupled to the drive motor;   the foam pump having
 a liquid pump chamber; and 
 two or more air pump chambers; and 
 one or more outlet valves; 
 wherein the liquid pump chamber has a smaller volume than the two or more air pump chambers; 
   a mixing chamber downstream of the one or more outlet valves for mixing foamable liquid from the liquid pump chamber with air from each of the two or more air pump chambers;   wherein the liquid pump chamber pumps a shot of liquid into the mixing chamber; and   wherein the two or more air pump chambers each pump a shot of air into the mixing chamber to mix with the shot of liquid;   wherein the mixing chamber includes a foam cartridge;   an outlet for dispensing foam wherein the outlet is in fluid communication with mixing chamber; and   an actuator for sequentially actuating the liquid pump chamber and the two or more air pump chambers to dispense foam.   
     
     
         22 . The dispenser of  claim 21  further comprising a refill unit, wherein the refill unit comprises a mating connector for connecting to the refill unit connector. 
     
     
         23 . The dispenser of  claim 21  wherein the foaming cartridge comprises two screens. 
     
     
         24 . The dispenser of  claim 21  wherein the motor and pump are configured to consume between 0.5 and 1.3 joules/12 milliliters of foam output. 
     
     
         25 . The dispenser of  claim 21  wherein the foam pump is configured to produce between 1 and 2.5 milliliters/second of foam. 
     
     
         26 . The dispenser of  claim 21  wherein the outlet has a flared tip. 
     
     
         27 . The dispenser of  claim 21  wherein the outlet has a length of between 0.3 inches and 1.25 inches. 
     
     
         28 . The dispenser of  claim 21  further comprising a throttle mechanism to throttle the liquid flow. 
     
     
         29 . The dispenser of  claim 28  wherein the throttle mechanism comprises a restrictor. 
     
     
         30 . The dispenser of  claim 29  wherein the restrictor comprises a restrictor valve. 
     
     
         31 . The dispenser of  claim 28  wherein the throttle mechanism comprises a liquid chamber that has a smaller diameter than the diameter of the two or more air pump chambers. 
     
     
         32 . The dispenser of  claim 28  wherein the throttle mechanism comprises lost motion. 
     
     
         33 . A foam dispenser comprising:
 a housing;   a refill unit connector for placing a refill unit in fluid communication a foam pump;   wherein the refill unit connector is a drip free connector;   a power supply;   wherein the power supply has a supply voltage of between  3  and  9  volts;   a drive motor;   the foam pump coupled to the drive motor;   the foam pump having
 a liquid pump chamber; and 
 two or more air pump chambers; and 
 one or more outlet valves; 
 a mixing chamber downstream of the one or more outlet valves for mixing foamable liquid from the liquid pump chamber with air from each of the two or more air pump chambers; 
   wherein the liquid pump chamber pumps a shot of liquid into the mixing chamber; and   wherein the two or more air pump chambers each pump a shot of air into the mixing chamber to mix with the shot of liquid;   wherein the motor and pump are configured to consume less than 1.3 joules of energy per 12 milliliters of foam output;   wherein the mixing chamber includes a foam cartridge;   an outlet for dispensing foam wherein the outlet is in fluid communication with mixing chamber; and   an actuator for sequentially actuating the liquid pump chamber and the two or more air pump chambers to dispense foam.   
     
     
         34 . The foam dispenser of  claim 33  wherein the motor and pump are configured to consume less than 1.0 joules/milliliter of foam. 
     
     
         35 . The foam dispenser of  claim 33  wherein the shot of liquid from the liquid pump chamber and the shots of air from the two or more air pump chambers comprise one revolution of the foam pump and wherein each dose of foam comprises  3  or more revolutions of the foam pump. 
     
     
         36 . The foam dispenser of  claim 33  wherein the shot of liquid from the liquid pump chamber and the shots of air from the two or more air pump chambers comprise one revolution of the foam pump and wherein each dose of foam comprises  10  or less revolutions of the foam pump. 
     
     
         37 . A foam dispenser comprising:
 a housing;   a refill unit connector for placing a refill unit in fluid communication a foam pump;   wherein the refill unit connector is a drip free connector;   a power supply;   a drive motor;   the foam pump coupled to the drive motor;   the foam pump having
 a liquid pump chamber; and 
 two or more air pump chambers; and 
 one or more outlet valves; 
 a mixing chamber downstream of the one or more outlet valves for mixing foamable liquid from the liquid pump chamber with air from each of the two or more air pump chambers; 
   wherein the liquid pump chamber pumps a shot of liquid into the mixing chamber; and   wherein the two or more air pump chambers each pump a shot of air into the mixing chamber to mix with the shot of liquid;   wherein the mixing chamber includes a foam cartridge;   an outlet for dispensing foam wherein the outlet is in fluid communication with mixing chamber; and   an actuator for sequentially actuating the liquid pump chamberr and the two or more air pump chambers to dispense foam; and   wherein the outlet is configured to generate a foam output has a foam density of between 0.08 and about 0.125 grams per milliliter of foam.   
     
     
         38 . The foam dispenser of  claim 37  wherein the foam has an air to liquid ratio of at least 6 to 1. 
     
     
         39 . The foam dispenser of  claim 37  wherein the foam dispenser dispenses 1.2 ml of liquid in the form of foam in 0.36 seconds. 
     
     
         40 . The foam dispenser of  claim 37  motor and pump are configured to consume less than 1.3 joules of energy per 12 milliliters of foam output.