S&F Ref: P015762 AUSTRALIA PATENTS ACT 1990 INNOVATION PATENT SPECIFICATION Name and Address Calfarme Australia Pty Ltd, of Applicant: an Australian Company (ACN) 107 399 235, of Unit 42, 55 Norman Street, Peakhurst, New South Wales, 2210, Australia Actual Inventor(s): Boon Lye Paul Neo Address for Service: Spruson & Ferguson St Martins Tower Level 35 31 Market Street Sydney NSW 2000 (CCN 3710000177) Invention Title: A dispenser unit The following statement is a full description of this invention, including the best method of performing it known to me/us: 5843c(5812191 I) - 1 A DISPENSER UNIT Technical Field of the Invention The present invention relates generally to dispensing units and, in particular, to s foam soap dispensing units. Background Foam soap dispensing systems are common and popular, as foam soaps provide effective cleansing using less soap than liquid or solid soaps. Many foam soaps can be absorbed into the skin and do not require washing or rinsing, and thus save water. 10 Disinfectant foam soaps are popular, as cleansing can be provided through the foam without use of water in areas such as hospitals, public bathrooms or laboratories. Foam soap dispensers generally require a user to press downwardly on a dispenser to operate a pump to draw liquid soap upwardly, and expel the liquid soap from the pump as foam. Such are typically bench mounted or freestanding. Freestanding units 15 may be prone to damage, as such unit can be removed from a surface on which they are placed. For reasons of hygiene, these foam dispensers are likely unpopular in areas such as hospitals, laboratories and public bathrooms. Such foam dispensing systems are also often costly to maintain and prone to leakage. A need therefore exists for a foam dispenser which is inexpensive to maintain, 20 unlikely to leak, and suitable for use in areas such as hospitals, public bathrooms, and laboratories. Summary According to a first aspect of the present disclosure, there is provided a dispensing unit, the unit comprising: -2 a reservoir configured to contain a volume of liquid detergent exposed to atmosphere; a pump positioned beneath a base of the reservoir, configured to dispense foam; a conduit having a proximal end coupled to an input of the pump, the conduit 5 extending upwardly from the base and curved such that a distal end of the conduit is positioned substantially adjacent to the base; and an operational mechanism comprising an actuator and a motorised unit, wherein the actuator is configured to activate the motorised unit to operate the pump to transport a portion of the liquid from the reservoir through the conduit to an outlet of the pump by 1o which the portion is dispensed as foam. A second aspect of the present disclosure provides a method of preparing a dispensing unit, the method comprising: sealing an air inlet of a foam pump, and assembling the pump, a reservoir of liquid detergent, a conduit and an operational 15 mechanism to form a dispensing unit according to the first aspect. Other aspects of the invention are also disclosed. Brief Description of the Drawings At least one embodiment of the present invention will now be described with reference to the drawings, in which: 20 Fig IA shows a front view of an embodiment of a dispenser unit; Fig. 1B shows the unit of Fig. IA containing liquid soap; Fig. 2A shows a front cross-sectional view of the container 110 of Fig. IA; Fig. 2B shows a top view of the container 110; Fig. 3A shows an exploded front view of the pump assembly 130 of Fig. I A; 25 Fig. 3B shows a front cross-sectional view of the pump assembly 130; -3 Fig. 4 shows an exploded view of the conduit 120 of Fig. IA; Fig. 5A shows a bottom view of the operational mechanism 140 of Fig. 1A; Fig. 5B shows a front view of the operational mechanism 140; Fig. 5C shows a top view of a motor unit 504 of the operational mechanism 140; 5 Fig. 5D shows a side view of Fig. 5C; Fig 5E shows a simplified circuit of a motor 530 of Fig. 5C; and Fig. 6 shows a front view of the dispensing unit 100 with a casing 600. Detailed Description including Best Mode Where reference is made in any one or more of the accompanying drawings to 10 features, which have the same reference numerals, those features have for the purposes of this description the same function(s) or operation(s), unless the contrary intention appears. Overview Fig. 1 A shows an embodiment of a foam dispensing unit 100 having a backplate 102, a container 110, a conduit 120, a pump assembly 130 and an operational mechanism is 140. The backplate 102 is substantially rectangular, and is preferably formed such that the unit can be affixed to a vertical surface such as a wall. The backplate 102 may be adapted for attachment to a wall by a mechanism such as plurality of screw threads 104. In other embodiments a mechanism such as recesses, grooves, gluing contacts or hooks (not shown) may be provided on the backplate 102 for attachment to a surface. 20 As seen in Fig. IA, the container 110 is positioned on a front surface 103 of the back plate 102. The conduit 120 protrudes through a base of the container 110, and connects the base of the container 110 to the pump assembly 130. The pump assembly 130 protrudes from the base of the container 110, in a position underneath the container 110, and is generally central to the operational mechanism 140. The mechanism 140 is 25 positioned underneath the container 110 and behind the pump assembly 130. The -4 container 110 and the mechanism 140 may be attached to the back plate 102 by techniques known in the art such as gluing, snap-fit mechanisms (not shown), screw mechanisms (not shown) and the like. As shown in Fig. I B, the container 110 is configured as a reservoir of liquid 112, 5 which is preferably a diluted detergent or soap substance. Container The container 110 is a substantially box-like container. The container 110 is preferably manufactured of a durable plastics substance, which is preferably substantially transparent, such that a user can see contents thereof, and user or maintainer can ascertain 1o if the container 110 requires refilling. As shown in Figs. 2A and 2B, the container 110 comprises side walls 202, a top surface 204, a lower surface or base 206 and front and back surfaces 208. A slot 210 is provided in the top surface 204 such that inner surfaces of the container 110 are exposed to surrounding atmosphere. In some embodiments, a mechanism such as a cap may be is provided to close the slot 210. The slot 210 allows the user or maintainer of the unit 100 to insert a quantity of liquid inside the container 110. A cylindrical wall 212 extends generally downwardly from the surface 206 to provide a cylindrical opening 214 in the surface 206. The wall 212 has a diameter configured such that the pump assembly 130 can be attached thereto. A screw thread 220 20 is provided on an outer surface of the wall 220, as a mechanism by which the pump assembly 130 may be attached thereto. In some embodiments, attachment of the assembly 130 to the container 110 may be provided by means such as snap-fit grooves, notches, ledges, gluing, and the like. In the assembled unit 100, the opening 214 is closed by the pump assembly 130 25 and the conduit 120, thereby preventing liquid from flowing out of the opening 214. The -5 slot 210 provides contact to external atmosphere to any reservoir of liquid contained inside the container 110. The liquid contained within the container 110 therefore absorbs an amount of atmospheric air by simple exposure. If a cap is used to close the slot 210, the cap should preferably not hermetically seal the slot 210. 5 The slot 210 also allows atmosphere to enter the container 110 to balance pressure within the container 100 following operation of the pump 130. Deformation of the container 110 due to atmospheric pressure following repetitive pump use is thus prevented. Pump Assembly 10 Fig. 3A shows a front view of a pump 300 of the pump assembly 130. The pump 300 is a foam dispensing pump, similar to that disclosed in International Patent Publication No. WO/2009/038454. The pump 130 has a cylindrical body 302, and a cylindrical dispensing nozzle 304. The nozzle 304 has a narrow diameter than the body 302 and protrudes downwardly centrally from the body 302. An output end of the nozzle i5 304 tapers to a mesh net 306 provided thereon. Foam is dispensed from the pump through the mesh 306. The pump 300 operates on similar principals to standard foam pumps, such as that disclosed in International Patent Publication No. WO/2009/038454. Pumps such as those disclosed in WO/2009/038454 are normally operated in an upright position, above a 20 reservoir of liquid soap, where a user presses down on an actuator of the pump so that liquid is drawn upwardly into the pump. Such pumps normally contain an air inlet, such as a hole 308 in a surface of the body 302, as shown in Fig. 3A. The air inlet permits air to mix with the liquid detergent to cause foam to be discharged from the pump. However, in this embodiment of the unit 100, the hole 308 is sealed by the 25 manufacturer of the unit 100. A plastics or resin substance can be used to seal the hole -6 308. As the pump 300 is used in an inverted position (such that the pump 300 is underneath the container 110), sealing the hole 308 allows for decreased leakage of liquid from the unit 100 through the pump 300. An input valve (not shown) is provided in an upper surface 312 of the pump 300, through which liquid detergent can be provided to the 5 pump 300. The pump 300 operates when the nozzle 304 is pushed or pressed towards and into the body 302. Operation of the pump creates a vacuum in an area surrounding the pump input, such that balancing of pressures thereafter sucks a volume of the liquid into the pump 300, similarly to operation described in WO/2009/038454. The volume of 10 liquid is dispensed as foam from the nozzle 304 through the mesh 306. In order for the pump 300 to operate correctly, liquid detergent provided for use with the pump is preferably diluted in a ratio of at least 1:1 with water, with a ratio of about 5:1 for detergent to water most preferable. The pump assembly 130 also comprises a pump housing 311, as shown is assembled in Fig. 3B. The housing 311 comprises a casing 314 and an output stage 316. The casing 314 has an inverted cylindrical cap shape, from which a tube-like extension 318 extends generally downwardly. Ridges 320 are provided on an inner surface of the casing 314, such that the casing 314 can be attached to the container 110 by screwing the casing to the wall 212, and thus engaging the ridges 320 with the screw threads 220. The 20 engagement of the ridges 320 with the screw threads 220 preferably provides a watertight seal with the wall 212 to prevent leakage of liquid soap therethrough. The casing 314 is formed such that the pump 300 can be contained therein. The nozzle 304 protrudes into the extension 318. The output stage 316 is attached to the nozzle 316 such that the mesh 306 is adjacent to an opening 320, and foam created the 25 pump 300 is dispensed therethrough. The housing 311 may be manufactured to -7 irremovably contain the pump 300, or to hold the pump 300 by gravity wherein the body 302 of the pump 300 lies on a base of the casing 314, as in Fig. 3B. In some embodiments a technique such as snap-fit fittings, screw-threads or the like may be provided in the casing 314 and/or on the pump 300 such the pump 300 may be removably contained in 5 the casing 314. A manufacturer of the unit 100 may also attach a spring 310 to the input of the pump. The spring 310 is positioned between the conduit 120 and the pump 300, and may provide smooth operation of the pump, as discussed hereafter. Conduit 10 As shown in Fig. 4, the conduit 120 comprises a hose 402 and a coupling device 404. The various components discussed above may be manufactured separately and supplied as an assembled unit. Manufacturing techniques for plastics materials such as injection moulding, laser cutting or combinations thereof may be used for each component, or for the complete conduit. is The coupling device 404 is preferably formed with a hollow, inverted funnel-like shape, comprising a body 405 from which a hollow cylindrical neck 406 extends upwardly and outwardly. The neck 406 also extends inside the body 405, and narrows to form an output pipe 408. The neck 406 has a diameter of size such that a proximal end 410 of the hose 402 can be inserted therein. The body 405 has a diameter such that the 20 coupling device can be secured to the pump assembly 130 by means such as a snap-fit, screws or gluing to the top surface 312 of the pump 300. The body 405 is preferably attached to the assembly 130 in a watertight manner, to prevent leakage from a liquid reservoir in the container 110. In the unit 100, the pump assembly 130 is attached to the container 110, and the 25 pipe 408 protrudes into the input of the pump 300. The hose 402 protrudes upwardly -8 from the neck 406 of the coupling device and curves to a distal end 418, positioned at a similar height to the neck 406, as seen in Fig. IA. Therefore, in an assembled unit 100, the coupling device 404 is coupled to the pump assembly 130 into the opening 214, and the hose 402 extends upwardly from the neck 406 into the container 110 such that the 5 distal end 418 is adjacent to a base of the container 110. The distal end 418 is submerged in any liquid reservoir held in the container 110, as seen in Fig. I B. Motor Compartment As shown in the bottom view of Fig. 5A, the operational mechanism 140 is seen to be substantially U-shaped, with a protruding motor unit 504, a protruding battery 1o section 506 and a recessed section 508. A back surface 502 of the may be configured to for attachment to the backplate 102, by means discussed hereinbefore. A lever 510 protrudes substantially outwardly from an inside surface of the recessed section 508. The lever 510 has a pronged, U-shaped end 511. An actuator 512 is provided in a bottom surface 516 of the mechanism 140. In some embodiments, an indicator bulb 518 and an is activation pin 520 may be provided on the protruding unit 504 and 506. A removable door 514 to the battery compartment 514 may also be provided. The battery compartment 406 contains at least one battery (not shown) such as alkaline or lithium batteries and the like, such as AA batteries. In embodiments where the door 514 is provided, such batteries can be replaced by an owner or maintainer of the unit 20 100. The actuator 512 is desirably a motion sensor which detects user operation and operates the motor unit accordingly. The motion sensor 512 may be a short-range passive infra-red or ultrasonic sensor or the like, preferably having an operating range about 10 cm to 15 cm. The motion sensor 512 provides at least one control signal to a motor 25 contained within the motor unit 504, as described hereafter. The motion sensor 512 is -9 provided power by the at least one battery of section 506. In other embodiments, the actuator may be a button, a lever, or the like. The sensor 512 can scan for, and sense, motion in a given space surrounding the sensor 512, for example if a user places a hand in or near that space. The sensor 512 may 5 scan the surrounding space constantly as long as power is supplied thereto from the battery compartment 506. In some implementations, the unit 504 may contain power saving circuitry to limit the sensor 512 to scanning the given area periodically after a specific time period, such as 100 ms or 250 ms. As illustrated in Fig. 5B, the lever 510 protrudes from a slot 522 provided 10 centrally in a front surface of the section 508 of the mechanism 140. The lever 510 is shown in a resting position in Fig. 5B, wherein the lever 510 is adjacent to a lower edge of the slot 522. In the unit 100, the resting position of the lever 510 is positioned directly underneath the output 316 of the pump assembly 130. The lever 510 is positioned in the unit 100 such that upward motion of the lever 510 pushes the output 316 upwards, is depressing the nozzle 304 of the pump 300 into the body 302. The motor unit 504 contains an electrically-driven internal DC motor 530, formed of size to fit within the unit 504 as shown in Fig. 5C. The at least one battery of the battery section 506 provides power to energise the motor 530 through provided connecting terminals (not shown). 20 The motor 530 is attached to a series of gears 532, as shown in Figs. 5C and 5D. The gears 532 are connected to a disc 534, which is coupled to the lever 510 by a U shaped connecting lever 536. Action of the internal motor 530 causes rotation of the gears 532 and disc 534, and thus lowers or raises the connecting lever 536 and, in turn, the lever 510. In some implementations, a mechanism other than gears may be used, such as a 25 pulley mechanism. Connection of the lever 510 to the connecting lever 536, the disc 534 -10 and the gears 532 allows the lever 510 to be positioned at a suitable distance from the motor 300 to protrude through the slot 522. The motor 530 is connected to battery B, stored in the battery section 506, as illustrated in Fig. 5E. A switch matrix 540 may be provided. The switch matrix 540 s controls the connection of the battery B to the motor 530 according to a control signal 542 provided by the actuator 512. The control signal is generated by the motion sensor 512 and input to the switch matrix 540. The switch matrix 540 can be implemented using digital logic, discrete components, integrated circuits, and the like. If the control signal 542 indicates that motion has been detected in the range of 10 the motion sensor 512, the switch matrix 540, if used, connects the battery B to the motor 530 with a given polarity to energise the motor 530 to rotate. Operation of the motor 530 causes the gears 532 to operate such that an outer gear 535, and thus the disc 534, moves though one full rotation of 3600. The lever 510 is thus raised from, and returned to, the resting position. The raised position is determined by positioning of the disc 534 on the is gear 535. Upon completion of one full rotation of the disc 534 on the gear 535, the lever 510 is restored to the resting position. In some embodiments, a simple single switch and timer circuit, or similar arrangement, may be used instead of the switch matrix. In other embodiments, the lever 510 may be raised by rotation of the motor 520 in a first direction, then lowered by rotation of the motor 520 in the opposite direction, as controlled by the 20 switch matrix 540. In some embodiments, the switch matrix may simply disconnect the battery B from the motor 530 after a given time period has elapsed following raising of the lever 510. The lever 510 may then be returned to the resting position through gravity. Use - 11 If a user places a hand in the given area surrounding the assembled unit 100, operation of the motor 530 as described above raises the lever 512 and pushes the output 316 of the pump assembly 130 upwards. The slot 522 has a height such that the lever 510 is raised to a sufficient degree to operate the pump 300 by depressing the nozzle 316 into 5 the body 302 of the pump 300. Operation of the motor 530 subsequently lowers the lever 512 to allow the nozzle 306 to release. In embodiments where the spring 310 is used, the pump 300 may also be pushed upwardly to compress the spring 310, and the nozzle 316 depressed sufficiently to operate the pump 300. Decompression of the spring 310 allows the pump and lever to return to resting position with greater speed to Operation of the pump creates a vacuum in a valve of the pump, which causes a portion of liquid soap in the container 110 to be sucked from the distal end 418, through the proximal end 420 and the pipe 408 to the input of the pump 300. The pump 300 dispenses the liquid soap as foam through the mesh 306 and the casing 316. The U shaped end 511 of the lever does not block the casing 316 of the pump assembly 130, and 15 allows the foam to be dispensed through the casing 316 and fall due to gravity in to the hand of a user held underneath the casing 316. Atmospheric air may be dissolved into the liquid detergent upon mixing to the desired ratio with water, and/or on pouring liquid detergent into the container 110. The container 110 and the hose 402 also contain atmospheric air when empty prior to initial 20 use. Dissolved air in a reservoir of liquid detergent is sufficient to create foam. In some embodiments, the operational mechanism 140 will have an indicator bulb 518, as shown in Figs. 5A and 5B. The indicator bulb 518 receives energy from the battery in the battery section 506. The bulb 518 preferably has control circuitry which provides energy to the bulb 518 from the batteries at regular interval such that the bulb - 12 flashes on and off regularly. A user or maintainer of the unit 100 can therefore determine easily if batteries in the section 506 are depleted and require changing. In some embodiments of the dispensing unit 100, the motor unit 130 may also have an activation pin 520, as seen in Fig 5A. In such instances, the dispensing unit 100 5 also has an outer casing 600, as shown in Fig. 6. The casing 600 may be adjustably attached to the backplate 102 by a mechanism such as a hinge, a snap fit, clips, and the like. The adjustable attachment allows the casing 600 to be attached to the unit 100 in a closed position, enclosing the container 110, and partially enclosing the pump assembly 130 and operational mechanism 140, as shown in Fig. 6. In the closed position the casing to presses on the activation pin 520. The activation pin 520 is a switch which controls delivery of energy from batteries in the section 506 to the actuator 512, the motor 530 and, if appropriate, the bulb 518. If the casing 600 is on the closed position, the activation pin 520 closes a switch and power is provided from the section 506 to the unit 504. The adjustable fit of the casing 600 allows for an open or removed position of 15 the casing 600, such that a user or maintainer of the unit 100 can access the container 110, the conduit 120, the pump assembly 130 and the operational mechanism 140 for maintenance, refilling, replacement of batteries, and the like. The activation pin 520 will disconnect the section 506 from the unit 504 when the casing 600 is not in the closed position, preventing unnecessary use of the batteries. If a casing 600 is used, the bulb 518 20 is preferably visible through, or uncovered by, the casing 600 such a user can easily ascertain if batteries in the section 506 are depleted. The actuator 512 is accessible when the casing 600 is closed, such that the unit 100 can be used. An owner or maintainer of the unit 100 can refill the container 110 when necessary without buying specific sealed cartridges of liquid soap, thus cutting expenses and 25 decreasing in waste products such as empty cartridges. The owner or maintainer can -13 dilute a standard liquid detergent to a suitable ratio, decreasing expenses. The sealed hole 308 allows the pump 300 to become less likely to leak. As a user is not required to touch the unit 100 for foam to be dispensed the unit 100 is suitable for use in areas such as public bathrooms and hospitals for hygiene reasons. As s the hole 308 is sealed, liquid soap is less likely to leak from the dispenser 100. Disinfectant liquid soap, and/or alcohol-free soap may be used. As such foam can be absorbed into the skin of a user, the dispenser may be suitable for providing cleansing in an area where water is not supplied. The backplate 102, container 110, casing 311, conduit 120, and casing 600 are io preferably manufactured of durable plastics materials such as polyurethane, polyethylene, nylon, and preferably injection mouldable plastics such as ABS and the like. Such components of the dispensing unit 100 may be formed by any of a number of manufacturing techniques including injection moulding and laser cutting, or combinations of these. 15 Many foam dispensers often use a sealed cartridge to provide liquid soap for foaming. The required sealed cartridges are often of design specific to a single dispenser model or type, and can be expensive for businesses or users to replace when emptied. As the dispensing unit 100 can be refilled, expense to an owner or user is decreased. As the unit 100 does not require a user to push downwardly on a pump actuator, the 20 unit 100 is unlikely to become dislodged from a vertical surface such as a wall to which the unit 100 is attached via the backplate 102. Attaching the unit 100 to a surface such as wall makes theft or damage of the unit 100 less likely. The foregoing describes only some embodiments of the present invention, and modifications and/or changes can be made thereto without departing from the scope and 25 spirit of the invention, the embodiments being illustrative and not restrictive.
-14 In the context of this specification, the word "comprising" means "including principally but not necessarily solely" or "having" or "including", and not "consisting only of'. Variations of the word "comprising", such as "comprise" and "comprises" have correspondingly varied meanings.