Note: Descriptions are shown in the official language in which they were submitted.
WO 97/05056 2 2 0 0 B 6 4
PGTIUS96/12202
Title of the Invention
a 5
Rechargeable Dispensers
Meld of the Invention
This invention relates to rechargeable dispensers, in particular rechargeable
spray
bottle dispensers, that can be recharged or refilled. Specifically, the
present invention
is particularly directed to spray bottle dispensers having a reservoir
containing chemical
and a refillable reservoir containing water or solvent associated with the
spray bottle
dispensers so that the spray bottle dispensers can be recharged by simply
adding water
or solvent to the refillable reservoir.
In addition, the present invention is directed to bottles and adapters for use
with
the rechargeable dispensers according to the present invention.
Background of the Inveirtion
The use of spray bottles for dispensing chemical reagents (e.g., water,
cleaners,
soaps, insecticides, hair spray, etc.) are well-known. Due to regulations
limiting the
amount of volatile organic carbons (VOCs) released in the atmosphere, products
~ originally contained and dispensed through aerosols are currently being
replaced with
spray bottles.
WO 97/05056 2 2 0 0 8 6 4 PCT~S96/12202
-2-
Bottlers of chemical reagents typically market their products by purchasing
separately empty plastic container bottles and sprayheads. The bottlers then
fill,
assemble, and label the completed spray bottle packages for delivery to
retailers.
Consumers purchase the filled spray bottles at the point-of sale, and then
consume the
chemical contents of the spray bottle. Most consumers dispose of the spray
bottles upon
the one time use of the contents of the spray bottles. However, the spray
bottles are still
fully functional with respect to containing and dispensing chemical reagents,
since the
plastic bottles are substantially chemically resistant and the sprayheads
remain fully
functional after consuming the contents. Conventional point-of sale type spray
bottles
m
_.. .:m u~ rcx;ndrgea numerous times wiih Chemical concentrate and water
(i.e., at least 10
times, possibly 100 times while maintaining full operation).. Thus, consumers
dispose
of large quantities of reusable product (i.e., empty spray bottles) having
high utility
value.
15 In today's environment of numerous regulations to control pollution, and
consumer and industrial awareness for conserving resources and reducing
landfill waste,
it is highly desirable to promote the reuse of products that maintain their
utility, and
dispose of only products that no longer have any utility. Many hottlers are
currently
selling concentrate in various sized containers to allow consumers to recharge
point-of
20 sale type spray bottles with their particular concentrates. However, many
consumers are ,
WO 97/05056 2 2 0 0 8 6 4 PCT/US96/12202
-3-
unwilling to adopt such methods apparently due to some inconvenience in the
steps
involved with the recharging process of the spray bottles. In particular,
there is some
inconvenience in removing the sprayhead, opening the chemical concentrate
container,
pouring the chemical concentrate into the empty spray bottle, adding water,
and re-
attaching the sprayhead to the bottle. Further, consumers apparently lack
interest in
recharging spray bottles due to some reluctance based on their inexperience
and
knowledge in mixing and diluting liquids, which is done by processing chemists
for the
bottlers. In addition, recharging is usually a messy undertaking due to
spillage of
chemical concentrate while pouring from one container to the other,
overfilling,
~.~r.;,~o.,~.~11.. L......t.:__ _ .~_ v _.
-- ~awaw.uaolly AtIIJVJ~111~' ever u1e DOLLie being
filled due to its instability when unfilled, and other undesirable mishaps
that can occur,
that provide substantial inconveniences.
Importantly, sizeable containers (e.g., pint, quart, gallon, liter sizes) of
chemical
concentrate can be significantly hazardous to transport and handle by
consumers unaware
of the potent chemical properties of the chemical concentrates. Specifically,
chemical
spills of concentrate can damage items around the home including flooring,
carpeting,
countertop in kitchens and bathrooms, shelves, and other items the chemical
concentrate
WO 97/05056 PCT/US96/12202
2200864
-4-
could potentially come into contact with. Further, chemical concentrate can
impose a
significantly greater health risk to persons coming into accidental contact
therewith
potentially causing tissue burns and other damage.
Most impoa~antly, chemical concentrate imposes a great risk to children who
may accidentally ingest the chemical concentrate and become poisoned. Chemical
concentrate greatly increases the chance of permanent injury or death in this
regard to
children versus current diluted chemical reagents contained in point-of sale
type spray
bottles.
Summary of the Ine~ention
A first object of the present invention is to provide a rechargeable
dispenser, for
example, a spray bottle dispenser, having a chemical concentrate reservoir and
a water
or solvent reservoir associated with the spray bottle dispenser.
WO 97/05056 2 2 0 0 ~ G ~. PGTIUS96i12202
-5-
A second object of the present invention is to provide a rechargeable
dispenser,
for example, a spray bottle dispenser, having a chemical concentrate reservoir
and water
or solvent reservoir disposed within the spray bottle dispenser.
A third object of the present invention is to provide a rechargeable
dispenser, for
example, a spray bottle dispenser, comprising a bottle with a chemical
concentrate
reservoir and water or solvent reservoir.
A fourth object of the present invention is to provide a rechargeable
dispenser,
for example, a spray bottle dispenser, having a chemical concentrate reservoir
and a
refillable water or solvent reservoir.
A fifth object of the present invention is to provide a rechargeable
dispenser, for
example, a spray bottle dispenser, having a refillable chemical concentrate
reservoir and
a refillable water or solvent reservoir.
A sixth object of the present invention is to provide a dispenser comprising a
liquid chemical concentrate reservoir and a liquid solvent or dilutent
reservior.
WO 97/05056 2 2 0 0 8 6 4 pCT~S96/12202
-6-
A seventh object of the present invention is to provide a rechargeable
dispenser
comprising a liquid chemical concentrate reservoir and a liquid solvent or
dilutent
reservoir.
An eight object of the present invention is to provide a rechargeable spray
bottle
dispenser comprising a liquid chemical concentrate reservoir, a liquid solvent
or dilutent
reservoir, and a sprayhead in liquid communication with the reservoirs.
A ninth object of the present invention is to provide a rechargeable spray
bottle
dispenser comprising a refillable/non-refillable liquid chemical concentrate
reservoir, a
refillable solvent or dilutent reservoir, and a sprayhead in liquid
communication with the
reSCIVOlIS.
A tenth object of the present invention is to provide a rechargeable spray
bottle
dispenser comprising a bottle for containing solvent or dilutent, a liquid
chemical
reservoir disposed within the bottle, and a sprayhead in liquid communication
with the
bottle and reservoir.
An eleventh oject of the present invention is to pmvide products with chemical
contents using the dispensers of the above objects one through ten.
WO 97/05056 2 2 0 0 8 6 4 PCT/US96l12202
_7_
These and other objects can be achieved by the rechargeable dispenser, in
particular the spray bottle disg~enser according to the present invention.
The main concept according to the present invention is to provide a
rechargeable
dispenser, in particular a spray bottle dispenser package having at least one
supply of
chemical to allow the spray bottle dispenser to be recharged at least one
time. The
chemical can be in the form of a gas, liquid, semi-solid or solid.
Specifically, the
chemical liquid can be a one phase mixture, a two phase mixture, a dispersion
or any
other chemical reagent having liquid characteristics. The chemical semi-solid
can be in
the form of a slurry, paste, soled dispersed in a liquid that still exhibits
some liquid type
characteristics, and the solid can be in the form of powder, granules, tablet
or other solid
material form.
The chemical is preferably a concentrated chemical that is readily diluted
with a
solvent, in particular plain water. Preferably, the chemical can be
immediately diluted,
however, a chemical substance that can go into solution over a 24 hour or
longer period
of time can potentially be suitable for some applications.
The preferred embodiments of the present invention involve associating at
least
one quantity of chemical with the spray bottle dispenser itself. Specifically,
the chemical
WO 97/05056 2 2 0 0 8 6 4 PCT~S96/12202
_g_
is stored in some manner, and connected directly internally or externally to
the spray
bottle dispenser. However, the present invention is broader in scope to
include
packaging the chemical and spray bottle dispenser together (i.e., connected
indirectly) '
to be marketed at the point-of sale. In this embodiment of the invention, a
consumer
would purchase the package containing a supply of chemical and the spray
bottle
dispenser, separate at home the spray bottle dispenser that has been filled by
the bottler
from the package and store the chemical portion of the package separate from
the spray
bottle dispenser in the household. The user would then retrieve the stored
chemical upon
consuming the initial contents of the spray bottle dispenser for purposes of
recharging
the spray bottle dispenser.
The preferred embodiments of the invention store the at least one quantity of
chemical directly or indirectly inside or outside the spray bottle dispenser.
In the case
of an indirect connection to the spray bottle dispenser, a mechanical fastener
such as a
plastic strip connects an external chemical reservoir to the spray bottle
dispenser. In the
case of a direct connection, the chemical reservoir is directly connected
internally or
externally to the spray bottle dispenser. The most preferred embodiments store
the at
least one quantity of chemical inside the spray bottle dispenser, particularly
the bottle
portion, to fully contain any inadvertent spills or leakage of chemical
through the life of
the spray bottle dispenser. These most preferred embodiments provide
substantial
WO 97/05056
2 2 0 0 8 6 4 PGTIUS96/12202
-9-
advantages for handling, recharging and protecting household items from
contact with
chemical, and most importantly to prevent accidental ingestion by children.
This
particular point is especially important due to the much greater potency of
chemical
concentrate versus diluted chemical reagents currently being sold by bottlers
at point-of
The most preferred embodiments also utilize conventional spray bottle
dispenser
components including plastic bottles, plastic sprayheads, and plastic
downtubes. In order
to promote products incorporating the present invention, it is particularly
important to
utilize the standard components that are readily available and relatively very
inexpensive
due to the large quantities sold and consumed. Thus, an add-on chemical
reservoir for
storing the chemical is highly desirable.
The most preferred add-on type chemical reservoir is an insert received within
the
bottle portion of the spray bottle dispenser. This type of insert can be
manufactured
extremely cheaply in high volume while providing all the performance
characteristics
necessary for a safe and reliable product. Specifically, the insert can be
made with one
or more chambers or cells containing chemical that can be accessed in various
ways. For
example, the reservoir can be sealed with membranes that can be punctured with
an
instrument, in particular the tip of the downtube. Alternatively, the walls of
the chemical
WO 97/05056 2 2 0 0 8 6 4 PCT/(JS96/12202
- 10-
reservoir can be designed or configured so as to be readily burst upon
application of
external pressure to the chemical reservoir. Adding lines of weaknesses,
thinning of
walls and other means for locally weakening a portion of the chemical
reservoir can be
implemented for use in the present invention.
Alternatively, one or more of the components of the conventional spray bottle
dispenser (e.g., bottle portion, sprayhead portion, downtube) can be modified
to provide
the chemical reservoir. For example, the walls or bottom of the bottle portion
can be
modified, by molding a chemical reservoir in one or more sides of bottom of
the bottle
portion, the sprayhead portion can be provided with a chemical reservoir,
and/or the
downtube can be provided with an add-on chemical reservoir or the walls of the
downtube can be molded to provide a chemical reservoir. However, all of these
approaches will initially be substantially greater in cost due to the
modification of
conventional components not necessitated by the use of an insert according to
the present
invention.
The insert according to the present invention can take on many different forms
and configurations. A first preferred embodiment of the insert is defined by a
cylinder
having one or more chambers or cells disposed therein. The interior of the
cylinder can
be provided with one or more bisecting walls to define the chambers along the
length .
WO 97/05056 ~; ' PCTJUS9b112202
-11-
thereof. A plastic cylinder having one or more bisecting walls can be easily
extruded in
plastic. The top and bottom of the one or more chambers of the insert are
sealed by
upper and lower sealing membranes. The membranes can be films, foils,
composites of
films and foils, or any other suitable composite that is both chemically
resistant and
subject to being punctured readily by an instrument, in particular, the tip of
the
downtube, or can be made to burst.
The upper and lower sealing membranes can be connected to the insert by
bonding, adhesive bonding, thermal bonding, sonic welding, or suitable methods
for
forming a liquid tight seal (e.g., hermetic seal).
This embodiment of the insert can be marketed inside a filled spray bottle
dispenser at point-of sale. The downtube extends through an open chamber of
this insert
down into the lower portion of the bottle portion to access premixed chemical
reagent
added by the bottler during manufacture. After consumption of the chemical
reagent, a
user unscrews the sprayhead and lifts the downtube from the bottle portion.
The insert
is rotated so that one chemical reservoir is now positioned where the open
chamber was
previously positioned (i.e., now registered for being punctured by the
downtube). The
user then forces the tip of the downtube through the upper sealing membrane,
down
through the chamber, and then punctures the lower sealing membrane. Water can
be
WO 97/05056 PGT/US96/12202
22008b4
-12-
added through the open chamber of the insert before or after the step of
accessing the
chemical reservoir by puncturing with the downtube. This configuration allows
the
chemical to be always stored within the confines of the spray bottle
dispenser, and
minimizes the steps needed for recharging the spray bottle dispenser.
The consumer will experience little inconvenience in removing the sprayhead
and
downtube from the bottle portion, rotating the insert, puncturing the chemical
reservoir,
adding water through the open chamber of the insert, and reassembling the
sprayhead
portion to the bottle portion. Further, the chemical concentrate stored within
the insert
is extremely safe for handling and preventing accidental consumption by
children (i.e.,
a child would have to successfully unscrew the sprayhead portion from the
bottle portion,
fully remove the downtube from the bottle portion, and successfully puncture
the insert).
Further, even in the event of puncture of the insert by a child, the access
opening
through the upper sealing membrane would be sufficiently small to
substantially limit
spilling and containing most chemical from being easily ingested by a child.
Thus, the
present invention provides substantial safeguards over curnent methods of
selling large
quantities of chemical concentrate at the point-of sale, and subsequently
having the
consumer handle and mix the chemical concentrate in his or her home.
WO 97/05056 PCTlUS96/12202
-13-
This particular insert ~n have one, two, three, four or more separate chambers
or cells. For example, in the case of four cells, one cell would be an open
cell through
which the downtube is initially placed by the bottler during assembly when the
spray
bottle dispenser is provided with an initial charge of diluted chemical. Thus,
in this
example, there remains three cells that can be utilized as three separate
chemical
reservoirs. This four cell configuration would allow the user to initially
consume the
premixed diluted chemical reagents of the spray bottle dispenser, and then
recharge the
spray bottle dispenser three more times prior to consuming all the chemical
contained in
the spray bottle dispenser. If the consumer then disposed of the spray bottle
dispenser
at that point, this would provide a three time improvement over the current
practice of
consumers utilizing a spray bottle dispenser one time prior to disposal. Thus,
the
consumption of spray bottle dispensers could be reduced three-fold (i.e., one-
fourth the
waste) if fully implemented.
However, this invention can even provide for an even greater improvement over
current practices by consumers. Specifically, this insert can also be sold at
the point-of
sale as a separate item that could be added to conventional point-of sale type
spray bottle
dispensers having no inserts after the initial consumption of the contents, or
for use with
spray bottle dispensers having inserts according to the present invention
after the
complete chemical consumption of the inserts initially sold with the units.
WO 97/05056 2 2 ~ 0 8 6 4 PCT~s96/12202
i
-14-
This new system would greatly decrease the shipping weight and costs
associated
therewith, decrease retail shelf space for marketing the product, and most
importantly
greatly decrease the consumption and waste of plastic material. Specifically,
the volume
of plastic needed to make the four chamber insert described above would be a
small
fraction compared with the weight of plastic of four conventional spray bottle
dispensers
based on equal amounts of useable diluted chemical reagent. Further, the
insert when
the chemical is completely consumed has little utility value versus the
utility value of an
emptied conventional spray bottle dispenser that can be reutilized numerous
times.
Further, conventional spray bottle dispensers are substantially much greater
in cost to
produce relative to the insert according to the present invention, and would
conserve
significant labor and other direct and indirect costs associated with the
production of
conventional spray bottle dispenser components versus the insert according to
the present
invention. Further, the insert according to the present invention can readily
be recycled,
and could potentially be refilled if an adequate system were developed to
reprocess such
inserts, however, more than likely the inserts would be disposed of by
consumers based
on convenience factors.
A second embodiment of an insert according to the present invention involves
forming a strip of chemical reservoirs that can be disposed within the bottle
portion of
the spray bottle dispenser. The strip of chemical reservoirs can be made at
high speed,
WO 97/05056 2 2 0' 0 8 6 4 pCTNS96/12202
-15-
and would most likely be made in a continuous strip and cut to length when
completed
for insulation in each spray bottle dispenser. The strip type insert ran be
manufactured
by a high speed molding technique such as vacuum forming the chemical
reservoirs from
a plastic strip, filling the chemical reservoirs with chemical, and sealing
the chemical
reservoirs. This completed strap is then cut to length based on the number of
reservoirs
to be added to the spray bottle dispenser, and is preferably attached by
adhesive or other
technique to the inside surface of the bottle portion. The chemical reservoirs
made of
the plastic strip are made in such a manner so that the chemical reservoirs
can be
punctured by an instrument, in particular, the tip of the downtube, or can be
made to
burst by adding external pressure to the chemical reservoir. A user can burst
one or
more (i.e., one, two, three, etc.) of the chemical reservoirs to specifically
tailor the
concentration of the diluted chemical reagent. Thus, the concept according to
the present
invention allows the consumer some latitude in selecting concentration levels
currently
unavailable with conventional spray bottle dispensers.
In a third embodiment, a plurality of separate cylindrical chemical reservoirs
can
be added to the inside of the bottom portion. The cylinder chemical reservoirs
are
provided with an upper sealing membrane that can be punctured by an
instrument, in
particular the tip of the downtube. The cylinder reservoirs can be separate
units or
connected together by a strip, or by some other manner. The cylindrical
chemical
WO 97/05056 PCT/US96/12202
2200844
-16-
reservoirs are preferably located at the bottom wall of the bottom portion to
allow easy
access by the tip of the downtube during a puncturing operation.
In a fourth embodiment, cylindrical chemical reservoirs bridge the side walls
of
the bottle portion. The cylinder reservoirs are made so they can be burst by
simply
pressing together the walls at the location of the particular cylinder
reservoir.
In a fifth embodiment, separate donut-shaped chemical reservoirs are added to
a
conventional downtube. The donut-shaped reservoirs can be made so as to be
punctured
,.. _ .
m or ourst for chemical access. Alternatively, one or more small holes through
the inner
surface of the donut-shaped reservoirs can be provided and sealed by the
downtube itsclf
(adhesive can also be provided to insure adequate sealing). In this type of
arrangement,
the chemical inside the donut-shaped reservoir can be accessed by simply
pulling the
donut-shaped chemical reservoir off the downtube exposing the opening through
the inner
wall of the donut-shaped reservoir. The donut-shaped reservoir can be removed
by
unscrewing the sprayhead portion from the bottle portion, lifting the downtube
until the
lowermost donut-shaped reservoir is located at or near the opening of the
bottle portion,
holding the donut-shaped reservoir by the fingertips of one hand at the
opening to the
bottle portion, and then lifting with the other hand the downtube so as to
detach the
donut-shaped reservoir from the downtube, and then allowing the donut-shaped
reservoir
2200864
WO 97/05056 PGT/ITS96/12202
-17-
to drop into the bottle. Water is added before or after to dilute the
concentrate to form
the diluted chemical reagent.
In a sixth embodiment, an insert is provided with a plurality of reservoirs in
a
stepped and stacked array. T'tie top reservoir is thinner and deeper compared
with a
bottom reservoir that is wider and shallower. One or more reservoirs having
dimensions
in between that of the top and bottom reservoirs can be provided therebetween.
This
stepped and stacked arrangement allows easy access to any of the chemical
reservoirs by
an instrument, in particular the tip of the downtube for puncturing a membrane
sealing
each reservoir.
In a seventh embodiment, a plurality of reservoirs are provided in an insert
and
a stacked arrangement. Each reservoir is sealed at the top and bottom with a
sealing
membrane. A person using a spray bottle dispenser containing this insert
initially
punctures the upper and lower sealing membranes of the upper reservoir during
a first
recharging operation, punctures the upper and lower sealing membranes of the
middle
reservoir to access chemical in the middle reservoir during a second
recharging
operation, and does the same to the third chemical reservoir in the third
recharging
operation.
WO 97/05056 PCT/US96/12202
2200864
-18-
Another mode of the present invention is centered on utilizing liquid chemical
concentrate as the preferred source of chemcial concentrate. A preferred
embodiment
of this mode involves a rechargeable spray bottle dispenser having a liquid
chemical
concentrate reservoir to store one or multiple fills or refills of liquid
chemcial
concentrate. In a most preferred embodiment, the liquid chemical concentrate
reservoir
is located inside the spray bottle to safely and securely store the liquid
chemical
concentrate therein. Further, in the most preferred embodiment the size and
configuration of the liquid chemical reservoir is selected for a predetermined
concentration of liquid chemical concentrate so that the spray bottle
dispenser can be
refilled at least one time, preferably one to ten times, and potentially up to
100 times.
In addition, in the most preferred embodiment, the spray bottle is provided
with another
access opening (e.g., second neck with cap closure) to allow dilutent such as
water to be
added to the spray bottle for recharging the spray bottle dispenser without
removing the
sprayhead from the spray bottle. This configuration allows a user to consume
the water
in the spray bottle (i.e., one charge), and then replenish the same by simply
again adding
water to the spray bottle dispenser without any regard to the addition of
liquid chemical
concentrate, since there is sufficient liquid chemical concentrate contained
in the liquid
chemical concentrate reservoir to supply one or more charges of water in the
spray
bottle.
WO 97/05056 2 2 0 0 8 6 4 PCTlUS96112202
- 19-
The most preferred spray bottle embodiment of this mode can also be utilized
so
that the liquid chemical concentrate reservoir only contains enough liquid
chemical
' concentrate for one charge of water into the spray bottle. This chemical
product
embodiment would potentially allow the chemical product to be shipped and
marketed
at a point-of sale with no water supplied in the spray bottle to significantly
decrease the
shipping weight of the spray dispenser chemical product. The consumer would
later
charge the spray bottle with water, and then consume the liquid chemical
concentrate
when using up the one charge of water. Alternatively, the liquid chemical
concentrate
reservoir can contain additional liquid chemical concentrate to allow more
than one
charge of water to the spray bottle. Again, however, the spray dispenser
chemical
product can be shipped initially without water in the spray bottle, and then
allowing one
fill and one or more refills of the spray bottle dispenser.
The liquid chemical reservoir and the dilutent reservoir can be provided in a
variety of different manners. The reservoirs can be separate containers
attached or not
attached together, reservoirs connected together, reservoir inside a
reservoir, or
potentially any other type of arrangement. The use of a separate liquid
chemical
reservoir inside a conventional container such as a conventional spray bottle
is
particularly desirable, since the molds for the conventional liquid containers
would not
need to be modified or adapted for use in the present invention. Instead, one
focus of
WO 97/05056 2 2 0 0 8 6 4 p~~s96/12202
-20-
the present invention is towards developing an insertable liquid chemical
concentrate
reservoir that can be accomodated within a conventional container such as a
spray bottle.
Further, again it is highly desirable in the case of a spray dispenser to
utilize
conventional sprayheads again to avoid the cost of new development and
manufacturing
of modified sprayheads. The adapter according to the present invention allows
for the
use of a separate liquid chemical reservoir with a conventional sprayhead and
located
inside of a conventional spray bottle.
The adapter arrangement according to the present invention utilizes a downtube
extending into the spray bottle and a downtube extending into the liquid
chemical
reservoir. The adapter includes a mixing chamber for allowing the liquid
chemical
concentrate and water to be mixed therein prior to reaching the conventional
sprayhead.
Further, the adapter according to the present invention has a unique
configuration to
minimize the amount of space consumed inside the liquid storing spray bottle,
located in
the normal air space (i.e., neck or upper portion) of the spray bottle and
configured to
be easily molded and cheaply made in very high volume with minimal assembly
involved. This unique arrangement should minimize the difficulties required to
modify
existing production lines or bottlers who institute the present invention in
high volume
production.
PGT/US96/12202
WO 97/05056 2 2 0 0 8 6 4
-21-
Brief Description of the Dmovings
Figure 1 is a side elevational view of a first preferred embodiment of the
spray
bottle dispenser according to the present invention.
Figure 2 is a perspective view of the insert having three (3) separate
chambers or
cells defining two chemical reservoirs and an empty chamber with the insert
removed
from the bottle portion of the spray bottle dispenser shown in Figure 1.
Figure 3 is a top planer view of the insert shown in Figure 2.
Figure 4 is a bottom planer view of the insert shown in Figure 2.
Figure 5 is a partial detailed view showing the lip of the insert being
supported
by the mouth of the bottle portion of the spray bottle dispenser shown in
Figure 1 to
suspend the insert in the bottle.
Figure 6A is a preferred alternative insert having an empty center chamber to
accept a downtube centered in the mouth of the bottle portion, and having four
(4)
chemical reservoirs.
WO 97/05056 . 2 2 0 C 8 E 4 p~~S96/12202
-22-
Figure 6B is a preferred alternative insert having four (4) chambers or (i.e.,
three
chenucal reservoirs and one empty chamber) cells, instead of three (3)
chambers of the
insert shown in Figure 2.
Figure 7 is a side elevational view of a second preferred embodiment of the
spray
bottle dispenser according to the present invention.
Figure 8 is a partial detailed side cross-sectional view through one reservoir
of
the spray bottle dispenser shown in Figure 7.
Figure 9 is a perspective head-on view of the outer surface of the reservoir
shown
in Figure 8, showing the lines of wealrness in the reservoir.
Figure 10 is a side elevational view of a third preferred embodiment of the
spray
bottle dispenser according to the present invention.
Figure 11 is a side cross-sectional view of one reservoir of the spray bottle
dispenser shown in Figure 10.
WO 97/05056 PCT/US96/12202
2200864
-23-
Figure 12 is a side cross-sectional view of a fourth preferred embodiment of
the
spray bottle dispenser according to the present invention.
Figure 13 is a cross-sectional view through one reservoir of the spray bottle
dispenser shown in Figure 12.
Figure 14 is side elevational view of the one reservoir shown in Figure 13,
showing it bridging between the sides of the bottle portion, and connected at
both ends
to the sides of the bottle portion.
Figure 15 is a side elevational view of a fifth preferred embodiment of the
spray
bottle dispenser according to tine present invention.
Figure 16 is a perspective view of one donut-shaped reservoir of the spray
bottle
dispenser shown in Figure 15.
Figure 17A is a side cross-sectional view of the donut-shaped reservoir shown
in
Figure 16.
WO 97/05056 PCT/US96/12202
2200864
-24-
Figure 17B is a side cross-sectional view of an alternative donut-shaped
reservoir.
Figure 18 is an insert of a sixth preferred embodiment of the spray bottle
dispenser according to the present invention.
Figure 19 is a cross-sectional view of the upper reservoir of the insert as
indicated
in Figure 18.
Figure 20 is a cross-sectional view of the middle reservoir of the insert as
indicated in Figure 18.
Figure 21 is a cross-sectional view of the lower reservoir of the insert as
indicated
in Figure 18.
Figure 22 is an insert of a sixth preferred embodiment of the spray bottle
dispenser according to the present invention.
Figure 23 is a side longitudinal cross-sectional view of the insert shown in
Figure
22.
WO 97/OS056 2 2 0 0 8 6 4 PCT~S96/12202
-25-
Figure 24 is a side elevational view of an insert with a mechanical connector
according to the present invention.
Figure 25 is a cross-sectional view of the mechanical coupler, as shown in
Figure
24.
Figure 26 is a diagrarnmatic view of an embodiment of a spray dispenser
according to the present invention having a separate refillable solvent
container and a
separate refillable chemical concentrate container.
Figure 27 is a diagrammatic view of an embodiment of a spray dispenser
according to the present invention having a combined refillable solvent
container and
refillable chemical concentrate container.
Figure 28 is a diagrammatic view of an embodiment of a spray dispenser
according to the present invention having a refillable solvent container and a
refillable
chemical concentrate container each having a downtube connected to a pump type
sprayhead.
WO 97/OSOS6 2 2 0 0 8 6 4 P~~S96/12202
-26-
Figure 29A is a diagrammatic view of a spray dispenser according to the
present
invention having a non-refillable solvent container and a non-refillable
chemical
concentrate container.
Figure 29B is a diagrammatic view of a spray dispenser according to the
present
invention having a non-refillable solvent container and a refillable chemical
concentrate
container.
Figure 29C is a diagrammatic view of a spray dispenser according to the
present
invention having a refillable solvent container and a refillable chemical
concentratc
container.
Figure 30 A is a diagrammatic view of a spray dispenser according to the
present
invention having a separate solvent container and a separate chemical
concentrate
container.
Figure 30B is a diagrammatic view of a spray dispenser according to the
present
invention having a combined solvent container and chemical concentrate
container.
WO 97/05056 2 2 0 0 8 6 4 PCT/US96112202
-27-
Figure 30C is a diagrammatic view of a spray dispenser according to the
present
invention having a separate larger solvent container and a separate smaller
chemical
concentrate container.
Figure 30D is a diagrammatic view of a spray dispenser according to the
present
invention having a combined larger solvent container and a smaller chemical
concentrate
container.
Figure 31A is a diagrammatic view of a spray dispenser according to the
present
m
_.. iiwciiuun naVlIlg a smaiier chemical concentrate container disposed within
and located
at the bottom of a larger solvent container.
Figure 31B is a diagrammatic view of a spray dispenser according to the
present
invention having a smaller chemical concentrate container disposed within and
located
15 on the side of a larger solvent container.
Figure 31C is a diagrammatic view of a spray dispenser according to the
present
invention having a smaller chemical concentrate container disposed within and
located
on the top of a larger solvent container.
WO 97/05056 PGT/LTS96/12202
2200864
-28-
Figure 31D is a diagrammatic view of a spray dispenser according to the
present
invention having a smaller chenucal concentrate container disposed within and
located
in the center of a larger solvent container.
Figure 32 is a partially broken away and cross-sectional view of an embodiment
of a spray device according to the present invention.
Figure 33 is a partially broken away and cross-sectional view of an embodiment
of a spray device shown in Figure 32, however, with the sprayhead removed.
Figure 34 is a detailed cross-sectional view of a fully assembled adapter used
in
the spray device shown in Figures 32 and 33.
Figure 35 is a detailed cross-sectional view of a dissassembled adapter shown
in
Figure 34.
Figure 36 is a top planar view of the lower body portion the dissassembled
adapter shown in Figure 35.
WO 97/05056 2 2 0 0 8 6 4 PCT/pS96/12202
-29-
Figure 37 is a side cross-sectional view of the lower body portion as indiin
Figure 36.
Figure 38 is a side elevational view of another type of adapter for converting
a
conventional one neck spray bottle to a two neck spray bottle.
Detailed Description of the Preferred Embodiments
Dej=nitio~s
to
The spray bottle dispenser according to the present invention includes one or
more
reservoirs containing chemical or chemicals (i.e., chemical reservoirs).
The chemical reservoir can be a separate unit indirectly associated with the
spray
15 bottle dispenser by packaging, or directly associated to the spray bottle
dispenser by
connection to the spray bottle dispenser externally or internally. Preferred
embodiments
contain the one or more chemical reservoirs internally, most preferably
contained inside
the bottle portion to fully contain any inadvertent chemical spill or release
from the one
or more chemical reservoirs.
WO 97/05056 PGT/US96/12202
2200864
-30-
In the case of an external connection with the spray bottle dispenser, the
chemical
reservoir can be connected by a separate piece mechanical fastener such as a
plastic tab
or strip connector connecting the chemical reservoir to the bottle portion,
sprayhead
portion, or connected to both the bottle portions and sprayhead portions of
the spray
bottle dispenser.
Alternatively, the chemical reservoir can be formed as an integral portion of
the
bottle portion, sprayhead portion, and/or downtube. In the integral
embodiments, the
chemical reservoir can be connected by adhesive, plastic welding, plastic
forming (e.g.,
molding), or by other means to directly integrate the reservoir into the spray
bottle
dispenser components.
In a preferred embodiment, the spray bottle dispenser is provided with one or
more separate chemical reservoirs to allow the spray bottle dispenser to be
recharged one
or more times. In a most preferred embodiment, the spray bottle dispenser is
provided
with one or more chemical reservoirs to allow the user to access more than one
chemical
reservoirs during a single recharge to increase (e.g., double, triple,
quadruple, etc.) the
chemical concentration of the recharging mixture in the particular recharging
operation.
WO 97/05056 2 2 0 0 8 6 4 p~~sg6/12202
-31-
The chemical reservoirs can be identical units to simplify and reduce costs of
manufacturing, or alternatively, can be different size, shape and/or
configuration of
chemical reservoirs. For example, both internally and externally connected
chemical
reservoirs can be applied, and/or integral and separate type chemical
reservoirs can be
combined.
The one or more chemical reservoirs of the spray bottle dispenser contain
chemical or chemicals. Specifically, the reservoir can be filled or partially
filled with
only a single chemical compound, a one phase mixture of chemicals, a two phase
mixture
of chemicals, a dispersion, or any other liquid type chemical(s).
Alternatively, the
chemicals) can be in the form ~f a solid such as a tablet, powder, or
granules, or semi-
solid such as a thick slurry. In any event, the reservoir should contain a
chemical
reagent that is readily diluted or dissolvable with a solvent, particularly
plain water.
A preferred embodiment of a spray bottle dispenser 10 according to the present
invention is shown in Figures 1-5. The spray bottle comprises a sprayhead
portion 12
including an inner threaded coupler 16 threaded onto an outer threaded neck of
the bottle
WO 97/05056 PCT/US96/12202
~2~fl~~~
-32-
portion 14. A downtube 18 is connected to the sprayhead 12 portion, and
extends down
into the bottom of the bottle portion 14.
The spray bottle dispenser 10 is fitted with an insert 20 having three
separate
chambers 22, 24 and 26. In the embodiment of the insert 20 as shown in Figure
2, the
insert is provided with a rim 28 on an upper portion of the insert 20. The rim
28 has
a diameter greater than the inner diameter of the threaded neck 30 of the
bottle 14, as
shown in Figure 5. Thus, the rim 28 functions to suspend the insert 20 within
the bottle
14.
The chambers 22, 24 and 26 are used for storing a predetermined quantity of
liquid concentrate in each chamber. The chambers 24 and 26 are sealed at the
top by
an upper sealing membrane 32 and the bottom of the chambers 24 and 26 are
sealed by
lower sealing membrane 34 as shown in Figure 5. The chamber 22 is open (i.e.,
not
covered by sealing membranes 32, 34) to accommodate the downtube 18, and also
allow
solvent such as water to be added through the insert into the bottle portion
14.
The insert 20 is preferably made of suitable plastic material, and the upper
sealing
membrane 32 and lower sealing membrane 34 are preferably made of suitable
plastic
film, metal foil, or other suitable single or composite layer. The membranes
should be
WO 97/05056 PCT/US96/12202
-33-
chemically resistant to the contents and suitable for malting a liquid tight
seal with the
insert. The upper sealing membrane 32 and lower sealing membrane 34 can be
attached
to the insert 20 by various means. For example, the membranes 32 and 34 can be
attached by bonding, adhesive bonding, thermal welding, sonic welding, or by
any
suitable conventional means for providing a liquid tight seal (e.g., hermetic
seal) of the
chambers 22, 24 and 26.
Various other inserts having suitable configurations can be substituted for
the
insert 20 shown in Figure 1. For example, a five(5) chamber insert 20' having
an open
center chamber 36 and four (4) chemical chambers 37, 38, 39 and 40, is shown
in Figure
6A, and a four (4) chamber insert 20" having chambers 41, 42, 43 and 44, is
shown in
Figure 6. Further, the length of the insert relative to the length of the
bottle 14 can be
substantially varied based on different concentration levels of the
concentrate utilized in
the insert. Specifically, higher concentration concentrate requires less
volume in the
chambers of the insert, and thus reducing the needed length of the insert.
The insert 20 can be made by a variety of different techniques, however,
injection
molding or extruding techniques are the most suitable methods of manufacture.
WO 97/05056 PGTJUS96112202
2200864
-34-
The insert 20 can be marketed inside the bottle at the point-of sale, and/or
can be
marketed as a separate unit that can be inserted into a conventional spray
bottle.
In the case of the insert being marketed inside the bottle, all three (3)
chambers
22, 24 and 26 can initially be chemical reservoirs. The bottle is filled with
water or
other suitable diluting liquid and the top sealing membrane 32 and bottom
sealing
membrane 34 sealing the chamber 22 can be punctured by the tip of the downtube
18
during insertion of the downtube into the bottle portion prior to securely
fastening the
sprayhead to the bottle portion to complete the packaging assembly. Al~vely,
the
chamber 22 may be open (i.e., devoid of any liquid concentrate, as discussed
above) and
the bottle is initially filled with proper concentration diluted chemical
reagent liquid ready
to be marketed with the downtube 18 passed through the open chamber 22 during
assembly. In the embodiment having three (3) chambers as shown in Figure 3,
two
additional doses of concentrate contained in chambers 24 and 26 can be
sequentially
punctured by the consumer to dose a bottle with concentrate. The bottle 14 can
be
supplied with water through empty chamber 22 before or after the dosing step
by the
consumer.
A second embodiment of a spray bottle 100 according to the present invention
as
shown in Figures 7-9. The spray bottle 100 comprises a sprayhead portion 102
and a
2200864
WO 97/05056 PGT/US96/12202
-35-
bottle portion 104. The sprayhead portion 102 includes a threaded coupler 106
for
connecting the sprayhead portion 102 to a threaded neck of the bottle portion
104. A
downtube 108 is connected to the sprayhead portion 102, and extends down to
the bottom
of the bottle portion 104.
In this second embodiment, a strip 110 having a plurality of chemical
reservoirs
112 containing liquid concentrate is provided in the bottle portion 104. The
strip 110 is
attached to an inside surface of one wall of the bottle portion 104. The
specific location
of the strip 110 can be changed from that shown in Figure 7 to other locations
on the
side and/or bottom of the bottle portion 104. Each chemical reservoir 112 is
made in
a manner so that it can be rupttu~ed either by forcing the tip of the downtube
108 into the
surface of the reservoir 112, or by pinching the outside walls of the bottle
portion 104
together to burst one or more chemical reservoirs 112. For example, the
chemical
reservoir 112 can be made so that its wall has one or more lines of weakness
114, as
shown in Figures 8 and 9.
The strip 110 is preferably made in an infinite length, and then cut to length
for
the particular application. Thus, different size bottles could potentially
have more or less
number of individual chemical reservoirs 112. Further, making the strip 112 in
an
infinite manner would allow for high speed production of the strip 110 for
high speed
WO 97/05056 2 2 0 0 8 6 4 pCT~s96/12202
-36-
insertion during bottling. In the embodiment shown in Figure 8, the strip 110
is
provided with an adhesive layer 116 connecting a sealing layer 118 to the back
of the
strip 110. Another adhesive layer connects the strip 110 to the wall of the
bottle portion
104.
A third embodiment of a spray bottle dispenser 200 according to the present
invention is shown in Figures 10 and 11. The spray bottle dispenser 200
comprises a
sprayhead portion 202 and a bottle portion 204. The sprayhead portion 202
includes a
threaded coupler 206 for connecting the sprayhead 202 to a threaded neck of
the bottle
portion 204. A downtube 208 is connected to the sprayhead portion 202, and
extends
down to the bottom portion of the bottle portion 204.
In this third embodiment, a plurality of chemical reservoirs 210 are provided
at
the bottom of the bottle portion 204. The chemical reservoirs 210 can be
individual
chemical reservoirs, or alternatively, can be connected together by mechanical
coupler
in some manner. In any event, the chemical reservoirs 210 must be configured
in such
a manner so that they can be passed through the open mouth of the bottle
portion 204.
A detailed cross-sectional view of one of the chemical reservoirs 210 is shown
in
Figure 11. The chemical reservoir 210 can be cylindrical or some other
suitable shape
WO 97/05056
PCTJUS96/12202
-37-
with an open end 212 at a top portion thereof. The open end 212 is sealed with
a metal
foil 214 that can be punctured by an instrument, in particular the tip of the
downtube
208. T_h_e _re_Serv~eiyr 21_(1 is at ~P, ;st ~"'''uall~. ;aiiW'vi;n a cheWicai
r~ y concentrate liquid ~.
In use, the spray bottle dispenser 200 is filled by the bottler with diluted
chemical
reagent. The four (4) chemical reservoirs 210 are each at least partially
filled with a
chemical concentrate. Thus, this particular configuration allows for four (4)
recharging
operations. Each recharging operation begins with unscrewing the threaded
coupler of
the sprayhead portion 202 from the spray bottle 204, and slightly lifting the
sprayhead
,n
portion 202 upwardly until the tip of the downtube 208 clears the upper
surfaces of the
rGServoirs 210. The user then forces the tip of the downtube 208 through the
metal foil
214 of one of the reservoirs 210 causing it to be punctured. The bottle
portion 204 is
filled with water either before or after the step of accessing one of the
chemical
reservoirs 210.
A fourth embodiment of a spray bottle dispenser 300 according the present
invention is shown in Figures 12 to 14. The spray bottle dispenser 300
comprises a
sPmYh~ portion 302 and a bottle portion 304. The sprayhead portion 302
includes a
threaded coupler 306 for connecting the sprayhead portion 302 to a threaded
neck of the
W~ 97/05056 2 2 D 0 8 6 4 pCT~s96/12202
-38-
bottle portion 304. A downtube 308 is connected to the sprayhead portion 302,
and
extends down to the bottom portion of the bottle portion 304.
In this fourth embodiment, strips 310 and 312 connect together a plurality of
chemical reservoirs 314. Five (5) reservoirs are shown in Figure 12, however,
either
more or less reservoirs can be utilized.
The reservoir 314 is provided with lines of weakness 316 as shown in Figures
13
and 14. The lines of weakness allow the reservoir 314 to burst upon
application of force
to the reservoir
14. For example, the sides of the bottle portion 304 can be squeezed at the
location of
one of the chemical reservoirs 314 causing it to burst.
The strips 310 and 312 are preferably secured to the walls of the bottle
portion
304. For example, the strips 310 and 312 can be adhered with adhesive, or
connected
by sonic welding or thermal welding. The strip 310 and chemical reservoirs can
be
molded from plastic.
In this particular embodiment, the spray bottle dispenser 300 is recharged by
bursting one or more of the reservoirs 314. The more reservoirs 314 that are
burst, the
WO 97/05056
2 2 0 0 8 6 4 PCT~S96/12202
-39-
stronger in concentration the rcsulting diluted chemical reagent will be. A
solvent such
as water can be added before of after the bursting operation. The spray bottle
dispensers
are preferably filled with diluted chemical reagent by the bottler containing
the plurality
of reservoirs 314 to allow numerous recharging operations.
A fifth embodiment of a spray bottle dispenser 400 according to the present
invention is shown in Figures 15 to 17. The spray bottle dispenser 400
comprises a
sprayhead portion 402 and a bottle portion 404. The sprayhead portion 402
includes a
threaded coupler 406 for connecting the sprayhead portion 402 to a threaded
neck of the
,n L _...
oocue portion 404. A downtube 408 is connected to the sprayhead portion 402,
and
extends down to the bottom portion of the bottle portion 404.
In this fifth embodiment, a plurality of donut-shaped chemical reservoirs 410
are
provided on the downtube 408. Specifically, the donut-shaped chemical
reservoirs 410
each have a center hole 412 through which the downtube 408 passes. The
chemical
reservoirs 410 are provided with a metal foil 414 for sealing an upper end of
the
chemical reservoir 410 for containing the chemical reagent liquid ~, as shown
in Figures
16 and 17.
WO 97/05056 2 2 0 0 8 6 4 PCT~S96/12202
In use, the spray bottle dispenser 400 is initially filled by the bottler with
dilute
chemical reagent and sold at the point-of sale. After the initial consumption
of the
diluted chemical reagent, a user unscrews the sprayhead portion 402 from the
body
portion 404 and lifts the downtube 408 from the bottle portion 404. The user
then grips
the lowermost reservoir 410 and simple pulls it off the end of the downtube
408, and
then punctures the metal foil 414 with and instrument, in particular the tip
of the
downtube 408. The punctured reservoir 410 is dropped into the bottle portion
410. A
solvent such as water is added to the bottle portion 404 before or after the
step of
puncturing the reservoir 410. The spray bottle dispenser 400 is then
reassembled by
screwing the sprayhead portion 402 onto the bottle portion 404.
Another embodiment of a donut-shaped chemical reservoir 410' is shown in
Figure 17B. This chemical reservoir 410', is sealed at the top to define an
annular
chamber 416 containing the chemical concentrate liquid ~. One or more small
holes 418
are provided on the internal wall of the throughhole 412' to allow chemical to
escape
therethrough. The hole 418 is sealed by the outer surface of the downtube when
the
downtube is inserted thmugh the center hole 118. Further, a thin layer of
adhesive or
sealant can be applied between the donut-shaped reservoir and the downtube to
further
ensure sealing of the hole 418.
WO 97/05056 2 2 0 0 8 d 4 pCT~S96/12202
-41-
A sixth embodiment of a spray bottle dispenser utilizes insert 500 as shown in
Figures 18 to 21. The insert 500 comprises a cylinder portion 502 having a lip
porn~n
504, a connector portion 506 connecting the cylinder portion 502 to an upper
reservoir
508, a connector portion 510 connecting the upper reservoir 508 to a middle
reservoir
512, and a connector portion 514 connecting the middle reservoir 512 to the
lower
reservoir 516. A downtube 518 is shown passing through the hollow cylinder
portion
502, however, is not connected to the insert 500.
The reservoirs 508, 512 and 516 are in a stacked and stepped arrangement. The
upper reservoir 508 is thinner in width and deeper in depth compared with the
lower
reservoir 516. The middle reservoir 512 has dimensions between those of the
upper
reservoir 508 and lower reservoir 516. This stepped and stacked arrangement
allows
access by an instrument to puncture sealing membranes (not shown) sealing each
reservoir 508, 512, 516 while the insert remains in the bottle portion of the
spray bottle
dispenser.
A seventh embodiment of a spray bottle dispenser having an insert 600 is shown
in Figures 22 and 23. The insert 600 comprises a cylindrical portion 602
having a lip
portion 604, a connector portion 608 connecting the cylindrical portion 602 to
upper
reservoir 610, a connector portion 612 connecting the upper reservoir 610 to
middle
WO 97/05056 PCT/US96/12202
2200864
-42-
reservoir 614, and a connector portion 616 connecting the middle reservoir 614
to lower
reservoir 618. The top and bottom of each reservoir 610, 614 and 618 are open,
and
each sealed by upper metal foil 620 and a lower metal foil 622.
In use, the spray bottle dispensers are filled with diluted chemical reagent
initially
by the bottler, and the downtube is passed only through the cylinder portion
602. After
consumption of the initial diluted chemical reagent, the user withdraws the
downtube
above the level of the upper reservoir 610, and forces the tip of the downtube
through
the upper metal foil 620 and lower metal foil 622 of the reservoir 610
releasing the
chemical concentrate liquid into the bottle portion. A solvent such as water
is added
before or after the step of accessing the chemical concentrate liquid. After
puncturing
the metal foil 620 and 622, the downtube is lifted upwardly and then passed
between the
cylinder portion 602 and the side of the reservoir 610. Alternatively, the
downtube can
be threaded through the reservoir 610 and down along the side of the middle
reservoir
614 so as not to puncture the chemical reservoir 614. The connector portion
608, 612
and 616 are substantially flexible enough to act as hinges to move the lower
reservoirs
out of the way so as not to be punctured by the downtube during the insertion
operation
of the downtube.
WO 97/05056 2 2 0 0 8 6 4 pCT~s96/12202
-43-
In an alternative embodiment, only the upper portion of each reservoir is
provided
with a membrane that can be punctured with the bottoms being molded portions
of the
' reservoirs, and not readily subject to being punctured.
In an eighth embodiment, a mechanical coupler 700 is connected to an insert
702,
The insert 702 is identical to the insert shown in Figure 2, however, with no
lip portion
28. The mechanical coupler includes a lip portion 704 and a connector portion
706
connected together by four (4) standoffs 708 (only two are shown in Figures 24
and 25).
The connector portion 706 is connected to an upper portion of the insert 702,
by
interference fit, adhesive, sonic welding, thermal welding, or by other
suitable
connection means.
This arrangement provides four (4) ports 710 to allow water poured through the
center of the mechanical coupler 700 to pass through and out the ports 7I0
into the bottle
portion when recharging the spray bottler dispenser with this arrangement.
This arrangement allows the inert 702 to be extruded continuously, since no
lip
need be molded in the insert 702. The insert 702 is provided with upper and
lower
sealing membranes (not shown) and then attached to the mechanical coupler 700
during
assembly. Thus, the insert 702 can be cut from a continuous length of material
extruded
WO 97/05056 2 2 0 0 8 ~ 4 P~~S96/1Z20Z
at high speed, filled with chemical concentrate, sealed with the sealing
membranes at
both ends, and then assembled with the mechanical coupler 700 to finish
complete
assembly.
Dual Reservoir Dispensers
The following embodiments include spray bottle dispensers having a chemical
reservoir and a solvent (e.g., diluent such as water) reservoir connected to a
dispensing
device. The solvent reservoir is refillable, and the chemical reservoir is
optionally
refillable. In preferred embodiments, both the chemical reservoir and solvent
reservoir
are located in the bottle of the spray bottle dispenser.
A diagrammatic view of a spray dispenser 800 having a separate refillable
solvent
reservoir 802 and a separate refillable chemical concentrate reservoir 804 is
shown in
Figure 26. This arrangement can be utilize with either a pump type sprayhead
and/or
a pressurized dispensing arrangement (i.e., aerosol).
The refillable solvent reservoir 802 is provided with a resealable closure
such as
the threaded cap 806 to allow solvent A to be initially added or refilled with
additional
solvent A. The refillable chemical reservoir 804 is provided with a resealable
closure
WO 97105056 2 2 0 0 8 6 4 pCT~S96112202
-45-
such as the threaded cap 808 to allow chemical concentrate B to be initially
added or
refilled with additional chemical concentrate B. The threaded caps 80 and 808
can be
replaced with other types of conventional resealable closures.
The conduit 810 eztending from the solvent reservoir 802 and the conduit 812
eztending from the solvent reservoir 804 connect to a mizing chamber 814.
Inside the
mizing chamber 814, chemical concentrate B is diluted with solvent A forming a
working
chemical solution having a predetermined chemical concentration of active
ingredient(s).
The working solution is then dispensed from the spray dispenser. For example,
the
wor~ng chemical solution is drawn up into the pump chamber 816 and forced out
of the
sprayhead 818.
l:n the embodiment shown in Figure 26, the entrance to the conduits 810 and
812
are located at the bottom of the solvent reservoir 802 and chemical
concentrate reservoir
804, respectively, to substantially empty the respective reservoirs. However,
other
suitable arrangements involving downtubes and other conduit passageway
arrangements
to be discussed in detail below can be substituted for the arrangement shown.
A diagrammatic view of another spray dispenser 900 having a solvent reservoir
902 directly connected to a chemical concentrate reservoir 904. Specifically,
the solvent
WO 97/05056 PGT/US96/12202
2200864
-46-
resmvoir 902 is connected to the chemical concentrate reservoir 904 by a
plastic
connecting web 905. For example, the solvent reservoir 902 and chemical
concentrate
reservoir can be blow mold from a single plastic piece. Alternatively, the
reservoirs can
be made separately can be connected together with fastening means provided in
the
reservoirs and/or by separate fastening means.
The refillable solvent reservoir 902 is provided with a resealable closure
such as
the threaded cap 906 to allow solvent A to be initially added or refilled with
additional
solvent A. The refillable chemical reservoir 904 is provided with a resealable
closure
such as the threaded cap 908 to allow chemical concentrate B to be initially
added or
refilled with additional chemical concentrate B. The threaded caps 906 and 908
can be
replaced with other types of conventional resealable closures.
A diagrammatic view of another spray dispenser 1000 having a solvent reservoir
1002 and a chemical concentrate reservoir 1004. The refillable solvent
reservoir 1002
is provided with a resealable closure such as the threaded cap 1006 to allow
solvent A
to be initially added or refilled with additional solvent A. The refillable
chemical
reservoir 1004 is provided with a resealable closure such as the threaded cap
1008 to
allow chemical concentrate B to be initially added or refilled with additional
chemical
WO 97/05056
PCT/US96I12202
-47-
concentrate B. The threaded caps 1006 and 1008 can be replaced with other
types of
conventional resealable closures.
A downtube 1010 is provided in the solvent reservoir 1002 and a downtube 1012
is provided from the chemical concentrate reservoir 1004. The downtubes 1002
and
1004 connect to a mixing chamber 1014. Inside the mixing chamber 1014,
chemical
concentrate B is diluted with solvent A forming a working chemical solution
having a
Predetermined chemical concentration of active ingredient(s). The working
solution is
then dispensed from the spray dispenser. For example, the working chemical
solution
is drawn into the spray pump 1016, and then dispensed from the sprayhead 1018.
There exists applications where it is desirable that both the solvent
reservoir and
chemical concentrate reservoir are not provided with resealable closures, as
shown in
Figure 29A. For example, the dispenser is marketed for one time use still
providing a
reduction of shipping weight per unit weight of the dispenser due to the use
of chemical
concentrate. Alternatively, only the chemical concentrate reservoir is not
provided with
a resealable closure, as shown in Figure 29B. For example, due to the toxic
and caustic
nature of chemical concentrate, it may be desirable to completely seal the
chemical
concentrate reservoir to prevent child poisoning or damaging chemical spills
while still
allowing the solvent reservoir of the dispenser to be refilled one or more
times.
WO 97/05056 PCT/US96/12202
220084
- 48 -
However, preferably both the solvent reservoir and the chemical concentrate
reservoir are both provided with nesealable closures, as shown in Figure 29C,
to allow
solvent and chemical concentrate respectively to be initially added and
subsequently
refilled. This arrangement allows the dispenser to be refilled numerous times
with both
solvent and chemical concentrate solutions prior to being ultimately disposed,
and would
have significant applications in the area of commercial cleaners consuming
large
quantities of cleaning chemicals.
In embodiments utilizing downtubes (e.g., Fig 28), the solvent reservoir and
chemical concentrate reservoir can be separate containers, as shown in Figure
30A.
Alternatively, the solvent reservoir and chemical concentrate reservoir can be
connected
containers, as shown in Figure 30B. Further, the relative size of the solvent
reservoir
and chemical concentrate reservoir can be different. For example, a separate
smaller
chemical concentrate reservoir can be utilize in conjunction with a larger
solvent
reservoir, as shown in Figure 30C, or can be connected to a larger solvent
reservoir, as
shown in Figure 30D. The use of a smaller chemical concentrate reservoir can
be
particular desirable to reduced dispenser weight and limit the amount of
poisonous and
caustic chemical concentrate contained in the dispenser. The smaller chemical
concentrate reservoir and concentration of chemical concentrate contained
therein can be
preselected so that it is completely consumed by the one time consumption of
the solvent
wo 9~rososs
2 2 0 0 8 6 4 p~T~S96/12202
-49-
reservoir, or alternatively, is only partially consumed by the one time
consumption of
solvent allowing the solvent reservoir to again be refilled one or more times.
A preferred embodiment of the dispensing device according to the present
invention includes a smaller chemical concentrate reservoir disposed within a
large.
solvent reservoir. This arrangement is particularly safe since the chemical
concentrate
is contained both inside the chemical concentrate reservoir and solvent
reservoir. Thus,
a child tampering with this arrangement cannot directly access the chemical
concentrate
without initially accessing the solvent reservoir. Further, the chemical
concentrate
reservoir can be made to be completely sealed and substantially impenetrable
(e.g.,
hermetically sealed plastic container). In addition, any inadvertent leakage
or spillage
of chemical concentrate from the chemical concentrate reservoir will be
contained inside
the solvent reservoir.
In the embodiments shown in Figures 31A to 31D, the chemical concentrate
reservoir can be provided in various manners. For example, the chemical
concentrate
reservoir can be a separate container disposed within another container
defining the
solvent reservoir. Alternatively, the chemical concentrate reservoir can be
potentially
made as an integral reservoir having one or more walls contiguous with one or
more
WO 97/05056 PCTIUS96/12202
22008~~4
-so-
walls of the solvent reservoir. In addition, the chemical concentrate
reservoir can be
made of pliable material (e.g., thin soft plastic film material).
In embodiments of the dispensing device using a suction pump type arrangement
(i.e., conventional spray pump type sprayhead), the liquid chemical
concentrate can be
drawn into a downtube by suction created by the suction pump arrangement of
the
sprayhead. If the chemical concentrate is contained in a chemical concentrate
reservoir
having rigid or semi-rigid walls, then the chemical concentrate reservoir must
be vented
in some manner to allow liquid to be sucked up the downtube, or alternatively,
the
chemical concentrate reservoir must be pressurized to force liquid chemical
concentrate
up the downtube. If the chemical concentrate is contained in a chemical
concentrate
reservoir having one or more flexible or pliable walls or membranes (i.e.,
collapsible in
some manner), then liquid can be sucked into the downtube without venting
causing the
chemical concentrate reservoir to collapse to allow for the removal of
chemical
is concentrate solution therefrom.
The chemical concentrate is preferably fn the form of a liquid to allow
conduits
such as downtubes to access the supply of chemical concentrate. Alternatively,
the
chemical concentrate can be store in one or more states such as solids,
particulate,
aggregate, emulsions, vapor and other suitable forms. In each of these
embodiments, ,
WO 97/05056 . 2 2 0 0 8 6 4 ~CT~S96/12202
-51 -
the dispensing device must includes some means for placing the chemical
concentrate in
contact with solvent to create the dilute working chemical reagent solution.
The means
for placing the concentrate in contact with the solvent can have continuous,
selective or
intermittent operation depending on the particular arrangement. For example, a
solid
chemical concentrate may be placed in continuous contact with liquid solvent
by
providing the chemical concentrate reservoir with one or more access holes or
conduits
fl~~Y ~~~~g the solvent reservoir with the chemical concentrate reservoir.
A preferred embodiment of a dispensing device according to the present
invention
is shown in Figure 32. The dispensing device 1100 comprises a spray bottle
1102 having
a neck 1104 and an optional neck 1106. A resealable cap 1108 is connected to
the neck
1006 to glow solvent A to be initially added or refill the spray container
1102. A pump
type sprp~;yhead 1110 is connected to the neck 1104 for spraying a working
mixture of
solvent A and chemical concentrate B.
The dispensing device 1100 includes an adapter 1112 comprising a plug-like
body
1114 with a radial outwardly extending upper flange 1116 for suspending the
adapter
1112 within the neck 1104. The plug-like body 1114 can be dimensioned to be
slightly
less than the inner dimensions of the neck 1104 to facilitate removal of the
adapter 1112,
particularly in an embodiment of the spray bottle 1102 not having the optional
neck 1106
WO 97/05056 PGTIUS96/12202
2200864
-52-
and resealable cap 1108, to allow refill'mg of the spray bottle 1102 with
solvent.
Alternatively, the plug-like body 1114 can be dimensioned to slightly greater
than the
inner dimensions of the neck 1104 to prevent removal of the adapter 1112, for
example,
to prevent access to the chemical concentrate B by children. In addition, the
plug-like
body 1114 can be adhered with adhesive or further connected in some manner,
for
example by fuzing or welding, to make it nearly impossible to remove the plug-
like body
1114 without destroying the plug-like body 1114 and/or spray bottle 1102. In
embodiments having the plug-like body 1114 directly connected to the spray
bottle 1102,
the flange 1116 can be optionally eliminate, since it would cease to function
for
suspending the plug-like body 1114.
The plug-like body 1114 is provided with a plug-like extension 1118 extending
below thereof. The plug-like extension 1118 connects to a container 1102 for
containing
the chemical concentrate B. For example, the container 1102 can be connected
by
interference fit between the outer dimensions of the plug-like body and inner
dimensions
of the upper portion of the container 1102. Alternatively, the container 1102
can be
connected in some other suitable manner to the plug-like extension 1114, for
example
screw connection, adhesive, fusing, welding, mechanical fastener, etc.)
providing either
a removable or non-removable connection therebetween.
WO 97/05056 2 2 0 0 8 6 4 pCT~s96112202
-53-
A particularly suitable container 1102 is a test tube shaped container having
a
c3'~~~ body with a hemispherical end portion as shown in Figure 32, The test
tube
shaped container 1102 can be made of glass providing outstanding chemical
resistivity,
however, plastic may be more suitable to prevent inadvertent breakage thereof.
Alternatively, other suitable shape and size containers can be substituted for
the test tube
shaped container 1102. The I<~rger the container 1102, the more chemical
concentrate
can be stored inside the spray container 1102, however, using up additional
space for
solvent A in the same size spray container 1102.
A downtube 1122 is provided inside the container 1120 for allowing chemical
concentrate B to be drawn up through the downtube 1122 into the plug-like
adapter 1112
where mixing occurs with the solvent A. In addition, a downtube 1124 is
provided
inside the spray bottle 1102 allowing solvent A to be drawn up through the
downtube
1124 into the plug-like adapter 1112 where mixing occurs with the chemical
concentrate
B,
The plug-like adapter 1112 is provided with a tubular extension 1126 for
connection with the sprayhead 1110. For example, the plug-like adapter 1112 is
a plastic
injection mold piece having a tubular extension 1126 mold upwardly therefrom.
The
tubular extension 1126 can be shaped and dimensioned to be the size of a
conventional
WO 97/05056 PCT/US96/12202
2200~~4
-54-
downtube so that it can be received within the conventional downtube receiver
of a
conventional sprayhead. Alternatively, plastic tubing other suitable conduit
arrangement
can be substituted to provide a liquid connection between the adapter 1114 and
sprayhead
1110.
The detail configuration of a preferred adapter 1112 will be described below
and
is shown in Figures 34 and 35. The adapter 1112 is made of four (4) separate
components including an upper body portion 1128, a lower body portion 1130, a
ball
float 1132, and a ball float 1134 assembled together as shown in Figure 34.
The upper body portion 1128 and lower body portion 1130 are preferable made
by plastic injection molding to have the configuration shown. The upper body
portion
1130 comprises a cylindrical body portion 1132 connecting to an upper flange
portion
1116a and a lower disk portion 1136. The tubular extension 1126 extends
upwardly
from the lower disk portion 1136 defining a fluid passageway 1138 through the
upper
body portion 1130.
A tubular extension 1140 having a fluid passageway 1142 is supported bclow the
lower disk portion 1136 by a plurality of spaced apart supports 1146. For
example, the
spaced apart supports 1146 are set apart at ninety (90) degree increments
providing four
WO 97/05056 2 2 0 0 8 6 4 PCT/US96/12202
-SS-
fluid passageways or ports therebetween (e.g., cage-like structure). The lower
portion
of the tubular extension 1140 is provided with a funnel-shaped passageway
portion 1148.
The lower body portion 1130 comprises a cylindrical body portion 1150
connecting to an upper flange portion 1116b and a lower disk portion 1152. The
cylindrical body 1150 is also is provided with a lower flange portion 1154
having an
upper surface portion 1154a on which the bottom of the upper body portion 1128
rests.
Specifically, the upper surface portion 1154a of the lower flange portion 1154
serves as
a stop to limit the extent the upper body portion 1128 fits inside the lower
body portion
1130. In addition, the plug-like extension is provided at the bottom of the
lower body
portion 1130 for connecting with the container 1120 as described above.
A mixing chamber MC is defined between the lower surface 1136a of the lower
disk portion 1136 of the upper body portion 1128 and the upper surface 1152a
of the
lower disk portion 1152 of the lower body portion 1130. The height of the
lower flange
portion 1144 of the lower body portion 1130 defines the height of the mixing
chamber
MC. The mixing chamber MC is in continuous fluid connection with the
passageways
1138 and 1142 of the upper body portion 1128.
WO 97/05056 PGT/US96/12202
2200864
-56-
The lower body portion 1130 is provided with a fluid passageway 1156
comprising a lower passageway portion 1156x, a funnel-shaped passageway
portion
1156b, and an upper passageway portion 1156c. The lower passageway portion
1156a
is dimensioned to provide an interference fit connection with an upper portion
of the
downtube 1124 (See Figure 35). Further, the upper passageway portion 1156c is
dimensioned to accommodate the ball float 1132 and the funnel-shaped
passageway
portion 1156b is oriented to cup the ball float 1132 and provide a one-way
valve so that
liquid solvent A can only move up the downtube 1124 into the mixing chamber MC
preventing mixed fluid in the mixing chamber MC to move through the one-way
valve
and down through the downtube 1124 into the spray bottle 1102. A spring 1132a
is
optionally provided to slightly bias the ball float 1132 to seat against
surfaces of the
funnel-shaped passageway portion 1156b to further ensure that there is no
leakage of
mixed fluid from the mixing chamber MC into the downtube 1124. The one end of
the
spring 1132a is biased against the curved surface of the ball float 1132 and
the opposite
end of the spring 1132a is received within a circular recess 1132b provided in
the bottom
of the cylindrical body 1150. This arrangement anchors the ends of the spring
1132a to
maintain its orientation during operation. Other types of springs or biasing
means can
be substituted for the spring 1132b (e.g., cantilever spring).
2 2 0 0 8 6 4 p~.~S96/12202
WO 97/05056
-57-
The lower body portion 1128 is also provided with a tubular extension 1158
having a fluid passageway 1160. The fluid passageway 1160 comprises a lower
fluid
passageway portion 1160x, a funnel-shaped fluid passageway portion 1160b, and
an
upper fluid passageway portion 1160c. The lower passageway portion 1160a is
dimensioned to provide an interference fit connection with an upper portion of
the
downtube 1112 (see Figure 35). Further, the upper passageway portion 1160c is
dimensioned to accommodate the ball float 1134 and the funnel-shaped
passageway
portion 1160b is oriented to cup the ball float 1134 and provide a one-way
valve so that
liquid chemical concentrate F can only move up the downtube 1112 into the
mixing
chamber MC preventing mixed fluid in the mixing chamber MC to move down
through
the one-way valve and down through the downtube 1112 into the container 1120.
Further, the funnel-shaped passageway portion 1148 of the tubular extension
1140 cups
the ball float 1134 when it moves upwardly stopping its upward movement and
creating
a one-way valve having an opposite flow operation with respective to the lower
one-way
valve.
The two (2) one-way valves of the tubular extension 1158 define a metering
valve. Specifically, the travel height H of the ball float 1134 defines a
metering chamber
C having a fixed volume for metering the amount of liquid chemical concentrate
to be
delivered to the mixing chamber MC. Further, the ball float 1134 is
dimensioned less
WO 97/05056 PCT/US96/12202
2200864
-s8-
than the inner diameter of the liquid passageway 1160 to allow liquid to move
around the
ball float 1134 during a portion of the metering operation to be discussed
below.
As shown in Figure 3s, the upper body portion 1128 is separate from the lower
s body portion 1130. The upper body portion 1128 is connected to the lower
body portion
1130 in the assembled adapter 1112. For example, the flange portions 1116a and
1116b
can be adhered or welded together to complete the assembly. In any event, the
junction
between the upper body portion 1128 and lower body portion 1130 must be sealed
in
order to seal the mixing chamber MC.
The plug-like adapter 1112 must be provided with an air passageway connecting
the air space located above the adapter 1112 and below the sprayhead 1110 to
air spaces
in the spray bottle 1102 and container 1120 so that when volumes of liquid
solvent A and
liquid chemical concentrate B are removed from the spray bottle 1102 and
container
is 1120, respectively, volumes of air are added therein to account for the
loss of volumes
of liquid. However, if the container 1120 is a pliable or flexible walled
container, for
example a collapsible container (e.g., balloon-like container) then an air
passageway is
not required to the container 1120.
wo 97ro5056 . 2 2 0 0 8 6 4 pCTlUS96/12202
-59-
An air passageway 1162 can be provided along the side of the plug-like adapter
1112. For example, a hole can be provided in the flange 1116 extending to a
groove
' provided along the side of the lower body portion 1130. This arrangement
provides an
~ P~~ewaY into the spray bottle 1102. The groove can be extended along the
plug-
Iike extension 1118 for also providing an air passageway into the container
1120
containing liquid chemical concentrate B.
In an alternative embodiment, it is possible to eliminate or rearrange the
location
of one-way valves to prevent contamination of the liquid solvent A and liquid
chemical
concentrate B. For example, a single one-way valve can be provide in the
liquid
passageway 1138, however, this arrangement still places the working liquid in
the mining
chamber MC with the liquid solvent A and liquid chemical concentrate B.
Further, other
suitable metering arrangements can be devised and substituted for the one
shown and
described.
Optionally, the plug-like adapter 1112 is provided with a valve to control
(e.g.,
open and close) the liquid passageway reaching or passing through liquid
passageway
1138. This would further prevent misuse, and/or prevent leakage of mixed
liquid
chemical from the mixing chamber MC.
WO 97/05056 2 2 0 0 8 6 4 pOT~S96/1ZZOZ '
In operation, after the downtubes 1112 and 1124 and mixing chamber MC have
been primed, operation of the sprayhead 1110 (Figure 32) draws liquid under
suction
upwardly from the mixing chamber MC, through the spaced apart ports defined by
the
supports 1146 and then up through the fluid passageway 1138 to supply the
sprayhead
1110 with a mixture of working liquid having the proper concentration of
active
ingredients.
As liquid is sucked from the mixing chamber MC, the ball float 1132 defining a
one-way valve moves upwardly allowing liquid solvent A to be drawn up through
the
downtube 1124, thmugh the passageway 1156 into the mixing chamber MC.
Simultaneously, the ball float 1134 of the metering valve moves upwardly
allowing the
volume of liquid chemical concentrate positioned above the ball float 1134 to
move
upwardly into the mixing chamber MC. The ball float 1134 will move upwardly
drawing
liquid chemical concentrate up the downtube 1112 into the metering chamber C
now
located below the ball float 1134 until the ball float 1134 is stopped by the
funnel-shaped
fluid passageway 1148. When the sprayhead relieves the liquid suction inside
the mixing
chamber MC at the end of each spray cycle (i.e., when trigger handle of pump
is pulled
fully in), the ball float 1134 moves downwardly due to gravity while allowing
liquid
chemical concentrate to flow around its outside and again fill the metering
chamber for
the next spray cycle.
WO 97/05056 2 2 0 0 8 6 4 pCT~S96/12202
-61-
The liquid solvent A and the liquid chemical concentrate B entering the mixing
chamber are free to thoroughly mix prior to moving upwardly through the liquid
passageway 1138 to the sprayhc~d 1110. Further, there exists some agitation
enhancing
liquid mixing inside the mixing chamber due to the different locations of
entrance of the
liquid solvent and liquid chemical concentrate in additions to the cage-like
structure of
the spaced apart supports 114 located inside the mixing chamber MC and
defining
spaced apart liquid ports entering into the liquid passageway 1138.
When the dispensing device 1100 is not in use, working chemical in the mixing
chamber cannot move downwardly through the downtubes 1124 and 1112 due to the
one-
way valves defined by the ball floats 1132 and 1134, respectively. This
prevents the
contamination of the spray bottle containing solvent A and the container 1120
containing
chemical concentration B from being contaminated with working liquid from the
mixing
chamber MC.
The liquid chemical concentrate located in the metering chamber C above the
ball
float 1134 mixes with time to some extent with the working liquid in the
mixing
chamber. However, in operation after one or two spray cycles, the metering
valve is
fully operative delivering a fixed volume of liquid concentrate to the mixing
chamber as
discussed above.
WO 97/05056 PCT/L1S96/12202
2200864 ._
-62-
Another type of adapter 1200 for converting a conventional one neck spray
bottle
to a two neck spray bottle is shown in Figure 38. Specifically, the adapter
1200
comprises an adapter body having a liquid passageway 1204 connecting into a
liquid
passageway 1206. The adapter body 1202 is provided with a inner threaded cap
1208.
6 The threaded cap 1208 can be molded as an integral unit with the adapter
body 1202, or
can be a separate piece rotatably connected to the adapter body. The
connection between
the adapter body 1202 and the threaded cap 1208 can be the same or similar to
the type
of connection between the inner threaded cap of a conventional sprayhead and
the body
of the conventional sprayhead allowing relative rotation and sealing
therebetween.
type arrangement allows the orientation of the adapter relative to the spray
bottle to
which it is connected to be varied.
The inner threaded cap 1208 is connected to the outer threaded neck of a
conventional one neck spray bottle. The adapter body 1202 is provided with a
first outer
threaded neck 1210 for connection with the inner threaded cap of a
conventional
sp~Yh~- The adapter body 1202 is also provided with a second outer threaded
neck
1212, which can be provided with a reusable inner threaded cap 1214.
Alternatively, the
WO 97/05056
2 2 0 0 8 6 4 p~'~1596/12202
-63-
adapter body 1202 can be provided with another type of second reseaiable
closure (e.g.,
threaded plug and inner threaded neck, twist open valve, stop cock type valve,
etc.).
