Note: Descriptions are shown in the official language in which they were submitted.
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1
IMPROVEMENTS IN OR RELATING TO PUMP-ACTION NOZZLE
DEVICES
The present invention relates to improvements in or relating to pump-
action nozzle devices.
S Pump-action nozzle devices are commonly used as a means for
dispensing a liquid from the interior of non-pressurised containers.
Conventional pump-action nozzle devices are adapted to be fitted to an outlet
opening of a container and comprise an internal chamber which is compressed
when an actuator of the nozzle device is operated, thereby increasing the
pressure within the chamber and forcing any liquid present therein to flow out
through an outlet of the device. Once the desired volume of liquid has been
dispensed, or the chamber has been compressed to its fullest extent, the
actuator
is then released by the operator and the chamber is allowed to re-expand,
which
causes the pressure within the chamber to reduce, which in turn causes more
liquid to be drawn into the chamber from the associated container through an
inlet. One-way valves are provided at the inlet and the outlet to ensure that
fluid can only be expelled from the internal chamber through the outlet and
drawn into the chamber through the inlet.
The actuator is typically a portion of the body of the nozzle device that
can be depressed and subsequently released by an operator (generally known as
pump nozzle devices), or a trigger that an operator can pull and then
CONFIRMATION COPY
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subsequently release (generally known as trigger-actuated nozzle devices), to
cause the chamber to be compressed and then re-expanded respectively.
There are a number of drawbacks associated with conventional pump-
action nozzle devices. Firstly, the conventional devices tend to be extremely
complex in design and typically comprise numerous different component parts
(usually between 8 and 10 individual components in pump nozzle devices and
between 10 and 14 individual components in trigger nozzle devices). As a
consequence, these devices can be costly to manufacture due to the amount of
material required to form the individual components and the assembly
processes involved. Secondly, the conventional devices tend to be bulky
(which again increases the raw material costs) and a proportion of this bulk
is
invariably disposed inside the container to which the device is attached. This
creates a drawback in that the nozzle device takes up a proportion of the
internal volume of the container, which can be a particular problem in small
containers where the available space inside the container is limited. Finally,
the
size of the pump-action device is also dictated to certain extent by the size
of
the container to which it is attached. Thus, the size of the device is usually
restricted in small containers, and especially small containers with narrow
necks, and this limits the amount of pressure that can be generated by the
device as well as the volume of fluid that can be dispensed, and, for this
reason,
can be detrimental to the performance of the device.
Therefore, there is a desire for a pump-action nozzle device which is:
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(i) simpler in design;
(ii) utilises less components; and
(iii) is generally less bulky and costly to produce when compared with
the conventional pump-action nozzle devices.
The present invention seeks to address the aforementioned problems
associated with conventional pump-action nozzle devices by providing, in a
first aspect, a pump-action nozzle device adapted to be fitted to a container
and
to enable fluid stored in the interior of said container to be dispensed
during
use, said device having a body which defines:
(i) an internal chamber;
(ii) an outlet through which fluid dispensed from said chamber is
ejected from the device, said outlet further comprising an outlet
valve configured to only open and permit fluid to be dispensed
from the chamber when the pressure therein exceeds a
predetermined minimum threshold pressure; and
(iii) an inlet through which fluid can be drawn into said chamber, said
inlet further comprising a valve configured to only open and
permit fluid to be drawn into the chamber when the pressure
within the chamber falls below the external pressure,
wherein said body comprises a base portion and a housing portion, said
base portion and housing portions together defining the internal chamber of
the
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device and being slidably mounted to one another such that said housing
portion can be slid towards the base portion to reduce the internal volume of
the
chamber during a first stage of operation, thereby causing the pressure within
the chamber to increase and any fluid stored therein to be dispensed through
said outlet to be dispensed when the pressure therein exceeds the
predetermined
minimum threshold pressure required to open the outlet valve, and then slid
away from the base to increase the volume of the chamber during a second
stage of operation, thereby causing the pressure within the chamber to reduce
and fluid to be drawn into the chamber through the inlet when the pressure
within the chamber falls below the external pressure.
For the avoidance of doubt the expression "external pressure" is used
herein to denote the pressure outside the device and may therefore include the
pressure in the surrounding environment (atmospheric pressure) or the pressure
within the container (which may differ from the atmosphere pressure).
When compared to conventional pump-action nozzle devices, the
devices of the present invention are simpler in design/construction and
comprise a reduced number of components. For instance, it is commonplace
for the internal chamber of a conventional pump-action nozzle device to be a
separate component part of the device which is fitted into the housing of the
nozzle device and typically extends into the interior of the container. In the
nozzle devices of the present invention, however, there is no separate
internal
chamber component because the chamber is defined by the base and housing
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portions of the body. Similarly, the inlet and outlet valves are, in preferred
embodiments, defined by the body of the nozzle arrangement, thereby obviating
the necessity for numerous individual components to be present. This enables a
functioning nozzle device to be moulded from a suitable material, such as
S plastic, and provides significant cost savings by reducing the amount
material
required to manufacture the devices, as well as reducing the
construction/assembly costs. Furthermore, in preferred embodiments of the
invention, the bulk of the device can be significantly reduced and the chamber
can be positioned outside the container (or substantially outside of the
container), thereby enabling the device to be fitted to the openings of
containers
of virtually any size, without the amount of pressure that can be generated
being influenced by the size of the container and the constraints that this
would
impose of the dimensions of the device (as is the case with conventional pump
nozzle devices).
The nozzle device of the present invention may be adapted to be fitted to
a container by any suitable means. Preferably, it is the base portion of the
nozzle device that is configured to be fitted to an opening of a container. In
a
preferred embodiment, the base comprises a cavity adapted to receive a
correspondingly neck of the container which defines the opening of the
container. The neck may be secured in the cavity by any suitable securing
means. Preferably, the base is a screw top which can be fitted to an opening
of
the container (i.e. the neck of the container is provided with a screw thread
that
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is adapted to screw into a groove formed in the internal wall of the base, or
vice
versa).
Preferably, the base also defines the inlet of the device.
It is also preferred that an upper surface of the base (or a surface
disposed on the opposing side of the base to the surface which is configured
to
be fitted to a container) forms an internal surface or wall of the chamber.
Most
preferably, the internal surface is an end wall or surface which is disposed
outside the interior of the container. The remaining walls of the chamber are
preferably formed by the housing, which is also preferably mounted onto the
upper surface on the base. As a consequence, it will be appreciated that the
chamber is defined between the base and housing will be substantially outside
of the container to which the base is attached. Thus, although a small portion
of the device may extend into the interior of the container, it is preferred
that
substantially entire internal chamber is positioned outside the container.
It is preferable, therefore, that the housing forms one or more internal
walls of the chamber. In especially preferred embodiments of the invention,
the
base defines one end of the chamber and the housing defines the opposing end
and a side wall of the chamber.
Preferably, the housing is slidably mounted within a recess or groove
formed on an upper surface of the base (or a surface disposed on the opposing
side of the base to the surface which is configured to be fitted to a
container).
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In certain preferred embodiments of the invention, the chamber of the
device further comprises a plunger. The function of the plunger is primarily
to
enable virtually the entire contents of the chamber to be expelled when the
volume of the internal chamber is reduced during the first stage of the
operation
of the device of the invention and to prevent any fluid leaking out between
any
gaps between the mounting of the housing and the base.
To enable the plunger to perform this function it must form a seal with
the sides of the chamber to contain the fluid within a sealed portion of the
chamber. In certain embodiments it is preferred that the plunger contacts the
side wall of the chamber. In such embodiments of the invention, it is
preferred
that the plunger forms two seals with the wall of the chamber, namely a first
seal which is formed where the plunger meets the side wall to define the
sealed
portion of the chamber and thereby prevents the product leaking past the
plunger during the first stage of operation, and a second seal formed on the
opposing side of the plunger which prevents air being drawn into the chamber
(from gaps or leaks between the housing and the base) instead fluid being
drawn in through the inlet during the second stage of operation of the device.
The seal or seals must be maintained while the housing is moved relative to
the
base to facilitate the expansion and/or compression of the chamber. The
plunger may be fixed to the housing within the chamber so that when the
housing moves relative to the base during the operation the device, the
plunger
also moves. Preferably, however, the plunger is seated on an upper surface of
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the base of the device so that the space within the sealed portion of the
chamber
is defined between said plunger and the internal walls of the housing. It will
be
appreciated that the plunger will remain stationery within the chamber in this
position as the housing is slid relative to the base during the operation of
the
device.
The plunger may be made from any suitable material, such as rubber or
plastics materials, for example. The plunger may be integrally formed with the
base, but is preferably a separate component that may optionally be formed
from a different material to that of the base.
In alternative preferred embodiments of the invention, the plunger may
be replaced by a resiliently deformable insert which defines an internal
sealed
compartment which contains the fluid present in the chamber. Preferably the
insert extends from one end of the chamber to the opposing end (as described
further in reference to the accompanying drawing below). In such cases, the
1 S insert is configured to resiliently deform from an initial resiliently
biased
configuration when said housing is slid towards the base to compress the
chamber, and return to its non-deformed or resilient biased configuration as
the
housing is returned to its original position and the internal volume of the
chamber is increased.
Preferably, the nozzle device comprises a resilient means which is
resiliently biased to urge said base and said housing apart. In certain
preferred
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embodiments of the invention, the resilient means is a spring disposed within
the chamber. In alternative embodiments wherein the fluid present within the
chamber is contained within a resiliently deformable insert, as discussed
above,
said insert forms the resilient means which is biased to urge the base and the
S housing apart. Preferably, cooperating detents provided on the base and the
housing contact each other to limit the distance that the housing may slide
away
from the base.
Thus, in use, an operator wishing to dispense the contents of the
container can apply pressure to the housing of the device against the action
of
the resilient means and thereby cause the volume of the internal chamber to be
reduced and any fluid present therein to be dispensed through the outlet. Once
the pressure applied by the operator to the housing has been released, the
resilient means urges then urges the housing and the base apart and thus
causes
the contents of the container to be drawn into the chamber of the device ready
1 S for the next actuation by the operator.
Preferably, at least a portion of the internal passageway of the outlet is
defined between the abutment surfaces of two or more component parts of the
nozzle device.
In certain embodiments of the invention a portion of the internal
passageway may be defined by just one of said component parts. In preferred
embodiments of the invention, however, each of said parts has an abutment
surface which contacts opposing abutment surfaces of the other parts when the
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respective parts are contacted together in the assembled nozzle device and at
least one of the abutment surfaces has one or more groove and/or recesses
formed thereon which defines the internal passageway when said parts are
contacted together.
5 It is most preferred that the at least a portion of the internal passageway
is defined between two component parts of said body. In such cases, the at
least a portion of the passageway is defined between opposing abutment
surfaces of said two parts and at least one of said abutment surfaces has one
or
more grooves and/or recesses formed thereon which define the passageway
10 when the abutment surfaces of the two parts are contacted together. Most
preferably, both of said abutment surfaces have one or more grooves and/or
recesses formed thereon which align to define said passageway when the
abutment surfaces of said parts are contacted together.
Examples of nozzle devices formed of two separate parts having
abutment surfaces which define an internal passageway of a nozzle device are
described in WO 01/89958 and WO 97/31841, and the entire contents of these
documents are incorporated herein by reference.
The outlet valve may be any suitable valve assembly configured to only
open and permit fluid to flow through the outlet when the volume of the
chamber is reduced and the pressure therein exceeds a predetermined minimum
threshold pressure. The minimum threshold pressure required will depend on
the application of the nozzle device. For instance, the threshold pressure may
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be set very low if the product is to be dispensed slowly or gradually (as is
the
case with, for example, soaps, creams etc.) whereas the threshold pressure may
be much higher if the nozzle device is to be used to generate a spray. In the
latter case, the contents of the chamber may be ejected at a pressure of 6
bars,
for example, and in such cases the minimum threshold pressure of the outlet
valve may be set at 5 bars. The outlet valve could be a ball valve, for
example,
where the ball is displaced to open the valve when the pressure within the
chamber exceeds a predetermined minimum threshold.
In preferred embodiments of the invention, however, the outlet valve is
defined by the body of the nozzle arrangement.
Furthermore, in preferred embodiments of the invention wherein the
outlet comprises a outlet orifice and an internal passageway, at least a
portion
of which is defined between the abutment surfaces of two or more parts of the
nozzle device, the outlet valve is preferably formed within said portion of
the
internal passageway that is defined between the abutment surfaces of two or
more parts of the nozzle device, although it may also be formed in a portion
of
the internal passageway that is defined by just one of said parts. Most
preferably, the valve comprises a valve member that is formed on one of the
component parts, said valve member being resiliently biased against the
opposing surface of the other component part or parts, thereby closing the
internal passageway formed there between, and being configured to be
displaced so as to define an open channel through which fluid can flow when
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the pressure within the chamber exceeds a predetermined minimum threshold
pressure.
Preferably, the valve member is in the form of a resiliently deformable
flap that is mounted to one of said component parts and is resiliently biased
into
a configuration whereby the flap extends across the internal passageway and
closes the passageway. The flap is further configured to resiliently deform
when the pressure within the chamber is at or exceeds a predetermined
minimum threshold pressure to define an opening or channel through which
fluid from the chamber can flow along the internal passageway to the outlet
orifice, where it is ejected in the form of a spray. The flap may simply
extend
across the passageway, but it is preferable that the flap is resiliently
biased
against an opposing abutment surface or surfaces, which define the internal
passageway. It is especially preferred that the flap is mounted within a
chamber
formed within the internal passageway. The chamber provides sufficient space
for the flap to be deflected from its resiliently biased position to open the
valve
when the pressure within the chamber is at or exceeds the predetermined
minimum threshold. The flap will also be configured so that it can only be
distended by fluid pressure acting towards the outlet and not in the opposite
direction, there by making the valve a one-way outlet valve.
Alternatively, the valve member is in the form of a plug which is
resiliently biased into a position in which the plug blocks the internal
passageway, but is configured to also be displaced to define an opening or
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channel through which fluid can flow when the when the pressure within the
chamber is at or exceeds the predetermined minimum threshold. Although the
plug itself may be configured to deform so as to define a channel or opening
through which fluid can flow when the pressure within the chamber (and acting
on the plug) is at or exceeds the predetermined minimum threshold, it is most
preferable that the plug is mounted to a resiliently deformable surface which
can deform to withdraw the plug from the internal passageway when the
requisite pressure within the chamber has been achieved.
As a further alternative, the valve member may be adapted to resiliently
collapse or otherwise deform, thereby forming a channel through which fluid
can pass when a minimum pressure within the chamber has been achieved.
The valve member and/or the surface on which it is mounted may be
made from any suitable resiliently deformable material, such as a deformable
plastic material or a rubber material.
The outlet orifice is positioned at the end of the internal passageway.
Preferably, the outlet orifice is formed at an edge of the abutment surfaces
of
the at least two parts.
In a preferred embodiment of the invention, the outlet is defined by the
housing portion of the body. Preferably, the housing comprises two component
parts and said at least a portion of the internal passageway of the outlet is
defined between the two component parts of the housing. In an especially
preferred embodiment of the invention the housing comprises a first component
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part that defines the internal chamber together with the base and comprises an
aperture which forms an initial section of the internal passageway, and a
second
component part which is fitted to the first part to such that abutment
surfaces of
said first and second parts are contacted together to define the remainder of
the
internal passageway there between.
In embodiments of the invention which are adapted to generate a spray
of the fluid dispensed through the outlet during use, it is preferable that
the
internal passageway further comprises one or more internal spray-modifying
features. As an alternative, the nozzle device may be configured to receive an
insert which comprises one or more spray-modifying features. The insert can
be positioned in relation to the nozzle device so that fluid exiting the
outlet
orifice flows into an inlet of said insert and through an internal passageway
comprising the one or more internal spray modifying features formed therein to
an outlet orifice of the insert where the fluid is ejected.
Suitable spray-modifying features that may be incorporated within the
internal fluid flow passageway or present in an insert fitted thereto are
known
in the art and are described further in, for example, Tnternational Patent
Publication No. WO 01/89958, the entire contents of which are incorporated
herein by reference. Illustrative examples of such features include one or
more
features selected from the group consisting of: an expansion chamber, a swirl
chamber, an internal orifice, multiple passageway branches, a dog-leg
arrangement (where the passageway comprises a turn in one direction, typically
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through ninety degrees, followed by a turn back in the opposing direction), a
venturi chamber (where air is drawn into the fluid stream by venture), an
outlet
orifice in the form of a slit, or multiple outlet orifices.
It is preferable that outlet valve is positioned before (or upstream from)
5 the one or more spray modifying features, such that fluid can only flow
through
the spray modifying features when the pre-compression valve is open.
The inlet valve may be any suitable valve assembly which enables the
contents of the container to flow into the chamber of the device only when the
pressure within the chamber falls below the external pressure, but which
10 prevents flow in the other direction during the first stage of operation of
the
device. In certain embodiments of the invention, the plunger is seated on the
upper surface of the base and comprises valve member or stem which extends
from the main body of the plunger and is received in a sealing engagement with
a valve seat formed in the base. In alternative embodiments, the valve member
15 or stem may be a separate component, i.e. it is not integrally formed with
the
plunger. During the second stage of operation, the valve member or stem is
displaced from the valve seat to form an opening through which the contents of
the container may flow into the chamber of the device when the pressure within
the chamber falls below the external pressure.
In order to prevent the container to which the device is attached from
collapsing when fluid is dispensed from the interior of the container and the
pressure therein is reduced, it is preferable that the device comprises an air
leak
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valve configured to enable air from the external environment to access the
interior of the container to equalise any pressure differential that exists
between
them. Any suitable form of air leak would suffice. Preferably, however, the
air
leak valve is a one-way valve, which enables air to flow into the container
from
the outside, but prevents fluid flow in the opposite direction, and hence,
prevents any product in the container from leaking out through the air leak
valve if the container is inverted, for example. Illustrative examples of
suitable
air leak valve arrangements formed in the device of the present invention are
described below in reference to Figures 9A, 9B and 9C.
Preferably, a dip tube is fitted to the base to enable a product stored in
the container to be drawn into the device from the interior of the container.
For certain applications, it is desirable to co-eject air together with the
contents of the container passing through the nozzle outlet. For instance, the
air
could be mixed with the product to impart a certain consistency to the
product,
which is desirable for certain products, such as, for example, foams or
mousses.
Alternatively a pressurised air stream could be used to atomise droplets of
liquid passing through the nozzle outlet to create a fme spray. For this
latter
application it is especially desirable to be able to introduce an air stream
at a
predetermined location along the length of the fluid flow passage of the
nozzle
outlet. Hence, in certain embodiments of the invention, the chamber of the
device is divided into two separate compartments, a first of said compartments
comprising the inlet valve and the outlet valve and being configured dispense
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fluid drawn in through the inlet of the device during the first and second
stages
of operation, and a second of said compartments being a separate an air
compartment or chamber configured to a eject a stream of air through the
nozzle outlet during the first stage of operation and draw air in from the
outside
during a second stage of operation. Hence, the movement of the housing
relative to the base to cause the compression of the chamber during the first
stage of operation in such embodiments causes the contents of the container to
be dispensed through the nozzle outlet in the usual manner, and additionally
forces air from the second compartment though an outlet channel into the
nozzle outlet, where the mixing of the air with the contents of the container
passing through the nozzle outlet occurs.
Preferably, the said air chamber is provided with an outlet valve
configured to only open and permit a stream air to flow through the outlet of
the nozzle arrangement when the pressure within the air compartment exceeds a
predetermined minimum pressure.
In preferred embodiments of the invention wherein the outlet comprises
an outlet orifice and an internal passageway, the air stream ejected from said
air
comparixnentlchamber during the first stage of operation may be introduced
into said internal passageway at any position along its length through an
outlet
channel of the air compartment.
It is also preferred that the nozzle device further comprises an air inlet
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valve .configured to open and permit air to access the air compartment only
when the pressure therein falls below the external pressure. Therefore, during
the second stage of operation of the device, air is drawn into the air chamber
from the external environment through a one-way air inlet valve which allows
air to access the air compartment of chamber when the pressure in the chamber
is decreased relative to that of the external environment, i.e. when the
volume
of the chamber is increased by moving the housing and the base apart, but
prevents the flow of air in the opposite direction during the first stage of
operation. The air may be drawn into the air chamber/compartment through
the nozzle, outlet and/or through gaps formed between the housing and the base
and/or a designated air inlet.
Preferably, the first compartment comprises a plunger as discussed
above and the second air chamber/compartment is also provided with an air
plunger. Preferably, the air plunger is adapted to form a seal with the
housing
which prevents the air present in the air chamber/compartment from ~ leaking
past the air plunger during the first stage of operation, but which allows air
to
flow past during the second stage of operation.
In a preferred embodiment, the air inlet valve also functions as the air
release between the interior of the chamber and the external environment.
The nozzle devices of the present invention are preferably formed from
plastic. The component parts of the nozzle arrangement may be moulded
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individually and then connected together to form the assembled nozzle
arrangement. Alternatively, some or all of the components may be formed by a
bi-injection moulding process whereby a first component is moulded during a
first moulding stage and a second component part is then moulded onto the
first
component part during a second moulding stage. The first and second
component parts may be made from the same or a different material.
In embodiments where the housing is composed of two component parts,
each component part may be made moulded separately and then j oined together
or by a bi-injection moulding process, as described above. As an additional
alternative, the two component parts may be connected to one another by a
hinge or foldable connection element and moulded in a single moulding
operation and then folded over about said hinge or connection element to form
the assembled housing component.
The respective parts, once formed, may be permanently fixed together
or, alternatively, the parts may be releasably connectable to one another.
This
latter form of assembly is preferred because it enables the respective parts
to be
separated to expose the interior of the nozzle device for cleaning.
The device of the present invention may also be provided with a trigger
actuator which enables the first and second stages of operation to be
facilitated
by the operation of a trigger, rather than applying pressure to the housing
directly. The trigger actuator is preferably configured so that, when the
trigger
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is pulled, the housing of the device is caused to move towards the base and
compress the chamber of the device formed there between, thereby causing the
pressure within the chamber to increase and the fluid present therein to be
dispensed through the nozzle outlet. When the trigger is released, the housing
5 is free to move away from the base so as to cause the volume of the chamber
to
expand and thereby draw more product (and air if an air compartment is
present) into the chamber.
Preferably, the trigger actuator is a separate component that is fitted to
the pump-action nozzle device and which comprises a trigger handle and two
10 attachment elements. Preferably, a first attachment element fixes the
actuator
to the base and a second attachment element attaches the trigger actuator to
the
housing, said elements being moveable towards each other when the trigger is
pulled and moveable apart from each other when the trigger is released and
returned to its original position.
15 Preferably, one attachment element is integrally formed with the trigger
and is pivotally attached to the base of the device and the other attachment
element, the other attachment element being pivotally mounted to the housing
of the device.
According to a second aspect of the present invention there is provided a
20 trigger actuator adapted to be fitted to a pump nozzle device comprising an
internally compressible chamber formed between a housing and a base of the
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21
device, said housing being moveable relative to the base to facilitate the
expansion of the internal chamber in a first stage of operation and the
compression of the chamber in a second stage of operation, said trigger
actuator
comprising a trigger handle and means by which the trigger actuator may be
connected to the base and means by which the trigger actuator may be attached
the housing, wherein said trigger actuator is configured so that when the
trigger
is pulled towards the nozzle device said housing is caused to move relative to
the base and compress the chamber during the second stage of operation and
when said trigger is released said housing is caused to move relative to the
base
to expand the chamber during the first stage of operation.
Thus, the trigger actuator provides a means by which a pump nozzle
device may be converted into a trigger actuated pump-action nozzle device.
The trigger actuator is preferably formed as discussed above.
In more general terms, it can be particularly desirable to co-eject air
from a pump-action nozzle device because, in the case of devices adapted to
generate a spray (e.g. forger pump and trigger spray nozzle devices), the
quality
of the spray produced at low pressures can often be poor and the mixing of the
fluid with an air stream provides a means by which the spray droplets ejected
from the nozzle device can be further atomised prior to ejection from the
nozzle
device. In addition, it can also be desirable to introduce air into a low
pressure
dispenser which is dispensing a product such as a foam or mousse. Although it
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is commonplace to co-ej ect air from industrial scale nozzle devices where
high
volumes of air and high pressures are can be used, it is less common (although
not unknown) to co-eject air with another fluid from a pump-action nozzle
device. This is because the amount of air that can be contained in such
devices
is limited (up to a maximum of 10 times the volume of liquid dispensed and
more typically between 5 and 10 times the volume of liquid) and the pressure
generated by such devices is typically low (between 3 and 6 bars).
Conventional nozzle devices (commonly referred to as air pumps) are
generally large complex structures that are difficult to manufacture,
particularly
at low cost (due to the material and assembly costs involved). It is a further
object of the present invention, therefore, to provide a pump-action nozzle
arrangement which can co-eject air together with another fluid from a
container
and which is also simple and compact nozzle device that is inexpensive to
produce and comprises only a few separate components.
Hence, according to a third aspect of the present invention there is
provided a pump-action nozzle device adapted to be fitted to an opening of a
container and enable a liquid to be dispensed from the interior of said
container
during use, said nozzle device having a body which defines an internal chamber
and which comprises:
(i) an inlet having a one-way valve through which fluid can be drawn
into said chamber;
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23
(ii) an outlet orifice;
(iii) an internal passageway that connects said chamber to said outlet
orifice;
(iv) a one-way outlet valve disposed in said internal passageway and
adapted to only open and permit fluid to flow along said passageway when the
pressure within the internal chamber exceeds a predetermined minimum
pressure; and
(iv) an actuator;
wherein said body is configured such that the internal volume of the
chamber is reduced when said actuator is operated, thereby causing fluid
stored
in the chamber to be ejected through said outlet valve and along said internal
passageway to the outlet orifice, and increased when said actuator is
released,
thereby causing fluid to be drawn into the chamber through the inlet;
characterised in that said body further defines an air chamber configured
to dispense a stream of air into said internal passageway or said outlet
orifice
when said actuator is operated through an outlet channel which connects said
air chamber to a position along said internal passageway or said outlet, said
body being configured such that the internal volume of the chamber is reduced
when said actuator is operated, thereby causing air present in the air chamber
to
be ejected through said outlet channel and into said internal passageway or
said
outlet orifice, and increased when said actuator is released, thereby causing
air
to be drawn into the air chamber from the external environment.
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24
Preferably the nozzle devices of the third aspect of the present invention
comprise one or more features of the nozzle arrangements of the first aspect
of
the present invention defined above (even if no specifically reiterated
below).
During the normal operation of the device of the third aspect of the
present invention, the actuator is operated to compress both the internal
chamber of the device and the air chamber to cause fluid present in the
internal
chamber and air present in the air chamber, respectively, to be dispensed
through the outlet orifice. Once the actuator is then released, the volume of
the
chambers can be increased to cause fluid to be drawn into the internal chamber
through the inlet of the device and air to be drawn into the air chamber.
It is preferable that one or more of the internal chamber, inlet (and inlet
valve), outlet valve (and outlet valve) are defined by the body of the device,
as
discussed above. Most preferably, all of the aforementioned components are
defined by the body of the device. Thus, in such embodiments, the device of
the
third present invention is simpler in design/construction and comprises a
reduced number of components. Furthermore, in preferred embodiments of the
invention, the bulk of the device can be significantly reduced and the chamber
can be positioned outside the container (or substantially outside of the
container), thereby enabling the device to be fitted to the openings of
containers
of virtually any size, without the amount of pressure that can be generated
being influenced by the size of the container and the constraints that this
would
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impose of the dimensions of the device (as is the case with conventional pump
nozzle devices).
Preferably, the device comprises a resilient means configured to cause
the volume of the chamber to increase once the actuator is released.
5 Preferably, the body of the device comprises two component parts that
can be moved towards one another to compress the internal chamber and the air
chamber, and away from one another to cause the chamber to expand. The
resilient means is preferably biased against both of said parts to urge the
two
parts away from one another. The resilient means may be a spring or other
10 resiliently deformable insert provided in one or both said internal chamber
and
said air chamber.
The air chamber may be a separate compartment of the internal chamber
or may be a separate chamber altogether.
Air may be drawn into the air chamber through outlet orifice and the
1 S internal passageway of the device and into the air chamber through the
outlet
channel when the actuator is released and the volume of said chamber is caused
to increase/expand. In such cases, air is prevented from accessing the
internal
chamber by the one-way outlet valve. Preferably, however, the device may
further comprise an air inlet through which air is drawn into the air chamber
20 from outside the device. The air inlet preferably comprises an air inlet
valve
configured to only open and permit air to be drawn into the chamber when the
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26
pressure therein falls below the external pressure (i.e. when the volume of
the
chamber is caused to increase).
The outlet channel may be one or more fme holes or pores which permit
air to flow through but prevent any liquid from the internal chamber flowing
through the internal passageway from accessing the air chamber. Most
preferably, however, the outlet channel comprises an air release valve adapted
to only open and permit fluid to flow along said passageway when the pressure
within the air chamber exceeds a predetermined minimum pressure. Any
suitable air release valve may be used. In embodiments of the third aspect of
the invention where air is drawn into the air chamber through the outlet
orifice
and the internal passageway, the air release valve will be a two-way valve
configured to permit air to flow out of the air chamber when the pressure
within
the chamber exceeds a predetermined minimum pressure, and flow into the air
chamber when the pressure therein falls below the external pressure. In
embodiments of the third aspect of the invention where air is drawn into the
air
chamber through a separate air inlet, the air release valve is preferably a
one
way valve configured to only open and permit air to flow out of the air
chamber
when the pressure therein exceeds a predetermined minimum.
Preferably, the outlet valve and the air release valve are configured to
open at substantially the same minimum threshold pressure. This ensures that
the fluid from the internal chamber and the air from the air chamber are both
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27
released at the same time. Clearly this can be modified to enable either the
air
or liquid to be dispensed first if this is desired.
Preferably, the internal passageway is separated from said air chamber
by a wall of the body and said outlet channel is formed in said wall at any
desired position so that air can be ejected into said internal passageway at
any
desired position along the length of the internal passageway.
In preferred embodiments of the third aspect of the invention the
chamber is positioned either above or below the internal passageway and said
outlet channel is formed in an upper or lower wall of the chamber
respectively.
Preferably the outlet channel is positioned so that air is introduced into
the internal passageway downstream from the outlet valve (i.e. it is
introduced
at a position between the outlet valve and the outlet orifice).
Preferably, at least a portion of the internal passageway of the outlet is
defined between the abutment surfaces of two or more component parts of the
nozzle device.
In certain embodiments of the third aspect of the invention a portion of
the internal passageway may be defined by just one of said component parts. In
preferred embodiments of the third aspect of the invention, however, each of
said parts has an abutment surface which contacts the abutment surfaces of the
other parts when the parts are contacted together in the assembled nozzle
device, and at least one of said abutment surfaces has one or more groove
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and/or recesses formed thereon which define said internal passageway between
the abutment surfaces when said parts are contacted together. It is most
preferred that the at least a portion of the internal passageway is defined
between two component parts of said body. In such cases, the at least a
portion
of the passageway is defined between opposing abutment surfaces of said two
parts and at least one of said abutment surfaces has one or more grooves
and/or
recesses formed thereon which define said passageway when the abutment
surfaces of said parts are contacted together. Most preferably, both of said
abutment surfaces have one or more grooves and/or recesses formed thereon
which align to define said passageway when the abutment surfaces of said parts
are contacted together.
Examples of nozzle devices formed of two separate parts which define
an internal passageway of the device are described in WO 01/89958 and WO
97131841, and the entire contents of these documents are incorporated herein
by
reference.
The outlet valve may be any suitable valve assembly configured to only
open and permit fluid to flow through the outlet when the volume of the
chamber is reduced and the pressure therein exceeds a predetermined minimum
threshold pressure. The minimum threshold pressure required will depend on
the application of the nozzle device. For instance, the threshold pressure may
be set very low if the product is to be dispensed slowly or gradually at a low
pressure (as is the case with, for example, soaps, creams etc.) whereas the
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threshold pressure may be much higher if the nozzle device is to be used to
generate a spray. In the latter case, the contents of the chamber may be
ejected
at a pressure of 6 bars, for example, (although it could be as low as 2 to 3
bars
in some cases) and in such cases the minimum threshold pressure of the outlet
valve may be set at 5 bars. The outlet valve could be a ball valve, for
example,
where the ball is displaced to open the valve when the pressure within the
chamber exceeds a predetermined minimum threshold. In a preferred
embodiment of the third aspect of the invention, however, the outlet valve is
a
flap valve in which the flap is resiliently mounted so as to reside in a
position in
which a channel between the chamber and nozzle outlet is closed (i.e. the
valve
is closed), but may be distended to a position in which said channel is open
(i.e.
the valve is open) when the pressure within the chamber exceeds the
predetermined minimum threshold pressure.
In preferred embodiments of the third aspect of the invention wherein
1 S the outlet comprises a outlet orifice and an internal passageway, at least
a
portion of which is defined between the abutment surfaces of two or more parts
of the nozzle device, the outlet valve is preferably formed by said portion of
the
internal passageway that is defined between the abutment surfaces of two or
more parts of the nozzle device, although it may also be formed in a portion
of
the internal passageway that is defined by just one of said parts. Most
preferably, the valve comprises a valve member that is formed on one of the
component parts, said valve member being resiliently biased against the
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opposing surface of the other component part or parts, thereby closing the
internal passageway formed there between, and being configured to be
displaced so as to define an open channel through which fluid can flow when
the pressure within the chamber exceeds a predetermined minimum threshold
5 pressure.
Preferably, the valve member is in the form of a resiliently deformable
flap that is mounted to one of said component parts and is resiliently biased
into
a configuration whereby the flap extends across the internal passageway and
closes the passageway. The flap is further configured to resiliently deform
10 when the pressure within the chamber is at or exceeds a predetermined
minimum threshold pressure to define an opening or channel through which
fluid from the chamber can flow along the internal passageway to the outlet
orifice, where it is ejected in the form of a spray. The flap may simply
extend
across the passageway, but it is preferable that the flap is resiliently
biased
15 against an opposing abutment surface or surfaces, which define the internal
passageway. It is especially preferred that the flap is mounted within chamber
formed within the internal passageway. The chamber provides sufficient space
for the flap to be deflected from its resiliently biased position to open the
valve
when the pressure within the chamber is at or exceeds the predetermined
20 minimum threshold.
Alternatively, the valve member is in the form of a plug which is
resiliently biased into a position ~ in which the plug blocks the internal
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31
passageway, but is configured to also be displaced to define an opening or
channel through which fluid can flow when the when the pressure within the
chamber is at or exceeds the predetermined minimum threshold. Although the
plug itself may be configured to deform so as to define a channel or opening
through which fluid can flow when the pressure within the chamber (and acting
on the plug) is at or exceeds the predetermined minimum threshold, it is most
preferable that the plug is mounted to a resiliently deformable surface which
can deform to withdraw the plug from the internal passageway when the
requisite pressure within the chamber has been achieved.
The valve member and/or the surface on which it is mounted may be
made from any suitable resiliently deformable material, such as a deformable
plastic material or a rubber material.
In general it is preferable that the outlet valve is defined by the body of
the device rather than being a separate component. Thus, one part of the body
comprises a valve member formed thereon as an integral component, which
shuts off or closes the internal passageway but which can be displaced to open
the valve when the pressure within the chamber exceeds the predetermined
minimum threshold pressure.
The outlet orifice is positioned at the end of the internal passageway.
Preferably, the outlet orifice is formed at an edge of the abutment surfaces
of
the at least two parts
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In embodiments where the internal passageway is defined by two or
more abutment surfaces (preferably two abutment surfaces), the outlet channel
of the air chamber extends from a position on one of said abutment surfaces to
the air chamber.
In embodiments of the third aspect of the invention which are adapted to
generate a spray of the fluid dispensed through the outlet during use, it is
preferable that the internal passageway further comprises one or more internal
spray-modifying features. As an alternative, the nozzle device may be
configured to receive an insert which comprises one or more spray-modifying
features. The insert can be positioned in relation to the nozzle device so
that
fluid exiting the outlet orifice flows into an inlet of said insert and
through an
internal passageway comprising the one or more internal spray modifying
features formed therein to an outlet orifice of the insert where the fluid is
ej ected.
Suitable spray-modifying features that may be incorporated within the
internal fluid flow passageway or present in an insert fitted thereto are
known
in the art and are described further in, for example, International Patent
Publication No. WO 01/89958, the entire contents of which are incorporated
herein by reference. Illustrative examples of such features include one or
more
features selected from the group consisting of: an expansion chamber, a swirl
chamber, an internal orifice, multiple passageway branches, a dog-leg
arrangement (where the passageway comprises a turn in one direction, typically
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33
through ninety degrees, followed by a turn back in the opposing direction), a
venturi chamber (where air is drawn into the fluid stream by venture), an
outlet
orifice in the form of a slit, or multiple outlet orifices.
It is preferable that outlet valve is positioned before (or upstream from)
the one or more spray modifying features, such that fluid can only flow
through
the spray modifying features when the pre-compression valve is open.
It is also especially preferred that the outlet channel is arranged to
introduce air into an internal chamber formed in the internal passageway or
the
insert (whereby the outlet channel may align with a hole formed in the insert
through which the air can flow into the insert). Such a chamber may be an
expansion chamber or a swirl chamber.
The inlet valve may be any suitable valve assembly which enables the
contents of the container to flow into the chamber of the device only when the
pressure within the chamber falls below the external pressure, but which
prevents flow in the other direction during the first stage of operation of
the
device.
The actuator may be any suitable means by which the compression and
subsequent re-expansion of the chamber may be facilitated. For instance, the
actuator may be a portion of the body that can be pressed by an operator to
facilitate the compression of the chamber, or the nozzle arrangement may
further comprise a trigger actuator that can be pulled by an operator to
facilitate
the compression of the chamber.
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In order to prevent the container to which the device is attached from
collapsing
when fluid is dispensed from the interior of the container and the pressure
therein is reduced, it is preferable that the device comprises an air leak
valve
configured to enable air from the external environment to access the interior
of
the container to equalise any pressure differential that exists between them.
Any suitable form of air leak would suffice. Preferably, however, the air leak
valve is a one-way valve, which enables air to flow into the container from
the
outside, but prevents fluid flow in the opposite direction, and hence,
prevents
any product in the container from leaking out through the air leak valve if
the
container is inverted, for example. Illustrative examples of suitable air leak
valve arrangements formed in the device of the present invention are described
below in reference to Figures 9A, 9B and 9C.
The nozzle devices of the third aspect of the present invention axe
preferably formed from plastic. The component parts of the nozzle
arrangement may be moulded individually and then connected together to form
the assembled nozzle arrangement. Alternatively, some or all of the
components may be formed by a bi-inj action moulding process whereby a first
component is moulded during a first moulding stage and a second component
part is then moulded onto the first component part during a second moulding
stage. The first and second component parts may be made from the same or a
different material.
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In embodiments where the housing is composed of two component parts,
each component part may be made moulded separately and then joined together
or by a bi-injection moulding process, as described above. As an additional
alternative, the two component parts may be connected to one another by a
5 hinge or foldable connection element and moulded in a single moulding
operation and then folded over about said hinge or connection element to form
the assembled housing component.
The respective parts, once formed, may be permanently fixed together by, for
example, ultrasonic welding, or alternatively, the parts may be releasably
10 connectable to one another. This latter form of assembly is preferred
because it
enables the respective parts to be separated to expose the interior of the
nozzle
device for cleaning
How the invention may be put into effect will now be described further
by way of example only in reference to the following Figures, in which:
15 Figure lA is a cross-sectional view taken through a first embodiment of
a device of the present invention;
Figure 1B is an exploded cross-sectional view showing the components
which make up the device shown in Figure 1 A;
Figure 2A is a cross-sectional view taken through a second embodiment
20 of a device of the present invention;
Figure 2B is an exploded cross-sectional view showing the components
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36
which make up the device shown in Figure 2A;
Figure 3A is a cross-sectional view of the housing 102 shown in Figures
2A and 2B;
Figure 3B is a plan view of the underside of the housing 102 shown in
Figures 2A and 2B;
Figure 4 is a plan view of the base 101 shown in Figure 2A;
Figure SA is a cross-sectional view of the plunger 108 shown in Figures
2A and 2B;
Figure SB is a plan view of the plunger 108 shown in Figures 2A and
2B;
Figures 6A and 6B are both cross-sectional views showing the top
portion of the housing shown in Figure 2A and 2B nozzle outlet with the lid
104 partly displaced from the housing (Figure 6A) and in contact with the
housing 102 (Figure 6B);
Figure 7A is a cross-sectional view of the nozzle outlet 106 shown in
Figures 2A and 2B;
Figure 7B is a perspective view of the recess 704 shown in Figure 7A;
Figure 7C is a cross-sectional view taken along line X-X' of Figure 7A
in an assembled nozzle outlet;
Figure 8 is a cross-sectional diagrammatical view taken through the
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37
upper portion of the housing 102 of an alternative embodiment of the present
invention which incorporates an alternative version of the second valve;
Figures 9A to 9c are cross-sectional diagrammatical views showing
various embodiments of an air leak valve;
Figure l0A is a cross-sectional view of a device of the present invention
which is fitted with a trigger actuator;
Figure lOB is a cross-sectional view of the device shown in Figure 8A
when the trigger has been pulled to cause the housing to move relative to the
base;
Figure 11 is a cross-sectional view taken through the housing 102 of an
alternative embodiment of the present invention;
Figure 12A is an exploded cross-sectional view of a fiu-ther alternative
embodiment of the present invention;
Figure 12B is a cross-sectional view of the assembled nozzle
arrangement shown in Figure 12A;
Figure 13 is a cross-sectional view of a further alternative embodiment
of the present invention; and
Figure 14 is a cross-sectional view to yet another alternative
embodiment of the invention.
Figures 1 to 14 all exemplify the first aspect of the present invention.
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Figures l0A and lOB exemplify the second aspect of the present invention and
Figures 2A to 8, 13 and 14 exemplify the third aspect of the present
invention.
In the following description of the Figures, like reference numerals will
be used to denote like or corresponding parts in different Figures.
A first embodiment of a device 100 according to the present invention is
shown in Figures lA and 1B. The device 100 comprises a base 101 which
defines a cavity 150, the internal walls of which are provided with a screw
thread 151 formed therein. This internal cavity 150 is adapted to receive a
corresponding shaped and screw-threaded neck of a container, thereby enabling
the device 100 to be screwed onto the container for use.
The device 100 further comprises a housing 102 which is slidably
mounted within a recessed groove 103 formed on the upper surface of the base
101. The groove 103 of the base is provided with detents (in this case an
inwardly projecting rim lOla) which abut co-operating detents (in this case an
outwardly projecting rim 102a) formed on the housing 102 to limit the upward
movement of the housing relative to the base and thereby prevent the housing
from sliding out of engagement with the base during use.
The base 101 and housing 102 together define an internal chamber 107
in which a plunger 108 is disposed. The plunger 108 is seated on the base 101
and extends across the entire width of the chamber 107 to abut the side walls
of
the chamber formed by the housing 102 and form a sealing engagement
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therewith.
The plunger 108 also comprises an integrally formed, downwardly
extending valve member 108a, which is received within a valve seat 109
formed in the base 101. The valve member 108x, together with the valve seat
109, form the so-called inlet valve of the device between the chamber and the
interior of the container. An inlet channel 110 is also formed in the base 101
and a dip tube (not shown) is fitted to this channel to enable the contents of
the
container to be drawn into the chamber 107 of the device 100 through the inlet
valve during use, as described further below.
The housing 102 comprises a first part 102c which defines the internal
chamber 107 and additionally comprises a second part in the form of a lid 104.
The first part 102c defines an upper wall 102d and side wall 102e of the
chamber, as well as an initial portion 106a of the internal passageway 106.
The
remainder of the internal passageway 106 is defined between respective
abutment surfaces of the lid 104 and the first part of the housing 102c. In
this
regard, the abutment surfaces of the first part 102c and the lid 104 comprises
recesses and/or grooves formed thereon which align when the respective
abutment surfaces are contacted together to define the remainder of the
internal
passageway 106. An outlet orifice 112 is formed where the grooves/recesses
meet the edge of the abutment surfaces of the housing 102c and the lid 104.
A one-way outlet valve is formed within the internal passageway defined
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by the abutment surfaces of the lid 104 and the first part of the housing
102c.
In this regard, the lid 104 is provided with a resiliently mounted flap 105
which
sits in a chamber lOSa formed in the internal passageway to form the outlet
valve. The flap 105 is resiliently biased against the upper surface of the
first
S part on the housing 102a to close the internal passageway 106, but can be
displaced towards the outlet 112 when the pressure within the chamber exceeds
a predetermined minimum threshold pressure. The outlet valve is a one-way
valve because the flap cannot be displaced towards the chamber 107.
A coiled spring 111 is positioned within the chamber 107. The spring is
10 biased at one end against the housing 102 and the base 101 at its other
end. The
housing additional comprises a support member 102b which extends
downwards from its upper surface and is positioned inside the bore defined by
the coiled spring 111. The support member 102b provides support to the
spring and also enables the spring to be kept in place while the device is
1 S assembled.
The spring urges the housing 102 upwards and away from the base so
that the rim 102a of the housing abuts the internal rim lOla of the base,
thereby
limiting the extent of upward movement of the housing 102. In this position
(and as shown in Figure lA) the internal chamber 107 possesses its maximum
20 internal volume. During use, the lid 104 of the housing 102 can be pressed
downwards by an operator so as to cause the housing 102 to slide towards the
base 101, against the action of the spring 111. During this movement, the
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41
internal volume of the chamber 107 is reduced and this in turn results in the
compression of the chamber 107. The resultant increase in pressure in the
chamber pushes the valve member 108a of the plunger into a sealing
engagement with the valve seat 109, thereby closing the inlet valve and
preventing the contents of the chamber flowing from the chamber 107 into the
interior of the container. Furthermore, once the pressure within the chamber
reaches a predetermined minimum threshold value, for example 5 bars, the
contents of the container cause the resiliently mounted flap 105 to be
displaced
from a position in which the outlet is blocked to a position in which the
outlet is
open, thereby. enabling the contents stored within the chamber 107 to flow
through the outlet valve, along the internal passageway 106 and then be
dispensed from the device through the outlet orifice 112.
Once the desired amount of product has been dispensed or the housing
has been depressed to its fullest extent so that the maximum quantity of
product
has been dispensed from the chamber, then the operator will release the
pressure applied to the housing and the housing will slide back to its initial
position (as shown in Figure lA) under the action of the spring 111. In doing
so the internal volume of the chamber 107 increases and this creates a reduced
pressure within the chamber 107. The outlet valve is closed during this
process
because once the pressure falls below the minimum threshold, the resiliently
mounted flap 105 returns to the position in which it covers the outlet l OSa.
The
reduced pressure within the chamber 107 causes the inlet valve to be opened,
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42
i.e. the valve member 108a of the plunger 108 is displaced from the valve seat
110 and the contents of the container are drawn into the chamber 107 to
replenish the contents previously dispensed.
In a preferred embodiment, the plunger would be replaced with the
plunger shown in Figure 9C, thereby additionally providing the device 100 with
an air leak valve.
Referring to Figure 2A and 2B, there is shown a second embodiment of
a device 200 of the present invention. This second embodiment is the same as
the embodiment shown in Figure 1 in many respects and this is illustrated by
the use of the same reference numerals to denote like or corresponding parts.
There is, however, one principal difference in that the housing 102 is formed
to
define a chamber 107 that is composed of two separate, internally sealed
compartments. The central compartment 107a is equivalent to the chamber 107
shown in Figure 1 in that the contents of the container pass through it during
use. The circular wa11.201 of the housing 102 defines the central compartment
107a. This wall 201 is received within a corresponding circular recessed
groove 202 formed in the upper surface of the base 101. Thus, during use the
wall 201 slides within the recessed groove 202. The chamber 107a comprises a
smaller plunger 108 and a spring 111, the functions of which are identical to
that described in reference to Figures lA and 1B.
The second compartment is an air chamber 203 which surrounds the
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central compartment 107a. The air compartment 203 is defined between the
outside wall of the housing 102 and the inner wall 201. An air plunger 204 is
seated on the base within the air compartment 203 and performs the same
function as the plunger 108 described in reference to Figure 1. In this
embodiment, the air plunger 204 is circular in shape and comprises a recess
205
formed in its under surface which, when seated onto the base in the final
assembly, as shown in Figure 2A, receives the upright protrusion 206 formed
on the base. A plan view of the upper surface of the base 101 is shown in
Figure 4 to illustrate the arrangement of the respective recesses and
protrusions.
The air chamber 203 comprises an outlet channel 204 which connects
the air chamber 203 to a position along the length of the internal passageway
106, such that air ejected from the air chamber 203 when the housing of the
device is displaced towards the base thereby comprising the chambers 107 and
203) entering the internal passageway 106 downstream from the outlet valve
and is dispensed with the liquid dispensed from the chamber 107.
An air release valve (not shown) is provided in the outlet channel 204.
The valve is a two way valve adapted to open and permit air to be dispensed
from the chamber 203 only when a predetermined minimum pressure is
achieved therein. The valve is preferably configured to open at the same time
as the outlet valve so that the liquid dispensed from the chamber 107 is
simultaneously released with air from the air chamber. This ensures that the
air
and liquid mix within the internal passageway 106.
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44
In alternative embodiments of the invention, the housing 102 may be
wider than the base and configured so that the outer wall of the housing
slides
over the outer wall of the base. This construction is preferred for
embodiments
of the invention which comprise an air leak, as discussed further below in
reference to Figure 9C.
For the purpose of illustration, housing 102 of the embodiment shown in
Figure 2 is shown in Figures 3A and 3B. Referring to these Figures, it can be
seen that the housing has two outlets formed in its upper surface, namely the
initial portion of the internal passageway 106a, and the outlet channel 204
through which the contents of the air chamber 203 are ejected during use into
the internal passageway 106 defined between the lid 104 and the upper surface
of the first part 102c of the housing 102.
The plunger 108 of the embodiment shown in Figures 2A and 2B is
shown in more detail in Figures SA and SB. The upper portion of the plunger
108 is shaped to form two tight sealing engagements with the wall 201 of the
central chamber 107a when positioned within the assembled device, as shown
in Figure 2A. Specifically, a first seal, which prevents air leaking past the
plunger during the second stage of operation, is formed by the edge 501
contacting the wall of the housing 201. A second seal, which prevents air
leaking past the plunger during the first stage of operation, is formed by the
contact of the edge 502 with the housing 201. If the second seal was not
present, the edge 501 could be displaced from contact with the housing during
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the first stage of operation of the device by the pressure difference between
the
interior of the compartment and the outside environment, thereby causing air
to
flow into the compartment 107a, instead of product being drawing in through
the inlet valve. The plunger also has a downwardly extending valve member
5 108a which terminates in a truncated cone which is received within the
aperture
defined by the valve seat 109 of the base 101 to form the inlet valve.
The upper portion of the housing 102 is shown in more detail in Figures
6A and 6B. Fitted to the upper surface of a first part of the housing 102c is
a
lid 104. The lid is composed of two parts, a body 601 which is adapted to be
10 fitted to the upper portion of the housing 102 and a hinged lid portion
602. The
hinged lid portion 602 has the resiliently deformable flap lOSa formed on its
under surface which, when the lid is brought together with the body 601, forms
the outlet valve, as previously described. The hinged lid portion 602 also has
an abutment surface having grooves and/or recesses formed thereon which,
15 when the lid is contacted with a corresponding abutment surface formed on
the
upper surface of the housing 102 which has corresponding grooves and/or
recesses formed thereon, defines the nozzle outlet 106.
A plan view of abutment surface of the upper surface of the housing 102
is shown in Figure 7A. The abutment surface 701 comprises an aperture which
20 extends to the internal chamber 107a and forms an initial portion 106a of
the
internal passageway and a groove 702 which extends from the second valve to
an edge of the abutment surface 703. Formed within the groove 702 is a
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46
deepened recess 704. The recess 704 is shown in more detail in Figure 7B
where it can be seen that the recess is semicircular in cross-sectional
profile and
the channel 204 that extends from the air chamber 203 into the recess. The
abutment surface of the lid 602 (not shown) comprises a similar groove to the
groove 702 with an equivalent a recess equivalent to the recess 704 formed
therein. Thus, when the two abutment surfaces are brought into contact, the
grooves and recesses formed therein align to form a fluid flow passageway
which extends from the second valve to the outlet 703 of the device and
comprises a circular chamber formed by the alignment of the recess 704 and the
corresponding recess of the abutment surface of the lid 602. The chamber thus
formed is known as an expansion chamber. In use, the contents of the internal
chamber 107a passes through the second valve into the passageway formed by
the groove 702 and its equivalent on the opposing abutment surface of the lid
104. The fluid is then sprayed into the expansion chamber (see reference 710
in Figure 7C) formed by the recess 704 and the corresponding recess in the
opposing abutment surface of the lid through an orifice formed in the
passageway (not shown). The spray droplets thus formed mix with an air
stream ejected from the air chamber 203 in the expansion chamber 710 and then
continue along the passageway to the outlet 112 where they are ejected from
the
device in the form of a spray.
To prevent the occurrence of leaks, the fluid outlet arrangement is
surrounded by a horseshoe-shaped recess 705 formed in the abutment surface
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47
of the housing 102 which receives a correspondingly shaped protrusion 706
(see Figure 7C) formed on the abutment surface of the lid, as shown in Figure
7C, to form a horseshoe-shaped seal barrier. In a similar manner, further
recesses 707 extend from either side of the horseshoe-shaped recess 705
towards the groove 702 at various points along the length of the groove 702.
These further recesses also receive correspondingly shaped protrusions on the
abutment surface of the lid and, together with the horseshoe-shaped seal
barner,
define a series of internally sealed compartments around portions of the fluid
flow passageway when the abutment surfaces of the upper surface of the
housing 102 and the lid 602 are brought into contact. Any fluid that leaks
from
the fluid flow passage during use is then trapped within one of these
compartments and prevented from seeping between the abutment surfaces and
leaking from the nozzle outlet.
The channel 204 is shown in Figures 7A and 7B as a direct channel
between the air chamber 203 (not shown) and the internal passageway 106 of
the nozzle outlet. Where the nozzle outlet is formed between the abutment
surfaces of two or more parts, as shown in Figures 7A and 7B, it shall be
appreciated that the air can be conveniently channelled to virtually any point
along the length of the fluid flow passage that is desired by positioning the
~ opening of the outlet channel 204 so that air enters the channel where it is
desired.
Figure 7C is a cross-sectional view taken along line ~-X' of Figure 7A.
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48
In Figure 7C the horseshoe-shaped recesses 705 and the horseshoe-shaped
protrusion 706, which form the horseshoe shaped seal, are visible on either
side
of the expansion chamber 710. The fluid flow passage 711 which opens to the
expansion chamber 710 is also shown.
An alternative embodiment of the lid 104 is shown in Figure 8. In this
embodiment, the lid 104 is fitted to the upper surface of the first part 102c
housing 102 shown in Figures 1 A and 1 B in the usual manner. The initial
portion of the internal passageway 106a formed by first part 102c of the
housing 102 is covered by a resiliently deformable membrane 801, which is
integrally formed in the lid 104, and has a downwardly extending plug 802
which is received within the upper portion of the initial portion of the
passageway 106a. The membrane 801 and plug 802 effectively form an
alternative form of valve member for the outlet valve of the device. During
use, i.e. when the housing is pushed towards the base 101 to eject the
contents
of the chamber through the internal passage 106 and the outlet 112, the
pressure
within the chamber increases to a predetermined threshold level and, once this
level is attained or exceeded, the membrane 801 is caused to deform away from
the opening of the portion of the passageway 106a thereby withdrawing the
plug 802 and forming an opening through which the contents of the chamber
may flow to the outlet 106. After use, i.e. when the pressure falls below the
minimum threshold, the membrane returns to its original position in which the
channel 301 is closed, as shown in Figure 8.
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49
Figure 9A shows a modification to the air plunger 204 and base 101
shown in Figures 2A and 2B which provides an air leak to equalise any
pressure differential that develops between the interior of the container and
the
external environment. Only the relevant portion of the device is shown in
Figure 9A for the purpose of illustration. As previously discussed in
reference
to Figures 2A and 2B, the housing 102 is slidably mounted in a recess 103 of
the base 101 and an air plunger 204 is seated on a protrusion ridge 206 formed
in the base 101. As shown in Figure 9A, the air plunger 204 is modified to
include a downwardly extending resiliently mounted arm 901 which contacts
the internal wall of the housing. The resiliently mounted arm 901 is
positioned
adjacent to an air leak opening 902 formed within the base and is capable of
movement between a position in which said arm covers and closes the air leak
opening and a position in which the air leak is open, thereby enabling air to
flow between the external environment and the interior of the container. As
can be seen in Figure 9A, the resiliently mounted arm 901 of the plunger 204
can be urged into the closed position by an enlarged annular rim 903 at the
base
of the internal wall of the housing 101, which urges the resiliently mounted
arm
into a position in which the air leak is closed when the device is not in use.
When the housing is pushed downwards relative to the base, the arm 901 of the
air plunger 204 is resiliently biased to still seal the opening 902, whereas
when
the housing moves upwards relative to the base, the arm 901 is displaced from
the opening 902 and air can pass through the opening until the rim 903 urges
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the arm 901 back towards the opening to reform the seal.
Figure 9B shows yet another alternative embodiment of the device of the
present invention which comprises an air leak formed therein. The embodiment
shown in figure 9B is similar to that shown in Figures 2A and 2B in certain
5 respects. However, this embodiment differs in that the central compartment
107a of the chamber is provided with a plunger of different construction to
the
plunger 108. In this embodiment, the plunger in the central cavity 107a is
shown by the reference 910 and a separate valve member 911 is received within
the valve seat 109 of the base 101 to form the first valve. A ledge or set of
post
10 912 onto which the spring 111 is mounted is provided between the valve
member 911 and the plunger 910. A further modification is that the second
valve is formed by a resiliently deformable membrane 801 having a
downwardly extending member 802 which is received within the outlet channel
301, rather than the flap 105 which covers the opening lOSa previously
15 described.
The air plunger 204 is also of a different form but, in common with the
embodiment shown in Figure 9A, comprises a resiliently mounted arm 901
which is also capable of being urged from a position in which the arm is
displaced from an air leak opening 902 formed in the base and the air leak is
20 open, to a position in which the air leak 902 is closed. Again, the arm 901
of
the air plunger 204 is urged into the position whereby the air leak 902 is
closed
when an enlarged rim 903 formed at the base of the internal wall of the
housing
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51
102 slides past the arm 901. Hence, when the housing is pressed down relative
to the base, as shown in Figure 9B, the air leak is open, but if the housing
is
released so that the spring 111 pushes the housing upwards until the rim 102a
abuts the rim 101 a, then the arm is urged into the position whereby the air
leak
is closed by the enlarged rim 903.
Figure 9C shows a further alternative embodiment of the device, which
comprises an air leak. In this embodiment, the outer wall of the housing
slides
over the outer surface of the base when the housing is pushed down relative to
the base, rather than being slidably mounted within a recessed groove formed
in
the upper surface of the base, as in aII of the previous embodiments. In this
embodiment, the air plunger 204 is in the form of a wedge which possesses two
arms. A first arm 901 contacts the side of the base to form a seal to close
the
air leak 902 formed in the base, whereas the second arm 920 forms a tight
sealing engagement with the internal wall of the air compartment 203. The seal
formed by the arm 901 is only very light and this are can be deflected to a
position in which the air leak is open if the external pressure exceeds the
pressure within the container. The leakage of the contents of the container
out
of through the air leak 902 is prevented, however, because the arm 902 forms a
seal against the wall of the base as shown in Figure 9C and cannot be
deflected
further to enable flow to occur out of the container.
Figures l0A and 10B show a container 1000 fitted with a device 100 of
the present invention which is provided with a trigger actuator 1001. The
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52
trigger actuator 1001 is composed of two pivotally connected parts 1002 and
1003 connected together by a plastic hinge at 1004. Part 1002 consists of an
attachment element 1002a which is pivotally connected to the base of the
device and a trigger 1002b which can be operated by a user in the normal
manner. Part 1003 is pivotally mounted to the lid 104 of the housing 102.
Operation of the trigger by pulling it towards the container pulls the part
1002
downwards about the pivotal connection to the base and this action in turn
causes the part 1003 to pull the housing downwards relative to the base, (thus
compressing the chamber therein and causing the product, or a mixture of
product and air (if an air chamber is present), to be dispensed through the
nozzle outlet).
The housing 102 and plunger 108 of an alternative embodiment of the
present invention is shown in Figure 11. This embodiment is the same as that
shown in Figures lA and 1B except that the plunger 108 comprises upwardly
and outwardly extending wall 108b which defines . a liquid containing,
resiliently deformable insert or compartment 107a within the chamber 107. The
upwardly and outwardly extending wall 108b is resiliently deformable so that
when the housing 102 is displaced towards the base 101 (not shown in Figure
11) the wall will deform/collapse so that the pressure within the compartment
107a increases and fluid present therein will be dispensed through the
internal
passageway 106 and the outlet when the pressure is sufficient to open the
outlet
valve. In this embodiment the resilient deformable wall/insert 108b is the
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resilient means which, instead of the spring 111 and post 102b required in the
embodiment shown in Figures lA and 1B, forces the housing 102 away from
the base 101 to cause the volume of the chamber to increase when the actuator
is not operated, or it is released after operation.
A further alternative embodiment of the present invention is shown in
Figures 12A and 12B. This embodiment is identical to the embodiment
described in reference to Figure 1 l, except that the resiliently deformable
insert
or wall 108b is formed as a resiliently deformable bellows or concertina,
which
compresses when the chamber 107 is compressed by the operation of the
actuator (i.e. pressing the housing downwards towards the base 101) and
subsequently returns to its original configuration, as shown in Figures 12A
and
12B, when the pressure applied to the actuator is released.
The embodiments of the invention shown in Figures 11, 12A and 12B,
are the simplest embodiments of the present invention comprising only three
separate component parts, namely the base 101, the housing 102 (including the
lid 104) and the insert/valve member 108. Accordingly, these embodiments
will be particularly cheap to produce.
A further modified embodiment of the invention is shown in Figure 13.
This embodiment is identical to that shown in Figures 12A and 12B, except that
an additional resiliently deformable bellows or concertina insert 1301 is
provided inside the insert 108b. In this embodiment, the compartment 107a
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forms an air chamber, equivalent to the air chamber 203, and the inner
compartment 1302 contains the liquid drawn in through the inlet. Liquid drawn
in through the inlet is transferred into the internal compartment 1302 through
the stem 1303 of the plunger 801.
A further alternative embodiment of the present invention is shown in
Figure 14. In this embodiment a resiliently deformable insert 1401 is
positioned within the internal chamber 107 defined between the first part of
the
housing 102c and the base 101. The insert 1401 is formed by two
interconnected sections 1401a and 1401bwhich define a central
compartment/chamber 1302 and an outer air compartment/chamber 203/107a.
The insert 1401 also defines a one-way inlet valve 1402, a one-way outlet
valve
1403, a one-way air release valve 1404, a one-way air inlet valve 1405 and a
one-way air release valve.
Thus, when the housing 102 is pushed downwards towards the base 101
(i.e. when the actuator is operated), the insert is compressed and the
pressure
within the chambers 1302 and 203/107a increases, thereby causing the valves
1403 and 1404 to open when the pressure within the chambers exceed the
minimum threshold pressure, and the fluid and air present in these chambers to
be ejected through the internal passageway 106 to outlet 112. Once the desired
amount of the fluid has been released, or the housing 102 has been depressed
its
fullest extent, the applied pressure is released (i.e. the actuator is
released) and
the insert then urges the base l0I and the housing I02 apart due to its
inherent
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resiliency. This causes more fluid to be drawn into the chamber 1302 through
the inlet valve 1402 and more air to be drawn into the air chamber through the
air inlet valve 1405. Any pressure differential between the interior of the
container and the external environment will be equalised through the air
release
5 valve.
