Note: Descriptions are shown in the official language in which they were submitted.
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PUMP FOR FLUID DISPENSERS
FIELD OF THE INVENTION
The present invention relates to a pump which can be easily made and assembled
from a
small number of moulded parts, particularly from injection moulded parts. The
invention
further relates to a dispenser comprising the pump and to valuing arrangements
for pumps
and dispensers. The pump and device are useful for dispensing fluids such as
medicines,
including nasal and throat sprays, perfumes, cosmetics, cleaning products and
the like.
BACKGROUND OF THE INVENTION
The delivery of substances from a dispenser, particularly in carefully
controlled amounts,
generally requires a pump of some sort typically with one or more valves
associated with
it. The provision of such pumps not only adds to the cost and complexity of
manufacturing dispensers, since typical pumps comprise many separate parts,
but can also
restrict their overall design. Efforts have been made to reduce the complexity
of pumps.
WO 98/08661 discloses a readily manufactured pump having a small number of
stackable
parts. However, it still requires four parts which need to be separately
manufactured and
assembled. WO 02/16047 discloses another simple diaphragm pump, incorporated
into
the inside of a dispensing flexible reservoir; it too comprises four parts.
US 6,460,781, US 2003/0071071, US 2002/0190081 and WO 00/06464 all describe
simple product dispensers, suitable as sampling devices which comprise a
reservoir and a
resilient means which is deformable in order to produce a pumping action from
the
reservoir.
US 5,492,252, EP 641 722 and EP 442 858 each describe dispensers incorporating
pumps
which utilise a resilient actuator as an insert into a pre-moulded pump.
chamber
comprising an inlet port.
Despite all the foregoing there remains a need for further improvements in
product
dispensers to enable simple, low cost manufacture of product dispensers
incorporating
pumps, in particular those which are capable of reliably delivering repeated
controlled
product doses. A related problem is that of enabling a simple method of
modular
construction of dispensers whereby differently functioning pumps, e.g.
delivering
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different size doses, can be fitted to a common dispenser, enabling a flexible
method of
adapting a production line to provide different products.
A pump of simple construction has now been developed which can be manufactured
from
as few as two separate parts and, in particular, each part can be formed by
mass
production techniques such as injection moulding, compression moulding or
thermoforming. The pump can be employed as a separate part in a more complex
dispenser or indeed can be integrally moulded into a simple dispenser. The
construction
of the pump provides for much greater design freedom in the way that the pump
is
employed in dispensers and, as a result, in the dispenser design.
SUMMARY OF THE INVENTION
The invention herein relates to pumps and valuing arrangements for fluid
dispensers. The
invention further relates to dispensers incorporating a pump. The pumps herein
comprise
a dose chamber, a resilient actuator and valves for controlling the flow of
fluid into and
out of the dose chamber. Combination of the pump with a fluid reservoir
provides a fluid
dispenser which may further comprise an atomiser for forming a spray as fluid
is ejected
from a dispenser outlet.
In accordance with a first aspect of this invention there is provided a pump
for a fluid
dispenser comprising:
a) an upper pump half comprising an upper inlet port wall and an upper outlet
port
wall;
b) a lower pump half engaging with the upper pump half and comprising a lower
inlet
port wall and a lower outlet port wall, wherein the upper inlet port wall
engages
with the lower inlet port wall to define a pump inlet port permitting fluid
communication from a fluid source into the pump and the upper outlet port wall
engages with the lower outlet port wall to define a pump outlet port
permitting fluid
flow out of the pump;
c) a resilient actuator connected to the upper pump half,
d) inlet and outlet valves associated with the pump inlet and outlet ports for
controlling fluid flow through them; and
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e) a dose chamber, at least partially bounded by the resilient actuator, for
containing a
single dose prior to delivery from the dispenser
whereby depression of the resilient actuator is effective to dispense the dose
of fluid
through the pump outlet port, and wherein the upper and lower pump halves are
formed
from unitary mouldings and at least the upper pump half comprises a semirigid,
thermoplastic material.
In accordance with a second aspect of this invention there is provided a
method of
making a pump for a fluid dispenser, the pump comprising an upper pump half
comprising a semirigid, thermoplastic material, a lower pump half, a dose
chamber, a
resilient actuator, a pump inlet port, a pump outlet port, an inlet valve and
an outlet valve,
the method comprising the steps of:
a) forming the upper pump half in a unitary moulding comprising the resilient
actuator, an upper inlet pout wall and an upper outlet port wall;
b) forming the lower pump half in a unitary moulding comprising a lower inlet
port
wall, a lower outlet port wall and a lower dose chamber wall ; and
c) fixing the upper pump half onto the lower pump half such that the resilient
actuator
and the lower dose chamber wall bound the dose chamber, the upper inlet port
wall
engages with the lower inlet port wall to define a pump inlet port permitting
fluid
communication from a fluid source into the pump and the upper outlet port wall
engages with the lower outlet port wall to define a pump outlet port
permitting fluid
flow out of the pump
In accordance with a third aspect of this invention there is provided a method
of making a
pump for a fluid dispenser, the pump comprising an upper pump half comprising
a
semirigid, thermoplastic material, a lower pump half, a dose chamber, a
resilient actuator,
a pump inlet port, a pump outlet port, an inlet valve and an outlet valve, the
method
comprising the steps of:
a) forming the upper pump half in a unitary moulding comprising an upper inlet
port
wall and an upper outlet port wall;
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b) forming the lower pump half in a unitary moulding comprising a lower inlet
port
wall and a lower outlet port wall;
c) fixing the upper pump half onto the lower pump half such that the upper
inlet port
wall engages with the lower inlet port wall to define a pump inlet port
permitting
fluid communication from a fluid source into the pump and the upper outlet
port
wall engages with the lower outlet port wall to define a pump outlet port
permitting
fluid flow out of the pump; and
d) attaching a resilient actuator to the upper pump half so that the resilient
actuator
bounds the dose chamber.
In accordance with a fourth aspect of this invention there is provided a valve
module for a
pump for a fluid dispenser comprising:
a) an upper pump half including an upper inlet port wall, an upper outlet port
wall and
a flow channel providing fluid communication between upper and lower surfaces
of
the upper pump half;
b) a lower pump half engaging with the upper pump half and including a lower
inlet
port wall, a lower outlet port wall and a lower dose chamber wall wherein the
upper
inlet port wall engages with the lower inlet port wall to define a pump inlet
port
permitting fluid communication from a fluid source into the pump and the upper
outlet port wall engages with the lower outlet port wall to define a pump
outlet port
permitting fluid flow out of the pump; and
c) inlet and outlet valves for controlling fluid flow through the pump inlet
and outlet
ports;
wherein the valve module comprises an alignment means selected from
positioning lugs,
indents, a non-circular external wall section and combinations thereof to
enable the valve
module to be received in a dispenser in a fixed orientation.
In accordance with a fifth aspect of this invention there is provided a
valuing
arrangement, suitable for use in a pump dispenser, comprising a flow channel
having
semirigid upper and lower walls, a fluid inlet through which fluid enters the
arrangement
from a fluid supply and a fluid outlet through which the fluid exits the
valuing
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arrangement, the flow channel further comprising inlet and outlet elastomeric,
flap
valves, mounted inside the flow channel, each valve having a surface immovably
fixed to
the upper flow channel wall and a flap sealingly compressed against the lower
flow
channel wall, whereby each valve prevents flow of fluid along the flow channel
until a
positive fluid pressure differential on an upstream side of the flap of the
valve causes the
flap to lift thereby allowing fluid to flow past the valve, the valves
permitting fluid flow
in the same direction along the flow channel whereby an increase in fluid
pressure in a
section of flow channel between the two valves causes the outlet valve to open
and the
inlet valve to remain closed and a reduction in fluid pressure in the section
of flow
channel between the two valves causes the inlet valve to open and the outlet
valve to
remain closed.
In prefeiTed embodiments of the invention the pump is incorporated into a
dispenser
further comprising a fluid reservoir in fluid communication with the pump
inlet port.
Preferably the reservoir is co-moulded with the pump.
The resilient actuator of the pumps preferably has a threshold force for
actuation which
facilitates consistent unit dosing. The pumps, valuing arrangements,
dispensers and
actuators herein are amenable to a modular approach to construction which
provides
substantial flexibility in a mass manufacturing environment.
DETAILED DESCRIPTION OF THE INVENTION
The invention will now be described in more detail with reference to component
parts of
the pumps, valve modules and dispensers herein, first in general terms and
then with
reference to specific embodiments.
Definitions
The pumps and dispensers comprise upper and lower halves. The terms "half' and
"halves" herein are intended only to indicate corresponding parts and are not
intended to
imply any equality in size, construction or function. The terms "upper" and
"lower" in
respect of the pump or dispenser are used only to distinguish the two halves
and are not
intended to imply any particular orientation of the parts in use.
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As used herein a "semirigid" refers to a material having a flexural modulus of
at least
about 300, preferably at least about 500 MPa, measured using ASTM D790. Pump
and
dispenser parts herein made from a semirigid material are generally moulded
with
sufficient wall thicknesses that they are self supporting, by which is meant
that they will
not substantially bend under their own weight. However, certain embodiments of
reservoirs herein, such as flexible sachets, are non-self supporting
structures through
being made of thin laminates, even though the laminates may comprise semirigid
materials.
By a "unitary moulding" is meant a moulding formed in a single piece or
completely
formed within a single mould. It may comprise only one material but the term
"unitary
moulding" also comprises workpieces formed from two or more materials in a
common
moulding operation such as a two-shot injection moulding where different
materials are
co-injected or sequentially injected into a common mould.
A "fluid" herein refers to a flowable liquid or gel.
"Monostable" as used herein in respect of an actuator or an element thereof
means having
a force-deflection curve including a priming region wherein the force
initially increases
for increasing deflection, in the mamzer of, say, a conventional spring, and
then at some
threshold force there is at least one inflection point such that further
deflection of the
element occurs with a reduction in the applied force. Such a curve is shown in
Figure 26.
Preferably the initial priming region deflection is kept as small as possible.
"Bi-stable", in respect of an actuator or an element thereof, refers to an
actuator or an
element thereof that behaves like a monostable actuator or element until the
defined force
threshhold is overcome but then "flips" to stay permanently in a depressed
position.
Dose Chamber
The pumps according to the invention comprise a dose chamber. The dose chamber
is
formed by the co-operation of the upper and lower pump halves when the pump is
assembled. The dose chamber holds a single dose of the fluid to be dispensed
which, in
preferred embodiments, can be replenished from a reservoir in fluid
communication with
the dose chamber. The dose chamber is in fluid communication with a pump inlet
port,
through which fluid can be received from the reservoir, and a pump outlet port
from
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which fluid can be dispensed. In certain embodiments illustrated herein the
pump inlet
and outlet ports are at opposite sides of the dose chamber and for many
applications this
will be the most appropriate geometry however the invention is not so limited.
The inlet
and outlet ports can be adjacent to each other or placed in any other position
relative to
each other and the dose chamber provided they perform their intended function
of
permitting fluid flow into and out of the dose chamber. Fluid flow into and
out of the
dose chamber is controlled by inlet and outlet valves described in more detail
below. The
pumps further comprise a resilient actuator, also described further below
whose actuation
results in the dispensing of a dose of fluid from the dose chamber. The volume
of the
dose dispensed by the pump will generally be less than the pump volume since
actuation
of the pump via the resilient actuator will generally not result in all of the
fluid contained
within the pump being dispensed. Dose volumes herein may vary from a few
microlitres
to several millilitres depending upon the pump dimensions and construction.
The dose
volume is preferably a metered dose substantially pre-determined by the
dimensions of
the dose chamber. Means for achieving this, comprising restricting a user's
ability to
modify the dose volume are described further below in the section on resilient
actuators.
Before first use the dose chamber may require priming with the fluid to be
dispensed.
The greater the ratio of the pump volume to the dose volume the greater the
number of
priming strokes needed to replace air inside the unprimed pump with fluid
drawn from a
reservoir. The preferred number of priming strokes is three or fewer.
In a preferred aspect of the invention the dose chamber has a lower wall which
creates an
endpoint for the deflection of the resilient actuator and stops its movement
when the
actuator abuts it. Changing the distance between the actuator in its resting
position and
the lower dose chamber wall can provide a method for fme adjustment of the
dose
volume of the pump, thereby at least partially defining a metered dose. This
is
advantageous in a commercial production environment when different dose
volumes need
to be produced in a cost effective way. Of course, the dose volume can also be
adjusted
by changing other parameters such as the actuator shape and size.
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Resilient actuator
An important feature of the pump herein is the actuator. The actuator is
preferably
resilient. It can be a separately manufactured piece fitted to the upper pump
half but is
preferably an integral, resilient wall section of the upper pump half bounding
the dose
chamber. Resilience is provided by selection of the material from which the
actuator is
made and by control over its thickness and shape. Suitable materials for the
actuator are
thermoplastic elastomers, silicones, rubbers or soft grades of polyolefms
(e.g. poly-
ethylene or polypropylene). A suitable thickness for the actuator when
manufactured
from the same semi-rigid material as the pump body is from about 0.1 to 0.8
mm,
preferably from about 0.3 to 0.7 mm, more preferably from about 0.4 to 0.6 mm.
In an
alternative embodiment, resilience may be provided by a two component system
whereby
a spring or other resilient apparatus is placed immediately beneath the
actuating wall to
return it to its unpressed position following actuation.
The actuator is depressed by a user in order to decrease the volume of the
dose chamber
and thus dispense a dose of fluid from the pump. For a resilient actuator,
when the
depressing force is removed, its resilience causes the actuator to spring back
to its
original shape causing a pressure reduction in the dose chamber to draw fluid
into the
dose chamber from a reservoir.
The design of the actuator influences the dose size and accuracy of the
overall system.
For many applications the precise requirement for the delivered dose is not so
critical and
dose tolerances of +/- 20% are acceptable. Simple resilient actuators in form
of buttons
are well known in the art. The actuator can be integrally moulded with the
upper pump
half (in a manner similar to the gas bellows shoran in US patent application
2002/074359), co-moulded, overmoulded, or moulded separately and assembled via
a
mechanical snap or friction fit, such as in the pump of WO 98/08661, or
attached via a
welding operation.
Simple actuators can have the disadvantage that the user can choose the force
applied
whilst dispensing a fluid, which can lead to a big variation in dose quantity
and quality.
The relationship between the applied force and the degree of deflection of the
actuator
may approximate to linear, or at least require continuously increasing force
for ever
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greater deflections. If a user only presses gently then the dispensed volume
and pressure
of the fluid may be suboptimal, resulting, for example, in incomplete or
variable dosing,
an undesirable spray pattern or poor particle size distribution. Although this
may be
acceptable for certain applications or products, applications in the area of
medical devices
typically require more rigorous dose tolerances, especially when delivering
active
pharmaceutical ingredients. In order to overcome this particular disadvantage
the
actuator herein preferably includes monostable or bi-stable elements. These
elements are
characterised in that they do not have a linear force-deflection relationship.
The use of
monostable or bi-stable elements in an actuator for a delivery system provides
added
control to a user's operation of the device.
The use of monostable elements in form of buttons or snap-domes is known in
the
electronics industry in form of input devices (keypads for mobile phones,
calculators, etc)
and circuit board switches. Snaptron Inc. of Loveland, Colorado 80537, USA
distributes
metal snap domes in various sizes and geometries. Monostable elements, in the
form of
"snap-domes" are known, for example, in switches from e.g., US patent nos.
4,933,522;
and 5,510,584. The principle has also been disclosed for use in a sample type
spray
dispenser in US 6,460,781. WO 02/016796, assigned to Valois SA, describes a
two-
leaved spring which acts a monostable element and can be used inside a
dispensing
reservoir. A further elaboration on this type of actuating element is
described in
US 6,271,487 which discloses a switch having tactile feedback and three states
of
switching. Monostable elements are also used in the toy industry. Monostable
elements
as used herein can be separate elements, such as a snap dome located
underneath the
resilient actuator or they can be an integral feature of the actuator formed
by appropriate
construction of the actuator wall as disclosed in US 6,460,781.
For monostable elements in an actuator the typical force-deflection curve is
lilce that
shown in Figure 26. Initial deflection requires a continuously increasing
force. If only a
low force is applied by a user's finger to an actuator fitted to a pump primed
with fluid,
there will typically be no delivery of fluid at all since the force applied
generates
insufficient pressure in the fluid to open the outlet valve of the pump. The
actuator has a
threshold point though at which further deflection of the element occurs with
a reduction
in the applied force, this threshold point should be a little greater than
that required to
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create sufficient fluid pressure to open the outlet valve. The practical
effect of this is that
the momentum of the user's finger depression results in a rapidly increasing
deflection
making it difficult to prevent full actuation once the pre-defined threshold
point has been
passed. The result is a much smaller variation in the dispensed amount of
fluid and better
control over any associated spray pattern. This process of passing the
threshold point is
preferably accompanied by an audible 'click' or tactile feedback to signal
correct
operation of the element to the user. Preferably, past the threshold point the
deflection D
(axis graduated in mm) increases by at least 50% even though the force F (axis
graduated
in Newtons) is reduced by at least 10%, more preferably the deflection
increases by at
least 75% even though the force is reduced by at least 25%. Preferably the
slope of the
curve from the origin to the first threshold point is at least 5 Nmni 1, more
preferably at
least 10 Nmni 1.
In a separate aspect of this invention there is provided an actuator for use
with a
dispensing pump, the actuator comprising a shaped, preferably disc-like, plate
comprising
an outer flange lying in a first plane and a central resiliently deflectable
dome, the dome
comprising an apex and at least one annular trough whereby, when the actuator
is fixed at
its outer flange, the actuator has, for forces applied perpendicularly to the
first plane, a
force-deflection curve that includes a priming region wherein the force
initially increases
for increasing deflection of the dome, and at least one inflection point such
that further
deflection of the dome occurs with a reduction in the applied force.
Typically, at some point past the threshold point on the force-deflection
curve of the
actuator, the applied force required to achieve further deflection increases
again, usually
as some material limit of the actuator is reached. A predefined endpoint for
the deflection
may also be achieved due to the actuator abutting some stopping element, in
which case
of course the applied force will increase very rapidly for slight or no
further deflection.
The deflection endpoint may be defined by the physical dimensions of the
actuator or a
further stop element can be introduced, such as the lower dose chamber wall.
For resilient actuators, when the applied force is removed then the actuator
returns to its
original undeflected starting point. Bi-stable actuators which stay in a
permanently
depressed position are not resilient as intended herein. Although this type of
actuator is
not suitable for repeated dosing, if several are used in one dispensing
package it can have
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advantages for controlled dosing regimens. In a further aspect of the
invention herein
there is provided a reservoir containing a fluid to be dispensed, the
reservoir comprising
boundary walls and a fluid outlet, wherein the boundary walls of the reservoir
comprise a
plurality of bi-stable actuators such that each depression of a bi-stable
actuator results in a
substantially identical dose of fluid being dispensed from the fluid outlet. A
preferred bi-
stable actuator will present a convex dome to the exterior of the reservoir
and, when
depressed past its threshold, will permanently deform to present a concave
depression to
the exterior of the reservoir. The preferred embodiment of this further aspect
of the
invention comprises a reservoir having a plurality of externally convex
deformable bi-
stable actuators arranged in a regular array on one face of the reservoir, to
give the
appearance of a blister pack.
Valves and valvin~ arran eig rents
Further important features of the pumps herein are inlet and outlet valves.
The inlet valve
is associated with the pump inlet port for controlling fluid flow through the
inlet port and
the outlet valve is associated with the pump outlet port for controlling fluid
flow through
the inlet port. By 'associated with' is meant that each valve is located in
the respective
port or in a flow channel directly connected to the port. If not located in
the port then the
valve can be upstream or downstream of the port provided it is able to perform
its
intended function of controlling fluid flow through the port. It is highly
preferred that
both the inlet and outlet valves are of the non-return type, allowing movement
of fluid in
one direction along a conduit or flow channel but preventing the flow of fluid
in the
reverse direction. Suitable valves include flap valves, duckbill valves, ball
valves and slit
valves. Flap valves are preferred for ease of in-situ moulding. In preferred
embodiments
the inlet and outlet valves are made from an elastomeric material having a
Shore A
hardness of from about 5 to about 90, more preferably from about 20 to about
70.
Suitable elastomeric materials include thermoplastic elastomers and silicones
and
rubbers. The flap and slit valves can be various shapes such as rectangular or
triangular
or more complex shapes as described in more detail below. The valves can be co-
injected, overmoulded, insert moulded as an extra part or separately assembled
such as by
welding, interference fitting or snap fitting. In an alternate embodiment the
inlet and
outlet valves are integrally moulded with either the upper or lower pump half
from the
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same semirigid, thermoplastic material as the pump half with which they are
integrally
moulded. In a further alternate embodiment the inlet and outlet valves may be
injection
moulded as a single piece with a bridge of material connecting the two. This
may enable
separate manufacture and ease of installation into the pump body, and
predetermined
directional arrangement.
A preferred valve arrangement comprises an elastomeric valve mounted inside a
flow
channel, the valve comprising an upper surface, the upper surface being
immovably fixed,
preferably by injection moulding, to an upper flow channel wall, the valve
further
comprising a flap having a lower surface which is sealingly compressed against
a lower
flow channel wall in the absence of a differential in fluid pressure across
the valve flap,
wherein an increase in fluid pressure on against the lower surface of the flap
lifts the flap
from the lower flow channel wall and permits fluid to flow past the valve. In
the
embodiments herein it is preferred that the one of the upper or lower pump
halves
comprises the upper flow channel wall of the valve arrangement and the other
of the
upper or lower pump halves comprises the lower flow channel wall against which
the
lower surface of the valve flap is sealingly compressed. The lower surface of
the valve
flap is generally coplanar with the lower flow channel wall and the valve flap
is oriented
in the direction of fluid flow along the flow channel. If back pressure in the
fluid should
urge it to flow in the reverse direction, the fluid presses against an upper
surface of the
valve flap, sealingly compressing the flap against the lower flow channel wall
and
thereby increasing resistance to reverse fluid flow. By varying the profile of
the valve
flap and/or by design of the upper and lower pump halves a desired threshold
pressure for
valve actuation can be set. Only when the pressure differential across the
valve exceeds
the threshold pressure is the valve opened. A normally closed valve system is
beneficial,
as it ensures that the pump only has to be primed once and it reduces the risk
of
contamination from outside. Preferably the threshold pressure for the valve is
such that
the outlet valve opens when the force applied to the resilient actuator is in
the range from
about 70% to about 100%, preferably from about 90% to about 100%, of the
threshold
actuation force for the resilient actuator.
In a particularly preferred valve arrangement the flow channel is restricted
at the point
where fluid flowing along it would first encounter the valve and the valve
comprises a
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foot portion which is permanently compressed against the lower flow channel
wall such
that the only fluid passage past it is along a groove in the lower flow
channel wall, the
groove being flanked by side walls. The groove is bridged by a sealing ridge
rising to the
height of the side walls and the valve flap sits across the sealing ridge and
the side walls
preventing fluid flow until the fluid pressure rises sufficiently to lift the
valve flap away
from the sealing ridge and the adjacent side walls. More particularly two such
valve
arrangements are preferably used in tandem with the valves in each aiTangement
being
separated from each other and a dose chamber being arranged on a fluid flow
path
intermediate the two valves such that the valves act as inlet and outlet
valves for the dose
chamber.
The pump herein without its resilient actuator can be used as a valve module
and is useful
in its own right since it can be combined with differently sized or shaped
actuators to
provide pumps with different characteristics, such as different dose volumes.
The pumps
and valuing modules herein can of course be designed so that the valves are
fixed to
either the upper or lower pump halves.
Atomiser
In certain embodiments herein the pump or dispenser includes an atomiser
associated
with an outlet flow channel to break up dispensed fluid into a spray. The
outlet flow
channel can be formed from upper and lower outlet flow channel halves which
are
preferably integrally moulded with the upper and lower pump halves.
US 6,059,150 illustrates a typical atomiser for a nasal spray application
using a hollow
nozzle adaptor which includes a spray orifice incorporating a swirl chamber
geometry.
Alternatively, atomisers are known wherein a cup shaped component, including a
spray
orifice and swirl chamber geometry, is separately assembled to a nozzle
adaptor, an
example of such a component is the nozzle cap disclosed in US 5,738,282.
These types of atomisers are typically separate units to the pump and
subsequently need
assembly to a pump unit. This is typically done via mechanical connection,
such as a
friction or snap fit and requires precise moulding and assembly effort to
achieve a fluid
tight seal. This necessarily imposes some limitations on the overall design of
the delivery
system.
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A solution for a much more versatile atomiser design is disclosed in WO
01/89958 where
the atomiser for an aerosol spray device is formed by two halves of a simple
injection
moulded component with tailor made geometry to allow atomisation of a
particular fluid.
Such an approach allows a greater design freedom for a spray delivery device
and offers
greater means of controlling the spray characteristics for a wide range of
products by
shaping the flow channel geometry in a suitable way.
A plain dispensing orifice is sufficient for highly viscous fluids that cannot
be broken up
into small particles to form a spray. The orifice can be formed entirely
within either of
the upper or lower outlet flow channel halves or from a combination of part
mouldings in
both halves. Where a circular orifice is required then this can be done by
moulding a
semicircular channel in each of the upper or lower outlet flow channel halves.
Due to the
small dimensions and tolerances it can be difficult to exactly match the edges
of top and
bottom half. In order to eliminate this particular issue the orifice can be
formed with one
side being flat, therefore small variations in assembly positioning will not
matter. This
principle is illustrated in WO 01/32317. A dispensing orifice can also be
formed entirely
within either of the upper and lower outlet flow channel halves.
The dispensing orifice can also comprise a movable plug to seal the orifice
when it is not
in use. This can help avoid clogging of the orifice and also provides better
protection
from contaminants for fluid remaining in the dispenser. WO 03/078073 discloses
an
arrangement whereby a plugging element is movable between a sealing and non-
sealing
position upon operation of the device without other intervention by the user.
Reservoir
The purpose of the pump is to enable dispensing of a fluid from a fluid source
or
reservoir. The fluid can be any that is compatible with components of the pump
and that
is not too viscous to be pumped including, without limitation, cosmetic
products such as
perfumes and lotions; medicines; veterinary products, liquid foods or sauces
and other
household products such as cleaning fluids. The pump can be permanently or
detachably
connected to a reservoir and, optionally, an atomising nozzle or applicator,
to form a
complete dispenser and/or it can form part of a more complex product
comprising other
parts such as a housing and a handle. An atomising nozzle is preferred for
certain
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medicinal applications, such as nasal or throat treatment. An applicator
suitable for
spreading the fluid onto a substrate may be preferred for other treatments.
Useful
applicators comprise spreading means selected from brush heads, elastomeric
wiping
blades and disposable cloths. The pump can be directly connected to a
reservoir or
connection can be made, for example by means of intermediate tubing if it is
desirable for
the pump and reservoir to be remote from each other. Provision for permanent
attachment to a reservoir can be made, for example by co-moulding a weld spout
with the
pump inlet port so that the pump can be sealed in a fluid tight manner to a
flexible sachet.
The pumps provided herein can be manufactured at low cost and are economically
suited
to applications where a pump is provided with each reservoir. In this case,
the reservoir
and pump are preferably peumanently connected via a heat-sealing, welding, in-
mould or
snap fit operation. There are applications though, in particular where the
pump is
associated with a more complex device, where it can be beneficial for the
reservoir to be
detachably connected to the pump such that replacement reservoirs can be
fitted to the
same pump. Though a detachable connection avoids throwing away the pump if the
reservoir must be replaced, it introduces further complexity in order to
provide a reliable,
fluid tight, re-usable connection. However, suitable fitments for this purpose
are known
in the art. Exemplary fitments are disclosed in WO 99/05446, WO 00/66448 and
WO 03/095322.
The reservoir itself can be semirigid or flexible. If it is semirigid then it
may be
necessary to provide means for venting the reservoir, for example by means of
a one-way
valve allowing air ingress, in order to avoid the development of a vacuum in
the reservoir
which could inhibit further dispensing or cause suck-back past the pump outlet
valve
requiring the pump to be re-primed. The venting means can also comprise a
narrow mesh
filter that prevents fluid passing through it and escaping to the external
environment. For
example a biofilter that filters out bacteria, spores and the like from the in-
drawn air, thus
enabling the fluid in the reservoir to be preservative free. A biofilter
capable of
maintaining a sterile filtration barrier can be made from GORE-TEX~ expanded
PTFE
laminate, available from W. L. Gore & Associates, Inc. of Newark, Delaware,
USA. In
preferred embodiments of a dispenser herein the pump is combined with a
reservoir in the
form of a flexible sachet containing a fluid, the sachet collapsing as fluid
is withdrawn
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16
from it by the pump. A reservoir made of a flexible laminate offers the
benefit of
improved barrier properties. Flexible reservoirs are preferably charged with
fluid via an
airless filling operation so that the charged reservoir contains no air.
In many cases it will be convenient and simpler to manufacture the pump as an
external
fitment to the reservoir. However, where total space is a problem then the
reservoir can
be built around the pump so that the pump is internal to, or contained within,
the
reservoir, by which is meant that walls of the reservoir substantially enclose
the pump
even though parts of the pump, such as, in particular its actuator and a lower
pump
surface opposed to the actuator may be contiguous with upper and lower outside
walls of
the reservoir. Preferred embodiments herein include a dispenser comprising a
reservoir
with an integral pump contained within the reservoir. Alternately the pump can
be
contained within a flexible sachet so that the actuator of the pump can be
actuated by
pressing against that portion of the sachet wall which overlies the actuator,
as shown for
example in the device of WO 02/16047. Preferably, in embodiments with the pump
contained within the reservoir, the pump upper and lower halves are integrally
moulded
with upper and lower halves of the reservoir.
Whether the reservoir is semirigid or flexible it may be preferable to include
a dip tube
inside the reservoir to assist the removal of all of the fluid in the
reservoir in certain
orientations dependent upon the orientation of the dispenser when in use. A
dip tube will
generally be used when the reservoir is semirigid and can also be useful in a
flexible
sachet. The method of construction of pumps, reservoirs and dispensers herein,
from
upper and lower moulded halves, can also be applied to the construction of
dispensing
devices and reservoirs with dip tubes, even if a pump is not incorporated.
Thus in a
further inventive aspect herein there is provided a dispensing device
comprising upper
and lower halves, the upper and lower halves co-operating to form a fluid
reservoir and'a
dispensing outlet at a first end of the reservoir characterized in that the
upper and lower
halves each comprise sections of an integrally moulded channel, the sections
co-operating
to form a dip tube, or flow channel, in fluid communication with the
dispensing outlet and
terminating at an inlet end close to a second end of the reservoir remote from
the first.
The dip tube preferably has a length from the dispensing outlet end to its
inlet end of at
least 90%, preferably at least 95% of the length of the reservoir. In a
preferred
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17
embodiment of this dispensing device at least one of its upper and lower
halves comprises
a resiliently deformable region enabling fluid to be pumped from the reservoir
through
the dispensing outlet. This resiliently deformable region may comprise a
substantial
proportion, say at least 30%, more preferably at least 50%, of the external
area of the
pump half comprising it. Alternatively the deformable region may be relatively
small and
be in the form of a resilient actuator as herein described, preferably
comprising a
monostable element. A further mechanism for dispensing fluid from the device
comprises providing a plurality of bi-stable actuators, as described further
above, such
that compression of each actuator delivers a unit dose of the fluid. As for
other
embodiments herein, this dispensing device can also comprise an atomising
nozzle in
fluid communication with the dispensing outlet and, if necessary an outlet
valve and a
vent valve.
Manufacture of the pump
In general the pumps, dispensers, valves, valve modules and actuators herein
can be made
by low cost making moulding techniques such as injection moulding, compression
moulding and thermoforming. Injection moulding is preferred. However, it is
also
possible for at least one of the upper and lower pump halves to be compression
moulded
or thermoformed, and the present invention comprises pumps with compression
moulded
or thermoformed upper and/or lower pump halves comprising valves as herein
described.
Assembly of the component parts can be by snap or friction fit or by welding.
Further
sealing, where necessary, can be provided by additional injection moulded
seals or by
other techniques known in the art, such as ultrasonic sealing, laser welding
or heat
sealing.
In an embodiment, each of the upper and lower pump or dispenser halves is
formed in
one single shot injection moulding operation from a suitable, semirigid
thermoplastic
resin material. Alternatively, the upper and lower pump or dispenser halves
may be
assembled after moulding. Suitable resins include thermoplastics having a
flexural
modulus of at least 300, preferably at least 500 MPa, preferably at least 1000
MPa,
measured using ASTM D790 and include polypropylene, polyethylene, polyethylene
terephthalate (PET), polyesters, polycarbonates, polyamides, polystyrenes and
blends
thereof. Preferred materials include polypropylene, polyethylene and
polyethylene
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18
terephthalate, most preferred is polypropylene. By careful choice of
dimensions, flap
valves can be integrally moulded with the upper or lower pump half in a single
shot
injection moulding process. Alternately, the valves can be co-moulded from a
softer
material in a two-shot injection moulding.
In certain embodiments it may be appropriate for all or part of the either the
upper of
lower pump half to be made of a more flexible material such as a thermoplastic
elastomer.
For example, an upper pump half may be substantially composed of a semirigid
material
with its resilient actuator being formed from a thermoplastic elastomer in a
two shot
injection moulding operation. In particular, the inlet and outlet valves can
be and
preferably are formed from a second resin material co-moulded with either of
the upper
and lower pump halves in a two-shot injection moulding operation. Conveniently
this
can be done within the same mould or tool as that employed for the first step.
The second
resin material is preferably an elastomeric material having a Shore A
hardness, measured
using ASTM D2240, of from 5 to 90, preferably from 20 to 70.
The upper pump half and the lower pump half are then assembled onto each
other.
Where flap valves are used, their compression takes place at this stage. Once
the two
pump halves are assembled, a sealing element can be formed by injecting an
additional
resin, bonding the sealing element to the upper and lower halves, thus holding
them
together and creating a fluid tight seal. An alternative option for sealing
the upper and
Iower half together is the use of a welding operation, such as by high
frequency sealing.
A third option for assembly of upper and lower halves is to integrate a snap
feature into
one or both halves which enables the upper and lower halves to maintain the
assembled
position once brought together. In this case it may be necessary to use an O-
ring or
gasket to provide adequate sealing. In an alternative embodiment, a co-moulded
TPE seal
may be used.
Though in the preferred embodiment the preceding steps are all integrated into
a single
injection moulding process using one injection moulding tool, it will be
appreciated that
each be performed on separate, dedicated injection moulding tools.
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19
If the resilient actuator has not been integrally moulded with the pump upper
half then it
can be made in a separate operation and assembled to form the completed pump
via e.g.,
an in-mould sealing operation.
The invention will now be described in more detail by reference to preferred
particular
embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a perspective view of a pump according to the invention, shown with
associated
nozzle and connector.
Fig. 2 is a perspective view of the lower half of the pump of Fig. 1.
Fig. 3 is a perspective view of the upper half of the pump of Fig. 1.
Fig.4 is a partial, longitudinal cross-section of the pump of Fig. 1 to show
the
relationship of the valves to the dose chamber.
Fig. 5 is a transverse cross-section of the pump of Fig. 1.
Fig. 6a shows, in perspective view, a flap valve used in the pump of Fig. 1.
Fig. 6b is a perspective view of an alternate flap valve shape.
Fig. 7 is a partial, perspective view of the lower half of the pump of Fig. 1
showing the
exit orifice.
Fig. ~ is a partial end view of the nozzle of the pump of Fig. 1 showing the
formation of
the exit orifice at the part line of the upper and lower pump halves.
Fig. 9 is a partial, longitudinal cross-section of the pump of Fig. 1 showing
an initial
force being applied to the resilient actuator.
Fig. 10 is a further cross-section view of the pump of Fig. 1, showing the
deformation of
the resilient actuator and the operation of the outlet valve as fluid is
dispensed.
Fig. 11 is a yet further cross-section view of the pump of Fig. 1, showing the
resilient
actuator returning to its start position and the re-priming of the pump with
fluid
from the reservoir (not shown).
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Fig. 12 is a perspective view of an atomising outlet for use with a dispenser
according to
the invention.
Fig. 13 is a perspective view of one half of the atomising outlet shown in
Fig. 12.
Fig. 14 is a perspective view of a second embodiment of a pump according to
the
invention incorporated with a reservoir to form a dispenser.
Fig. 15 is a perspective view of the dispenser of Fig. 14 shown without its
protective
sleeve.
Fig. 16 is a perspective view of the dispenser of Fig. 14 with a fitted
protective cap.
Fig. 17 is a perspective view of a third embodiment of a dispenser according
to the
invention.
Fig. 18 is a transverse section of the dispenser of Fig. 17 through its pump.
Fig. 19 is a perspective view of the lower half of the dispenser of Fig. 17.
Fig. 20 is a perspective view of the upper half of the dispenser of Fig. I7.
Fig. 21 shows a resilient actuator for use in the dispenser of Fig. 17.
Fig. 22 is a plan view of the monostable element built into the actuator of
Fig. 2I .
Fig. 23 is a further cross-section of the pump of Fig. 17 to more clearly show
the structure
and use of the actuator, with incorporated monostable element, of Fig. 21.
Fig. 24 is a sectional view of a fourth embodiment of a dispenser according to
the
invention.
Fig. 25 is a section through the monostable resilient actuator of the
dispenser of Fig. 24.
Fig. 26 Force (F) vs. deflection (D) curve showing the characteristics of a
monostable
element.
Fig. 27 is a sectional view of a fifth embodiment of a dispenser according to
the
invention.
Fig. 28 is a perspective view from above of the upper half of the dispenser of
Fig. 27.
Fig. 29 is a perspective view from below of the upper half of the dispenser of
Fig. 27.
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21
Fig. 30 is a perspective view from above of the lower half of the dispenser of
Fig. 27.
Fig. 31 is a perspective view of the actuator strip of the dispenser of Fig.
27.
Fig. 32 is a perspective view of a valve module for a pump.
Fig. 33 is a section through the valve module of Fig. 31.
Fig. 34 is a sectional view showing the valve module of Fig. 31 being
assembled into an
upper pump half.
Fig. 35 is a sectional view of an assembled pump comprising the valve module
of Fig. 31.
Description of preferred embodiments
Figures 1 to 11 show a first embodiment of a pump according to the invention
and its
mode of operation. Figure 1 shows the assembled pump 101 in perspective view.
Pump
1 comprises an extended nozzle and a connector 125 in the form of a weld spout
by which
the pump can be connected to a fluid reservoir (not shown). The pump comprises
an
upper pump half 102 and a lower pump half 103 sealed together via a joining
element
104. Figures 2 and 3 respectively show the lower and upper pump halves in more
detail.
The connector 125 is not shown in these figures. The upper and lower pump
halves co-
operate to form a dose chamber 114, an inlet flow channel 116 and outlet flow
channel
117, the dose chamber and flow channels being in fluid communication with each
other
and the reservoir. The joining element 104 is added by a moulding shot and
seals the
upper half and the lower half of the pump together, securing both parts
against further
movement and creating a fluid tight path for the fluid as it passes through
the pump. In
alternative embodiments the upper and lower pump halves can be fitted directly
together
by snap fit, welding or gluing operations eliminating the need for the sealing
element 104.
Referring in more detail to Figures 2 and 3, lower pump half 103 has a
geometry
corresponding to that of the upper pump half 102 which comprises opposed
sealing ridges
129 for receiving the lower pump half 103. Sealing ridges 129 comprise upper
inlet port
walls 115a, upper dose chamber walls 130 and upper outlet port walls 115b.
Lower inlet
port walls 110a are received inside upper inlet port walls 115a to define
inlet flow
channel 116 and pump inlet port 112. An inlet sealing ridge 108 bridges the
lower inlet
port walls. Lower dose chamber wall 122 is received inside upper dose chamber
walls
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22
130 to bound a dose chamber 114 which is closed by resilient actuator 105. The
lower
dose chamber wall in this embodiment is a substantially solid block, divided
by a flow
channel, extending across the width of the dose chamber. This enables it to
limit the
travel of resilient actuator 105 and thereby help define the dose volume. It
also has the
effect of reducing the pump volume so that fewer priming strokes are needed.
Lower
outlet port walls 110b on the lower pump half are received inside upper outlet
port walls
I 15b on the upper pump half to define pump outlet port 113. An outlet sealing
ridge 109
bridges the lower outlet port walls. Outlet flow channel walls 111 on lower
pump half
103 are received inside upper pump half sealing ridges 129 to form outlet flow
channel
117 leading from pump outlet port 113 to exit orifice 118. Outlet flow channel
117 is
further bounded by the outlet flow channel upper wall 121 on upper pump half
102.
Outlet flow channel walls 111 converge at one end of flow channel 117 to form
exit
orifice 118 in conjunction with outlet flow channel upper wall 121, as shown
more clearly
in Figures 7 and 8. Inlet and outlet positioning lugs 123 and 124 are provided
on upper
pump half 102 and are received in corresponding recesses in an outer rim of
the dose
chamber wall 122 to assist in positioning and sealing during pump assembly.
Upper pump half 102 is shown fitted with inlet and outlet flap valves 106 and
107, shown
separately in Figure 6. In a preferred embodiment the valves are co-moulded
onto upper
pump half 102 either in the same moulding operation or in a separate moulding
operation
("over moulding"). Alternatively, the valves can be moulded independently and
assembled to the upper pump half by e.g., friction fit and/or by thermal
sealing or gluing
or compressed between upper and lower pump halves. The inlet valve prevents
backflow
of a fluid from the dose chamber 114 into the reservoir. When the upper and
lower pump
halves are assembled the flap of inlet valve 106 is compressed against inlet
sealing ridge
108 and lower inlet port walls 110a. Similarly, the flap of outlet valve 107
co-operates
with outlet sealing ridge 109 and lower outlet port walls 110b to form a non
return outlet
valve at pump outlet port 113. The outlet valve prevents backflow of fluid
from outlet
flow channel 117 into the dose chamber. The outlet valve can also prevent
contamination
of fluid in the dose chamber from the air or other potential external
contaminant sources.
Moving outlet valve 107 and corresponding outlet sealing ridge 109 closer to
the exit
orifice 118 of the pump can help prevent drying out of the fluid in the outlet
flow channel
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23
and avoid potential clogging of certain products, as well as helping to avoid
contamination. This will have the effect, however, of increasing the pump
volume.
The upper pump half comprises resilient actuator 105 which is a thin wall
section of the
upper pump half where it bounds dose chamber 114. Figure 5 shows more clearly,
by
cross-sections, the formation of dose chamber 114 between resilient actuator
105 and
lower dose chamber wall 122. Joining element 104 helps seal the upper and
lower pump
halves together. Pressure by a user's finger on actuator 105 reduces the
volume of dose
chamber 114, forcing fluid to exit the dose chamber through the pump outlet
port 113 and
along outlet flow channel 117 towards exit orifice 118. In other embodiments
according
to the invention the actuator can be made from a different material to that of
the upper
pump half which can be co-injected in the same process step as when the valves
are
formed. It will be appreciated that the actuator can also be formed by a
combination of
materials when this is of advantage for the specific application.
Reference will now be made to Figures 9 to 11 to show more clearly the mode of
operation of pump 101. Figure 9 shows the situation as a user initially
applies a force Fi
to resilient actuator 105. The pump is primed and dose chamber 114 contains a
dose of
fluid to be dispensed. At this stage the actuator has not appreciably deformed
and inlet
and outlet valves 106 and 107 are still in their normal mode of being
compressed against
inlet and outlet sealing ridges 108 and 109 so that the pump inlet and outlet
ports, 112 and
113, are closed.
As shown in Figure 10, as the applied force is increased to the threshold
force FZ of the
actuator, the actuator deforms rapidly, significantly decreasing the volume
inside the dose
chamber 114 and increasing the pressure of its contained fluid. The increase
in pressure
has the effect of applying further pressure to the upper surface of inlet
valve 106 thereby
keep inlet port 112 closed. At the same time though, pressure on the underside
of the flap
of outlet valve 107 is increased, causing it to lift, opening pump outlet port
113 and
thereby allowing fluid to flow out of the dose chamber, along outlet flow
channel 117 and
ultimately to be dispensed through exit orifice 118, as shown by the arrows.
Figure 11 shows the situation after the dose of fluid has been dispensed and
the user
removes the force applied to the actuator. The resilience of the actuator now
causes it to
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24
return to its starting position with force F3. The effect of this is to
increase the volume
inside the dose chamber 114, reducing its internal pressure. The reduction in
pressure
results in outlet valve 107 closing once more through its natural resilience
combined with
atmospheric pressure on the upper surface of its flap. At the same time the
pressure on
the flap of inlet valve 106 is reduced so that fluid pressure from the
reservoir lifts it away
from the sealing ridge 10~ thereby opening pump inlet port 112 and allowing
the dose
chamber to be recharged from the reservoir. It will be understood that for
this process to
work efficiently preferably the reservoir needs to be collapsible or it needs
to be vented.
Figures 12 and 13 show cross sectional views of an atomising outlet 119 which
can be
moulded in two halves and integrally moulded into the design of the nozzle of
the first
embodiment according to the invention. A swirl chamber geometry has been
integrated
into the upper and lower halves around exit orifice 118, without need for side
action on
the moulding tool. This geometry will be coupled to a baffle (not shown) also
moulded
into each of the upper and lower halves of the nozzle to force fluid to exit
through the
swirl chamber.
Figures 14 to 16 show a second embodiment according to the invention which is
a
dispenser 250 comprising a pump having essentially the same construction as
that of
Figure 1 but with modifications to the nozzle. A flexible laminate reservoir
220 is
bonded to the weld spout connector 225. To provide the reservoir with some
protection
and to provide a more aesthetically appealing package a sleeve 260, which can
be made
of, say, folding boxboard or plastic, encloses the reservoir. A hole in the
sleeve provides
access to resilient actuator 205. If the sleeve is flexible then it can of
course be provided
without a hole and the actuator can be depressed through the sleeve. In this
case indicia
can be provided on the sleeve to indicate where the user needs to press. The
modifications to the nozzle 266 include the provision of a shoulder 265 which
provides
support to sleeve 260 and cap 255 which is provided to cover the nozzle and
keep it
clean. Shoulder 265 can be integrally moulded in two halves with the pump and
nozzle
or alternatively, as here, it can be a separate part assembled by a clip/snap
or friction fit.
A very different solution for a dispenser according to the invention is shown
in Figures
17 to 20 which represent a third embodiment of the invention. In this
embodiment the
whole dispenser 350, including reservoir 320, is integrally moulded with pump
301 in
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two halves. The advantage of following this approach is that an entire
multiple
controlled-dose dispenser can be obtained with a minimum of parts and moulding
l
assembly operations. Compared to the dispenser 250 shown in Figures 14 to 16
this
solution provides a more compact dispenser for the same amount of contained
fluid as it
utilises the otherwise unused space by building the reservoir around the pump
so that the
pump is internal to the reservoir. The need for the reservoir to be moulded
imposes some
restrictions on the materials that can be used for the reservoir, for example
laminates will
generally be unsuitable, but this may not be critical for many applications.
This design
also requires a process for sealing two areas: a first, inner, seal which
isolates the pump
components, including outlet flow channel 317, from the reservoir 320 and a
second,
outer, seal at the outer perimeter which seals the reservoir 320 from the
outside air. With
this design the inner seal can no longer be created via an injection moulded
joining
element as in the pump of Figure 1. The seal is instead created by a snap fit,
welding or
gluing process when upper pump / dispenser half 302 is assembled to lower half
303.
The outer seal can be formed using other processes such as the afore-mentioned
joining
element or by using in-mould sealing. The dispenser further comprises an
atomiser 319
to generate a spray from dispensed fluid as the fluid exits outlet flow
channel 317. Inlet
flow channel 316 is open to the reservoir 320 at a point close to an end of
the dispenser
disposed opposite to the atomiser 319, providing an inlet point whereby fluid
can be
drawn from the reservoir into the flow channel. Having the inlet point close
to the end of
the dispenser ensure that, in normal use, most of the fluid can be dispensed
from the
reservoir. Together, the inlet and outlet flow channels and the pump 301 form
a
continuous reservoir flow path, acting like a dip tube, having an outlet end
through which
fluid is dispensed from the dispenser and an inlet end through which fluid is
drawn from
the reservoir, the flow path being isolated from the reservoir along its
length except at its
inlet end. In order to optimise fluid withdrawal from the reservoir, the
reservoir flow
path preferably has a length from its outlet end to its inlet end of at least
90%, preferably
at least 95% of the length of the dispenser.
Reservoir 320 is in the form of compartments symmetrically disposed about pump
301
and inlet and outlet flow channels 316 and 317. The inlet and outlet valves
are not shown
in the Figures but operate in the same way as already described in relation to
Figures 9 to
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26
11 such that, after a dose of fluid has been dispensed from dose chamber 314,
fluid is
drawn from the reservoir via inlet flow channel 316 to recharge the dose
chamber.
Though it is not shown in the Figures it is highly preferred that the
reservoir is also fitted
with a vent membrane filter to keep the reservoir at atmospheric pressure.
During initial
manufacture the reservoir is filled with fluid via fill port 381 after the
assembly of the
upper and lower halves 302 and 303, the port then being sealed with fill port
plug 380
which may be integrally moulded to either the upper or lower halves 302 and
303. It will
be appreciated that dispenser 350 can be various shapes and thicknesses and
sized to suit
the particular application. It can also be moulded with a shoulder for
receiving a
protective cap. In preferred embodiments for medicament dispensers the
dispenser has a
length of from about 20 to about 100 mm, more preferably from about 40 to
about 70
rmn, a width of from about 15 to about 80 mm, more preferably from about 20 to
about
55 mm and a depth of from about 5 to about 10 mm. The reservoir preferably has
a
volume of from about 0.5 to about 40 mls. Of course for other applications
much larger
reservoirs may be appropriate.
Whilst dispenser 350 can incorporate an integrally moulded actuator as part of
the upper
half 302, as described in the first embodiment, Figures 21 to 23 show in more
detail a
composite resilient actuator 305 used in the third embodiment. The actuator
comprises a
separate monostable button 340 covered on top and bottom surfaces by a soft,
elastomeric
material to form the resilient actuator. The separate monostable element can
be made of
various materials, in this embodiment it is a commercially available metal
snap dome
from Snaptron Inc. The actuator °is insert-moulded into upper pump half
302 where it is
Located and fixed by means of positioning lugs 341.
Figure 24 shows a fourth embodiment of the invention comprising a dispenser
450 of
similar construction to that shown in Figures 17 to 20, including reservoir
420 moulded
around an integral pump, the whole being in two halves. Reservoir 420
comprises fill
port plug 480 sealing a fill port through which the reservoir can be charged
with fluid
during manufacture. In this embodiment outlet flow channel 417, in fluid
communication
with dose chamber 414, runs as far as a cylindrical projection on upper half
402, the
projection mating with a corresponding recess formed in a boss in lower half
403, the
recess being open to the outside by exit orifice 4I8. Although the cylindrical
projection
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27
and exit orifice 418 are shown as passing perpendicularly through lower half
403 they can
of course be formed at an oblique angle to it so that, for example, the
dispensed fluid
emerges at an angle to the plane of the reservoir.
The resilient actuator 405 of this embodiment is a thermoformed, polypropylene
disc
insert-moulded to a corresponding recess on upper half 402. The actuator is
shown in
section in Figure 25 to give a better appreciation of its shape. It includes a
central dome
487, a flange 486 for securing the actuator to a pump and an annular trough
485. The
function of the annular trough is to allow the central dome to distort
sufficiently to invert
without its distortion being inhibited by the flange which will be held fixed.
The actuator
can also be provided, as in the first embodiment, as an integrally moulded
thin wall
section of upper half 402.
Figure 27 shows a sectional view of a dispenser 550 which is a fifth
embodiment
according to the invention. This construction of the dispenser affords some
advantages in
construction and assembly at the expense of an additional part since the
dispenser now
requires a minimum of three parts. In this dispenser it is the upper pump half
502, shown
separately from above and below in Figures 28 and 29, which comprises the
lower dose
chamber wall 522. At the centre of the lower dose chamber wall is the pump
inlet port
512 which provides fluid communication between the dose chamber and the inlet
flow
channel. In this embodiment the resilient actuator 505 is formed as a separate
injection
moulded piece with two integrally formed strips extending from it, as
illustrated in Figure
31. Upper pump half 502 further comprises a recessed portion corresponding in
outline
shape to the actuator and strip moulding. This recessed portion comprises
substantial
portions of the lower part of inlet flow channel 516 and outlet flow channel
517 as
grooves running longitudinally along the centre of the recessed portion. For
these flow
channel portions the outlet flow channel upper wall 521 and an upper portion
of the inlet
flow channel 516 are provided by the actuator and strip moulding. A reservoir
port 526
at one end of the inlet flow channel 516 provides fluid communication between
the inlet
flow channel and the reservoir 520.
Referring again to Figure 27, inlet valve 506 and outlet valve 507 are pre-
formed duckbill
valves located in recesses of upper pump half 502, the recesses having holes
at the bottom
for fluid communication with lower pump half 503. One of these holes serves as
pump
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28
outlet port 513. Suitable duckbill valves include the DU 027.001 SD valve
available
from Minivalve International of Jaartsveldstraat 5a, 7575 BP Oldenzaal, The
Netherlands.
Alternate valves such as slit valves can be co-moulded with upper half 502,
lower half
503 or indeed the strip integrally formed with the actuator.
Referring now to Figure 30, lower pump and dispenser half 503 is a simple
moulding
comprising lower inlet port wall 510a at one end of a dumbbell shaped wall
defining a
portion of inlet flow channel 516. A further dumbbell shaped wall provides
lower outlet
port wall 510b which is continuous with outlet flow channel side wall 511, the
latter
defining a short portion of outlet flow channel 517. A raised lip running
around the
periphery of the lower pump and dispenser half fits snugly inside an outer
side wall of
upper pump and dispenser half 502. The two dumbbell shaped walls receive, in
their
interior spaces, correspondingly shaped projections, shown in Figure 29, on
the upper
pump and dispenser half 502. The projections include the upper inlet port wall
515a and
upper outlet port wall 515b.
As seen most clearly in Figure 31, the strip incorporating the actuator has on
its underside
two C-shaped projections which locate inside the recesses of upper pump half
502,
securing the duckbill valves in place. A portion of the strip comprises an
outlet flow
channel upper wall 521 which covers the outlet flow channel 517 on its upper
side.
Likewise a portion of the strip on the opposite side of the actuator covers
the inlet flow
channel 516 on its upper side.
When the actuator 505 is depressed with sufficient force, fluid in the dose
chamber,
located between dose chamber lower wall 522 and the actuator 505, is dispensed
through
outlet valve 507, located in outlet port 513, and passes along the portion of
the outlet flow
channel 517 formed between the upper and lower halves 502 and 503. The fluid
then
flows through a connecting channel formed in the upper half and along the
remaining
section of outlet flow channel 517 that lies between the outlet flow channel
upper wall
521 and the upper pump and dispenser half before being dispensed through the
exit
orifice.
When the actuator is released, fluid from the reservoir 520 is drawn along the
section of
inlet flow channel 516 lying between the upper pump and dispenser half 502 and
one of
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29
the strip extensions of the actuator. The fluid then passes through inlet
valve 506 and
along the section of inlet flow channel 516 formed between the upper and lower
halves
502 and 503, from where it passes through pump inlet port 512 into the dose
chamber.
Though not shown in the Figures, the reservoir of this embodiment, like that
of the
dispenser of the fourth embodiment can further comprise a vent valve such that
the
pressure inside the reservoir is maintained at atmospheric pressure. A
microfilter in the
vent valve can substantially prevent outside contamination of fluid in the
reservoir.
Finally, a sixth embodiment of the invention is a valve module as illustrated
in Figures 32
to 35. The valve module can be manufactured as a separate item for assembly to
variously shaped pump or dispenser constructions, thus providing greater
manufacturing
flexibility. The valve module comprises upper and lower halves 602 and 603.
Lower
half 603 comprises a flat injection moulded strip having a central groove
which forms the
basis for inlet and outlet ports 612 and 613. The groove is interrupted by
inlet and outlet
sealing ridges 608 and 609 against which the flaps of inlet and outlet valves
606 and 607
are compressed, preventing the flow of fluid along the groove until sufficient
pressure is
exerted by the fluid to lift the valve flaps (during dispensing in the case of
outlet valve
607 or during dose chamber recharging in the case of inlet valve 606). An
upper surface
of the upper half 602 provides lower dose chamber wall 622. A channel passes
through
the centre of this to provide fluid communication between the dose chamber and
the inlet
and outlet ports. The lower dose chamber wall is bounded by a raised annular
boundary
wall 631 for receiving an actuator or interacting with a dispenser, as shown
in Figures 34
and 35 which illustrate the assembly of the valve module into a dispenser
section (shown
only in part), comprising a resilient actuator 605 to provide a completed pump
601. The
lower half 603 of the valve module is shaped with a substantially rectangular
external
wall section which provides a means for ensuring correct alignment of the
valve module
with other parts of a dispenser with which it is intended to fit. Alternate
alignment means
which can be used include positioning lugs and indents. More than one type of
alignment
means can of course be used. An important feature of this embodiment is that
the valves
are sandwiched between the upper and lower halves 602 and 603, thus enabling
the
provision of a compact valve module and provides substantial design
flexibility.
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Reference key for the parts shown in the drawings
The following list provides a key to the part numbers used in the figures and
their
foregoing description. The same part number may be referred to in different
embodiments of the invention and will be prefaced by a number indicating the
number of
the embodiment. Thus a 'pump inlet port' number below as ' 12' will appear as
112 when
referred to as a part of the first embodiment but 612 when referred to as a
part of the sixth
embodiment. For consistency of numbering, a single digit number below will be
padded
with a leading zero to two digits before the embodiment number is appended.
Thus, a
'resilient actuator' (number 5 below) will appear as 405 in the description
when described
as a part of the fourth embodiment. Not all parts are described or necessarily
used in each
embodiment.
1 Pump
2 Upper pump (and, optionally, dispenser) half
3 Lower pump (and, optionally, dispenser) half.
4 Joining element.
5 Resilient actuator
6 Inlet valve
7 Outlet valve
8 Inlet sealing ridge
9 Outlet sealing ridge
10a Lower inlet port wall
l Ob Lower outlet port wall
11 Outlet flow channel side wall
12 Pump inlet port
13 Pump outlet port
14 Dose chamber
15a Upper inlet port wall
15b Upper outlet port wall
16 Inlet flow channel
17 Outlet flow channel
18 Exit orifice
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31
19 Atomiser
20 Reservoir
21 Outlet flow chamlel upper wall
22 Lower dose chamber wall
23 Inlet positioning lug
24 Outlet positioning lug
25 Connector
26 Reservoir port
29 Upper pump half sealing ridge
30 Upper dose chamber wall
31 Boundary wall
40 Monostable button for use in a resilient actuator
41 Monostable button positioning lug
50 Dispenser
55 Cap
60 Sleeve
65 Shoulder
66 Nozzle
80 Fill port plug
81 Fill port
85 Actuator annular trough
86 Actuator flange
87 Actuator dome
