Note: Descriptions are shown in the official language in which they were submitted.
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LIQUID DISPENSING APPLICATORS AND METHODS OF MANUFACTURE
TECHNICAL FIELD
The present invention generally relates to the field of liquid application
onto a surface.
More particularly, the present invention relates to a liquid dispensing
applicator having
certain liquid applications and engagement features, and methods of
manufacturing
such applicators.
BACKGROUND
Applicators for applying liquids to surfaces are broadly used in several
industries such as
the medical domain to treat or clean.
Hygiene, reliability, ease of use and safety are some of the desirable
characteristics for
such applicators.
One way to promote or improve the hygienic characteristics of an applicator
may be by
ensuring that the applicator can only be used once and then must be thrown
away.
Another way is by limiting environmental or user access to certain parts of
the applicator.
Another consideration for fluid applicators is fluid flow. Fluid flow
characteristics are an
issue because providing excessive or insufficient amount of liquid on a
surface can be
detrimental or problematic to the fluid application purpose.
In addition, in particular for medicinal or antiseptic liquids it is desirable
to reliably
liberate the liquid at the moment of application. For desirable operation, the
liquid
applicator is often provided with an absorbent material to receive the liquid
and then
spread the liquid onto a surface. Liberating the liquid into the absorbent
material can
have several challenges. The absorbent material plays a role in the regulation
of the
liquid flow and the design of the container component can also affect the
fluid flow. In
addition, the relative orientation and the position of the different
components of the
applicator can influence the fluid flow and method of dispensing the liquid.
There are some known liquid applicators that use certain mechanisms to hold,
liberate
and apply the liquid. One known type of applicator is described in U.S. patent
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No 7,614,811 B2 (hereafter "Kaufman '811"). Kaufman '811 describes a hand-held
dispensing applicator comprising a source of fluid, a frangible applicator tip
attached to
the fluid source, and an absorbent member attached to the frangible applicator
tip. When
the frangible applicator tip is broken, fluid flows from the source to the
absorbent
member, whereby the fluid is applied and spread on a surface. The frangible
applicator
tip may comprise a support element permanently connected to the fluid source,
a
relatively rigid tongue element extending outwardly of the support element,
and a
frangible region there-between. By deflecting the tongue element relative to
the support
element, the frangible region fractures to thereby permit fluid to flow from
the fluid source
into the attached absorbent member.
The Kaufman '881 applicator and method of operation have various limitations
and
disadvantages related to the deflection method and configuration of the tongue
element.
Having the tongue provide structural support for the absorbent member may also
lead to
inconsistent performance and complicated manufacture and design requirements.
Another known type of applicator is described in U.S. patent application No.
11/740,910,
published under No. 2007/0286668 (hereafter "Kaufman '910"). Kaufman '910
describes
several variants of a hand-held dispensing applicator. One of the variants
illustrated in
Figures 12-26 comprises a container with a tongue element and a stem piece
containing
a fracture anvil having a cruciform passage for receiving the tongue element
when the
container and stem piece are coupled together the cruciform passage and the
tongue
element engage to twist the tongue element at a weakened joinder location
resulting in
at least partial separation from the container to enable the liquid to flow
into the stem
piece toward an absorbent material.
Another fluid applicator with tongue-and-slot configuration is described in
U.S. patent
No. 6,533,484 (hereafter "Osei '484"). Osei '484 describes a fluid applicator
comprising a
solution container having a frangible twist-off member and an applicator head
having a
receiving member that the twist-off member engages when the applicator head is
rotated
relative to the solution container to open the container at the twist-off
member to enable
fluid to flow from the solution container into the applicator head and to an
applicating
material.
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The known fluid applicators have a number of disadvantages related to
reliability, ease
of use, safety, manufacturing and effective fluid application. There is a need
for a liquid
dispensing applicator that overcomes at least some of the disadvantages of
what is
known in this field.
SUMMARY OF THE INVENTION
The present invention responds to the above-mentioned need by providing liquid
dispensing applicators and method of manufacturing such applicators.
In one embodiment, there is provided a liquid dispensing applicator
comprising: a
container body for containing a liquid, the container body having a
longitudinal axis
about which the container body is rotatable and a first end and a second end,
the
second end comprising an offset projection located so as to avoid traversing
the
longitudinal axis; a head component having a passageway having a distal end
and a
proximal end, the proximal end being for receiving the second end of the
container body
and the distal end being for applying the liquid onto a surface, the
passageway
containing a slot system for receiving the offset projection of the container
body; wherein
the container body and the head component are rotatable with respect to each
other to
enable engagement of the offset projection and the slot system and cause
breakage of
the offset projection forming a fluid communication breach thereby allowing
the liquid to
flow from the container body into the passageway of the head component.
In one optional aspect, the offset projection is oriented in parallel relation
with respect to
the longitudinal axis.
In another optional aspect, the offset projection is spaced away from the
longitudinal
axis.
In another optional aspect, the offset projection is formed as a solid peg.
In another optional aspect, the offset projection is cylindrical.
In another optional aspect, the offset projection is sized and configured to
enable
formation of the fluid communication breach in the container body upon
breakage of the
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offset projection, the fluid communication breach having a size allowing
liquid flow
control. The fluid communication breach may be sized to prevent gravity-
induced liquid
flow. In another optional aspect, the fluid communication breach has a
diameter of less
than about 3 mm. In another optional aspect, the fluid communication breach
has a
diameter of between about 1.5 mm and about 2 mm.
In another optional aspect, the offset projection is a first offset projection
and the
container body comprises at least one additional offset projection,
constituting a plurality
of offset projections.
In another optional aspect, the plurality of offset projections are sized and
configured to
enable formation of a total fluid communication breach area in the container
body upon
breakage of the plurality of offset projections, the total fluid communication
breach area
having a size allowing liquid flow control. In another optional aspect, the
total fluid
communication breach area is below about 14 mm2. In another optional aspect,
the total
fluid communication breach area is between about 1.75 mm2 and about 3.15 mm2.
In another optional aspect, the at least one additional offset projection
comprises a
second offset projection provided in parallel and spaced-apart relation to the
first offset
projection.
In another optional aspect, the offset projection has a base and a tip and the
second end
of the container body comprises a weakened region proximate the base of the
offset
projection. In another optional aspect, the weakened region comprises an
indentation in
a wall of the second end of the container in opposed relation to the base of
the offset
projection. In another optional aspect, the indentation is provided with a
size and shape
conforming to a cross-section of the base of the offset projection.
In another optional aspect, the second end of the container body comprises a
frusto-
conical wall. In another optional aspect, the passageway of the head component
has a
cavity with a cooperative shape for receiving and abutting against the frusto-
conical wall.
In another optional aspect, the applicator also has an axial coupling system
for axially
coupling the head component to the container body. In an optional aspect, the
axial
coupling system comprises a ridge-and-groove system wherein the second end of
the
container body comprises an annular ridge and an inner surface of the
passageway of
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the head component comprises an annular groove cooperative with the annular
ridge for
axially coupling the head component to the container body. The ridge-and-
groove
system may be snap fitting.
In another optional aspect, the applicator has a radial locking system for
radially
securing the head component to the container body after rotation thereof and
breakage
of the offset projection. In an optional aspect, the radial locking system
comprises a lip-
and-channel system comprising at least one lip and at least one corresponding
channel,
the lip being radially slidable within the channel, the channel comprising a
locking nodule
at a far end thereof, wherein rotation from an initial position toward a
breakage position
causes the lip to slide through the channel and pass over the locking nodule
and
wherein the locking nodule prevents the lip from sliding back to the initial
position. The
radial locking system may be configured such that the container body is locked
with
respect to the head component in a fluid flow position wherein fluid flow
apertures of the
container body are aligned with openings of the passageway.
In another optional aspect, the container body is formed as a one-piece
plastic structure.
In another optional aspect, the head component is formed as a one-piece
plastic
structure.
In another embodiment of the present invention, there is provided a liquid
dispensing
applicator comprising: a container body for containing a liquid, the container
body having
a longitudinal axis about which the container body is rotatable and a first
end and a
second end, the second end comprising a projection; a head component having a
passageway having a distal end and a proximal end, the proximal end being for
receiving the second end of the container body and the distal end being for
applying the
liquid onto a surface, the passageway containing a slot system for receiving
the
projection of the container body; wherein the container body and the head
component
are rotatable with respect to each other to enable engagement of the
projection and the
slot system and cause breakage of the projection forming a fluid communication
breach
thereby allowing the liquid to flow from the container body into the
passageway of the
head component; and a radial locking system for radially locking the container
body and
the head component together after rotation with respect to each other.
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In one optional aspect, the projection is at least one offset projection
located so as to
avoid traversing the longitudinal axis.
In another optional aspect, the projection is a tongue arranged so as to
rotate in
response to rotation of the container body with respect to the head component.
In another optional aspect, the radial locking system comprises a lip-and-
channel
system.
In another optional aspect, the lip-and-channel system comprises at least one
lip and at
least one corresponding channel with a locking nodule over which the lip
passes.
In another optional aspect, the at least one lip is provided on the container
body and the
at least one corresponding channel is provided on an inner surface of the head
component.
In another optional aspect, the at least one lip comprises two opposed lips on
either side
of the container body and the at least one channel comprises two opposed
radial
channels.
In another optional aspect, the breakage of the projection forms a fluid
communication
breach and the radial locking system is configured such that the container
body and the
head component are locked together so that the fluid communication breach is
aligned
with the passageway.
In another optional aspect, the first end of the container body has a clamped
part
(pinched part) and the radial locking system is configured such that the
container body
and the head component are locked together so that the clamped part is
oriented for
easy and ergonomic grasping.
In another embodiment of the present invention, there is provided a liquid
dispensing
applicator comprising: a container body for containing a liquid, the container
body having
a longitudinal axis about which the container body is rotatable and a first
end and a
second end, the second end comprising a projection; a head component having a
passageway having a distal end and a proximal end, the proximal end being for
receiving the first end of the container body and the distal end being for
applying the
liquid onto a surface, the passageway containing a slot system for receiving
the
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projection of the container body; wherein the container body and the head
component
are rotatable with respect to each other to enable engagement of the
projection and the
slot system and cause breakage of the projection thereby allowing the liquid
to flow from
the container body into the passageway of the head component; and a dual-
locking
system for axially locking the container body and the head component together
upon
axially coupling and for radially locking the container body and the head
component
together after rotation with respect to each other.
In one optional aspect, the projection is at least one offset projection
located so as to
avoid traversing the longitudinal axis.
In another optional aspect, the projection is a tongue arranged so as to
rotate in
response to rotation of the container body with respect to the head component.
In another optional aspect, the dual-locking system comprises a radial locking
system
comprising a lip-and-channel system.
In another optional aspect, the lip-and-channel system comprises at least one
lip and at
least one corresponding radial channel with a locking nodule over which the
lip passes
for radial locking.
In another optional aspect, the at least one lip is provided on the container
body and the
at least one corresponding channel is provided on an inner surface of the head
component.
In another optional aspect, the at least one lip comprises two opposed lips on
either side
of the container body and the at least one channel comprises two opposed
radial
channels.
In another optional aspect, the dual-locking system comprises axial channels
communicating with the two radial channels, the axial channels allowing the
two lips to
be axially inserted therein.
In another optional aspect, the dual-locking system comprises an axial locking
system
comprising a groove-ridge system.
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In another optional aspect, the groove-ridge system comprises the at least one
groove
provided on the head component and at least one annular ridge provided on the
container body for snap-fitting into the corresponding at least one groove.
In another optional aspect, the breakage of the projection forms a fluid
communication
breach and the radial locking system is configured such that the container
body and the
head component are locked together so that the fluid communication breach is
aligned
with the passageway.
In another optional aspect, the first end of the container body has a clamped
part
(pinched part) and the radial locking system is configured such that the
container body
and the head component are locked together so that the clamped part is
oriented for
easy and ergonomic grasping.
In another aspect, there is provided a method of manufacturing a liquid
dispensing
applicator, having one of more of the above defined features, using a blow-
fill-seal (BFS)
operation.
In one aspect, the method includes the steps of:
a) making the container body having one of more of the above defined features,
using a BFS operation, including:
i) providing a heated parison made of a polymeric material;
ii) enclosing the heated parison between a pair of side molds;
iii) injecting a gas into the parison in order to effect blow molding of
the polymeric material to form a molded container having an open
top end;
iv) filling the molded container with a fluid; and
v) sealing the filled container using a top mold part, to form the
container body that is full of the fluid; and
b) making the head component using a molding operation.
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In another aspect, the method is performed such that the container body has an
offset
projection or a tongue and the fluid communication breach is formed in a
region at the
base of the projection or tongue where they are joined to the top surface of
the second
end of the container body. In another aspect, the method is performed such
that the
container body has a tongue element and the fluid communication breach is
formed in a
region in spaced relation with respect to the tongue at a frangible membrane
and/or
crimp around the neck of the container body. The frangible membrane and/or
crimp may
be located in distal or proximal relation with respect to other elements on
the container
body, such as the axial locking elements, radial locking elements, and other
elements
that may be present.
The top mold part may be configured and operated to form the second end of the
container body, while the pair of side molds may be configured and operated to
form the
first end and the main central part of the container body.
In another aspect, there is provided a method of manufacturing a liquid
dispensing
applicator comprising a container body, which is preferably tubular, and a
sponge affixed
directly to the liquid dispensing end of the container body. The tubular
container body
may have one or more features of the container bodies described and
illustrated herein,
or may be another type of container body. The container body may be a pre-
injected
tube, e.g. where the tube is pre-injected prior to undergoing a separate
filling step,
whereas in BFS such steps are done in a single process. The sponge may be
connected
to the container body after the latter has been formed, e.g. by a BFS method.
The
sponge may be attached using an adhesive, for example, around the neck of the
tubular
container body. A user may twist or otherwise break the tongue or projection
of the
container body by gripping or otherwise engaging it through the sponge that
covers the
liquid dispensing end of the container body.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig 1 is a side partial cut, partial exploded and partial transparent view
schematic of a
liquid dispending applicator according to an embodiment of the present
invention.
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Fig 2 is a side partial cut, partial exploded and partial transparent view
schematic of a
part of a liquid dispending applicator according to an embodiment of the
present
invention.
Figs 3a-3h are top plan view schematics of part of an end of a container body
according
to embodiments of the present invention.
Figs 4a-4o are perspective view schematics of an offset projection according
to
embodiments of the present invention.
Figs 5a-5g are side cut view schematics of part of an end of a container body
according
to embodiments of the present invention.
Figs 6a-6c are top plan and partial transparent view schematics of part of an
end of a
container body according to embodiments of the present invention.
Figs 7a-7m are top plan view schematics of part of a slot system of a head
component
according to embodiments of the present invention.
Figs 8a-8d are side partial cut and partial transparent view schematics of a
head
component according to embodiments of the present invention.
Fig 9 is a perspective view of a container body with offset projections
according to an
embodiment of the present invention.
Fig 10 is a side plan view of an end of the container body according to an
embodiment of
the present invention.
Fig 11 is a side cut view of part of a head component according to an
embodiment of the
present invention.
Fig 12 is a top plan view of part of a head component according to an
embodiment of the
present invention.
Figs 13a-13f are perspective view schematics of radial locking systems
according to
embodiments of the present invention.
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Fig 14 is a perspective view schematic of a radial locking system according to
an
embodiment of the present invention.
Fig 15 is a top perspective cross-sectional view of part of the head component
according
to an embodiment of the present invention.
Fig 16 is a bottom perspective view of the head component according to an
embodiment
of the present invention.
Fig 17 is a side cut and exploded view schematic of a head component and a
container
body according to an embodiment of the present invention.
Fig 18 is a perspective view of a container body with tongue according to an
embodiment of the present invention.
Fig 19 is an isolated perspective view of a tongue of the container body
according to an
embodiment of the present invention.
Fig 20 is a perspective view of the head component according to an embodiment
of the
present invention.
FIG 21 is a partially transparent perspective view of the head component
according to an
embodiment of the present invention, wherein engagement unit, recesses and
grooves
are shown transparently in dotted lines.
FIG 22 is a perspective cross-sectional view of the structure of the head
component
according to an embodiment of the present invention.
FIG 23 is a cross-sectional side view of the head component.
FIG 24 is a bottom perspective view of the head component.
FIG 25 is a close-up perspective view of the front end of the container body
without the
tongue member or offset projections.
FIG 26 is a perspective view of the head component coupled with an absorbent
material.
Fig 27 is a side plan view schematic of an end of the container body according
to
another embodiment of the present invention.
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Figs 28a-28d are side perspective view schematics of configurations of offset
projections
with support tabs.
Fig 29 is a process diagram.
Fig 30 is a perspective exploded view schematic of a container body and a
sponge.
Fig 31 is a perspective view schematic of an applicator including a container
body and a
sponge.
Fig 32 is a perspective exploded view schematic of an applicator.
Fig 33 is a perspective view schematic of a variant head component.
Figs 34a and 34b are perspective front and back view schematics of another
variant
head component.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to Fig 1, in a preferred embodiment of the present invention, the
liquid
dispensing applicator 10 includes two main parts: a container body 12 and a
head
component 14. These two components may be axially coupled together in
operation.
Some axial coupling mechanisms that may be used in connection with the present
invention will be described further below.
The container body 12 preferably has an outer wall 16 defining a container
cavity 18
therein for receiving and holding a liquid. The container body 12 may be a one-
piece
structure or it may be composed of two or more sub-components fixed or
otherwise
coupled together. The container body 12 is preferably formed as a generally
elongated
tubular structure with opposed first and second ends 20, 22. The container
body 12 also
has a longitudinal axis 24 about which the container body 12 can rotate.
Preferably this
longitudinal axis 24 passes through the center line of the tubular structure
having a
circular cross-section. The container body 12 also has at its second end 22 at
least one
offset projection 26. The illustrated embodiment of Fig 1 has a pair of offset
projections
26. Each of the offset projections 26 extends from a terminal surface 28 of
the container
body at the second end 22 thereof. Preferably each offset projection extends
at a right
13
angle with respect to the terminal surface 28 and is parallel with respect to
the
longitudinal axis 24 of the container body 12. When a pair of offset
projections 26 is
provided, they are preferably equally spaced away from a central point of the
second
end 22 through which the longitudinal axis 24 passes.
The offset projection is so-called because it is located on the second end of
the
container body so as to avoid traversing the longitudinal axis. Unlike a
central tongue or
tab that may span the width of the second end and thus traverse the
longitudinal axis 24,
the offset projections are located such that each offset projection does not
cross the
longitudinal axis 24. As will be explained further below, by locating the
offset projections
in such a way, they are not twisted in response to rotation but are rather
deflected and
sheared.
Referring still to Fig 1, the second end 22 of the container body 12 is fit
into part of the
head component 14. The head component 14 comprises a tubular trunk 30 for
receiving
the second end 22 of the container body 12 as well as a base portion 32 for
supporting
an absorbent material 34 such as a sponge. The tubular trunk 30 has a slot
system 36
configured for receiving the offset projections 26 of the container body 12.
In operation, the container body 12 is coupled to the head component 14 so as
to be
axially secured together while allowing rotational movement with respect to
each other
and so that the offset projections are inserted within the slot system 36.
Upon rotation of
the container body 12 with respect to the head component 14, the offset
projections 26
engage with the slot system 36 causing shearing and breakage at or near to
offset
projections 26, thereby allowing the liquid to flow from within the container
body 12 into
and through the head component 14 toward the absorbent material 34. Breakage
of the
projections 26 results in the formation of apertures in the second end 22 of
the container
body 12. Such apertures are schematically illustrated and identified with
reference
character 37 in Fig 25.
Referring now to Fig 2, the slot system 36 comprises one or more slots 38
sized and
configured to receive corresponding ones of the offset projections 26. The
slots 38 are
formed within the material of the engagement unit 40 which is mounted within
or unitary
with an outer wall 42 of the tubular trunk 30. In the embodiment illustrated
in Fig 2, the
offset projections 26 and the slots 38 have cylindrical shapes and are sized
such that the
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offset projections 26 fit entirely within the slots 38 which each extend
partially within the
engagement unit 40, rather than extending entirely there-through. The
engagement unit
40 also has a fluid passageway 44, which is sized and configured so as to
align with the
torn open apertures formed after breakage of the offset projections 26. The
fluid
passageway 44 is thus in fluid communication with the proximal end of the
tubular trunk
30 and allows fluid to flow into the base portion 32 and into the absorbent
material 34.
Referring to Figs 3a-3g, it should be understood that the at least one offset
projection 26
may be provided is several ways and may take various forms. There may be a
pair of
projections 26 equally spaced away from the axis as shown in Figs 3a, 3e, 3f
and 3h;
multiple projections 26 located around the terminal surface of the container
body as
shown in Figs 3c and 3d; a single projection 26 as shown in Fig 3b and 3g;
projections
that are all spaced away from the central axis as shown in Figs 3a-3f and 3h;
projections
that have a surface aligned with but not traversing the central axis as shown
in Fig 3g;
projections that have a circular cross-section as shown in Figs 3a-3e and 3g;
projections
of different sizes on a single container as shown in Fig 3d; projections that
have oval
cross-sections as shown in Fig 3f; and/or projections that have other cross-
sections as
shown in Fig 3h. In addition, referring to Figs 4a-4o, each offset projection
may have
various forms, some of which are illustrated here.
It is also noted that the container body is preferably constructed as a
unitary one-piece
structure made of plastic material. Thus, the projections are preferably
unitary with the
rest of the container body 12.
Referring to Figs 5a-5g, the second end of the container body may have an end
wall 46
from which the offset projections 26 extend and which has weakened regions 48
proximate the base of respective offset projections 26. The weakened regions
48 may
include indentations 50 as shown in Figs 5a-5d and 5g. The weakened regions 48
may
also be areas where the end wall 46 is thinner than the rest of the wall of
the container
body as shown in Fig 5f. The weakened regions 48 may also include hollow
sections 52
of the projections 26 as shown in Figs 5c-5e. The hollow sections 52 may be
joined with
the indentations 50 as shown in Fig 5c.
Referring to Figs 6a-6c, the weakened regions such as indentations 50 may be
sized
and located in several different ways. The indentations 50 may be provided in
a
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concentric manner with respect to the cross-section of respective offset
projections 26
as shown in Fig 6a; they may be provided offset with respect to the cross-
section of
respective offset projections 26 as shown in Fig 6b, for instance offset in
the rotational
direction in which the projections are sheared and displaced; and they may be
provided
as an annular continuous indentation 50 encircling the central axis and
located below
each of the offset projections 26 as shown in Fig 6c.
Referring to Figs 17, the weakened region 48 may also include a notch 54
provided in
the base of the offset projection 26 and optionally a corresponding edge 56 in
the upper
part of the slot 38 for engaging the notch and facilitating breakage of the
projection 26.
It should be noted that various other means may be used to facilitate the
breaking of the
projections and opening up of the apertures in the container body to enable
and facilitate
fluid flow.
Referring to Figs 7a-7m, the engagement unit 40 has one or more slots 38 and
one or
more fluid passageways 44. In the illustrated embodiments of Figs 7a-7I, the
preferred
rotation of the head component relative to the container body is 90 , thus
allowing the
torn open apertures of the container body to align with passageways. It should
be noted
that other configurations are also possible. For instance, Fig 7m shows a
configuration
for 180 rotation for ideal alignment.
Referring to Figs 7k and 3e, the container body may also have a central
protuberance 58
aligned with the longitudinal axis and the engagement unit 40 may have a
corresponding
hole 60 for receiving the central protuberance 58, which does not break but
rather helps
to stabilise and orient the components together for coupling and rotation.
Referring to Figs 8a-8d, the fluid passageway 44 and the slots 38 may have
several
different configurations. For instance, the slots 38 may extend only partially
down into
the engagement unit material as shown in Figs 8a and 8d, or they may extend
all the
way through as shown in Figs 8b and 8c. In addition, the engagement unit 40
may taper
inwardly as it extends toward the base portion 32 as shown in Figs 8c and 8d.
The fluid
passageway 44 may have a constant cross-section as shown in Figs 8a-8c, or it
may
have a variable cross-section where at least part of the passageway tapers
outwardly as
it extends toward the base portion 32 as shown in Fig 8d. The engagement unit
40 may
have a proximal surface 62 and a distal surface 64 which may be parallel to
each other
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as shown in Figs 8a-8c, or not. Fig 8d shows a configuration in which the
distal surface
64 is not parallel to the proximal surface 62 but rather to the base portion
32. It should
also be noted that the engagement unit 40 may be located at a desired depth
with the
tubular trunk 30 of the head component 14. In one embodiment, the engagement
unit 40
is located relatively deep in the trunk 30 as illustrated in Fig 8c such that
at least part of
the distal surface 64 is aligned with the undersurface 66 of a hollow space
defined in the
base portion for receiving the absorbent material.
Referring now to Fig 9, the container body 12 is preferably designed to have
an
elongated tubular structure so as to be manipulated as a handle by a user. The
container body 12 has a central portion 68 in between the first end 20 and the
second
end 22. The central portion 68 is preferably made of a deformable material,
such as
various plastic materials, so as to be squeezable in order to allow a user to
influence the
pressure exerted on the liquid and thus control the liquid flow. The first end
20 of the
container body 12 is preferably closed by a pinched plastic part 70.
Alternatively, the first
end 20 may be closed using a variety of other techniques depending on the
method of
filling the container body 12 with the liquid and on the particular
construction and parts
used to assemble the container body. In a preferred aspect, the container body
12 is
formed as a one-piece structure made from a plastic material. Such a one-piece
structure may be manufactured using various moulding techniques, for example.
It is
also possible to construct the container body is other ways. For example, the
container
body 12 may be assembled from two or more parts that are fused, melted or
screwed
together. The first and second ends 20, 22, for example, may be separate
components
that are permanently or reversibly attached to the central portion 68 to form
the container
body 12. It should be noted that such attachment between container body sub-
components should be fluid-tight.
Referring still to Fig 9, the second end 22 of the container body 12 may be
configured
and provided with several preferred features for advantageous functionality of
the liquid
dispensing applicator. The second end 22 preferably includes a side wall 72
and the end
wall 46. The side wall 72 has a cylindrical section 74 connected to the
central portion 68
of the container body 12 and has a frustro-conical section 76 extending
between and
connecting the cylindrical section 74 and the end wall 46. The cylindrical
section 74 has
a smaller diameter than that of the central portion 68, preferably sized such
that the
entire second end 22 of the container body can be inserted within the tubular
trunk of the
CA 02796699 2012-11-14
17
head component. An annular ledge 78 defined between the cylindrical section 72
and
the central portion 68 can abut on a corresponding annular surface (identified
with
reference character 80 in Fig 15) of the head component. The surface of the
outer wall
16 of the container body thus aligns to be generally coplanar with the outer
surface of
the tubular trunk, thereby providing a flush surface for the assembled
applicator. The
side wall 72 is preferably provided as a rigid, thick or strengthened plastic
wall compared
to the outer wall 16 of the rest of the container body, especially compared to
that of the
central portion 68.
In another preferred embodiment, the liquid dispensing applicator has a double-
locking
mechanism for both axially and radially locking the head component to the
container
body in the desired functional positions.
Preferably the axial locking system comprises ridge-and-groove system wherein
one of
the components has a ridge and the other component has a groove for receiving
the
ridge when the components are axially coupled together. Preferably the ridge-
and-
groove system is snap fitting. It is also noted that there may be multiple
ridges and
corresponding grooves for providing multiple snap fit connection points.
Referring to Fig 9, the second end 22 of the container body 12, preferably the
frustro-
conical section 72 comprises the annular ridge 82. Referring to Fig 11 an
inner surface
of the tubular trunk 30 has the annular groove 84 that is cooperative with the
annular
ridge for axially coupling the head component to the container body. It should
be noted
that the annular ridge may alternatively be provided on the head component and
the
annular groove may be provided on the second end of the container body.
Preferably the radial locking system for radially securing the head component
to the
container body after rotation thereof and breakage of the offset projection
comprises a
lip-and-channel system wherein one of the components has at least one lip and
the
other component has at least one corresponding channel with a locking nodule.
Referring to Fig 10, the second end 22 of the container body 12, preferably
the
cylindrical section 74, comprises the lip 86. Preferably there are two opposed
lips 86 one
on each side of the container body 12. Referring to Fig 11, an inner surface
of the
tubular trunk 30 has the channel 88. The channel 88 preferably has a radial
channel
section 90 and an axial channel section 92, which are interconnected so that
the lip can
18
slide axially through the axial channel 92 when axially coupling the two head
component
to the container body and then the lip can slide radially along the radial
channel 90 when
the components are rotated with respect to each other. The lip 86 is radially
slidable
within the radial channel section 90, which has a locking nodule 94 at its far
end 96.
When releasing the liquid from the container body 12, rotation from an initial
position
toward a breakage and liquid release position causes the lip 86 to slide
through the
radial channel 90 and pass over the locking nodule 94 and the locking nodule
94 then
prevents the lip 86 from sliding back. The far end 96 of the radial channel 90
is sized and
configured to receive the lip 86. It should be noted that the lips may
alternatively be
provided on the head component and the channels may be provided on the second
end
of the container body. Having two opposed lips and two opposed corresponding
channels enables, for example, improved guiding and stability for rotating and
radial
locking.
Referring to Figs 12, there are preferably two opposed channels such that the
axial
channel sections 92 are on either side of the tubular trunk 30.
Referring to Figs 13a-13f, the locking nodule 94 can be provided in a number
of ways
within the radial channel 90. The locking nodule 94 can take the form of a
round bump
as shown in Figs 13b and 13c, an inclined block with a straight back edge as
shown in
Fig 13a, a ledge defined by a sloping radial channel as shown in Fig 13d, or
another
shape or form. The locking nodule 94 may also be provided on a bottom surface
98 or a
side surface 100 of the radial channel 90. Fig 13e shows a flexible tab-like
nodule and
Fig 13f shows a configuration using two nodules on the bottom and side
surfaces of the
radial channel 90.
In addition, the radial locking system may be configured to have multiple or
staged
locking positions.
Referring to Fig 14, the radial channel 90 may have multiple locking nodules
including a
first nodule 94a and a second nodule 94b. Rotation of the head component
relative to
the container body will cause the lip to pass over the first nodule 94 and
retaining the lip
in a first channel section 102 and securing the components together at an
intermediate
position. Further rotation of the components causes the lip to pass over the
second
nodule 94b and to be retained in the second channel section 104 at the end of
the radial
channel 90. It should be noted that the passageway and offset projections may
be
CA 2796699 2019-03-20
19
configure and oriented such that in the intermediate rotational position, the
liquid can be
release in a different manner compared to a full rotation position, e.g.
different
passageway diameters could enable different flow control and flow rate of
liquid. In one
aspect, the fluid communication breaches formed by breakage of the projections
are
sized to prevent gravity-induced liquid flow, thus allowing fluid to be
retained within the
container body unless the user exerts pressure on the container body.
With regard to the radial locking system, various different structures and
interworking
parts may be provided to allow the head component to be secured to the
container body
after rotation. For instance, instead of having a channel inset into the inner
surface of the
tubular trunk of the head component, there may be an elongated slot through
the tubular
trunk and the container body may have a rod projecting so as to pass through
the
elongate slot and be slidable therein. The elongated slot may have a nodule,
edge or
another structural element at its far end to resist back sliding of the rod
after rotation.
Referring to Fig 15, once the offset projections have been sheared and liquid
has been
released though the passageway 44, the fluid flows through a downstream cavity
106
and into the base portion 32 of the head component 14. The base portion 32 has
an
inset region 108 which has the bottom surface 66. The base portion 32 also has
a lower
perimeter 110 surrounding the inset region 108. Preferably the absorbent
material is
attached to the lower perimeter 110 leaving a space between the absorbent
material and
the bottom surface 66. This spacing is preferably sized and provided so as to
allow the
liquid to flow into that inset region 108 to improve even distribution over
the absorbent
material (not illustrated here). Characters IS and SI illustrate forward and
rearward parts
of the insert region. The absorbent material is mounted to the base portion
preferably
around the perimeter 110 using an adhesive. Once the liquid penetrates through
the
absorbent material it can be dispensed by the absorbent material onto the
desired
surface.
Each offset projection may have a proximal side and distal side with respect
to the
center of the end tip. The proximal side may have a surface preferably located
in spaced
relation from the central axis by a distance. The distal side of the offset
projection may
preferably have a surface located so as to be near or defining a smooth line
with the
surface of the frustro-conical section of the end tip. While the location and
configuration
of the offset projections may be varied, it may be preferable that each offset
projection is
CA 2796699 2019-03-20
CA 02796699 2012-11-14
located closer to the perimeter of the end of the container body than to the
longitudinal
axis. Location of the offset projections should also be coordinated with their
size, shape
and configuration to ensure adequate breakage of the projections in response
to rotation
of the container body relative to the head component and to facilitate
manufacturing and
handling of the liquid dispensing applicator. For instance, projections
located further
away from the longitudinal axis may be preferred for breaking in response to
rotation.
Each of the projections also has a top end and bottom end, which may have the
same or
different cross-section and shape.
Referring now to Fig 27, when there are multiple offset projections 26 may be
joined
together via a bridging member 111. There may be one or more bridging members
111
which may be arranged in between the offset projections 26 for stabilizing the
projections during manufacturing, handling and packaging of the liquid
dispensing
applicator. For instance, when the liquid dispensing applicator comprises one-
piece
moulded container body and one-piece moulded head component, there may be a
bridging member 111 that is also unitary with the offset projections 26 for
stabilizing
them. The bridging member 111 may be structured and configured such that upon
insertion of the container body into the head component, the bridging member
folds,
moves or fractures to allow the offset projections to be received within the
slot system.
The bridging member 111 may be provided between the far ends of the offset
projections, in the middle or in another location and may have a variety of
forms and
structures.
According to another embodiment of the present invention, referring to Fig 18,
the
container body 12 has at its second end 22 a tongue 112 that extends forwardly
from the
end surface 46. The tongue 112 also preferably includes two ribs 114, 116
which are
provided at the opposed edged and at the base of a tab-shaped portion 118. The
tongue
has breakable regions that are connected to the tip of the second end 22 as
will be
explained further below in relation to the operation of the container body and
head
components when releasing the liquid.
It should be noted that this embodiment has many similar features as the
embodiment
described above, especially in relation to the axial and radial locking
systems as well as
the configuration and shape of the second end 22 of the container body 12. In
addition,
CA 02796699 2012-11-14
21
most head component constructions can be used with either embodiment of the
container body 12 corresponding to Fig 9 or Fig 18.
In operation, the container body 12 is coupled with the head component 14 and
the
tongue 112 engages part of the head component 14 such that rotation of the
container
body 12 relative to the head component 14 causes the tongue 15 to twist and
break
away and create fluid communication between the container body 12 and the
interior of
head component 14.
Referring now to Figs 20, 21 and 22, the head component 14 is shown in greater
detail
and comprises several features as described hereinabove. The head component 14
may
have a tapered section 120 in between the tubular trunk 30 and the base
portion 32.
More particularly, as shown on Figs 21 and 22, the engagement unit 40 has a
slot 122
oriented, sized and configured to receive and engage with the tongue of the
container
body. In one optional embodiment, the slot 122 may have a shape corresponding
to the
shape of the tongue as shown in Fig 18. In such a case, the slot 120 as shown
in Figs
21 and 22 has two cylindrical portions 124, 126 that extend a part of the way
along its
length (L) and a central flat portion 128. The cylindrical portions 124, 126
receive and
engage the ribs of the tongue while the flat portion 128 receives the tab-
shaped portion
118 of the tongue. Providing this matching configuration of the tongue and
slot enables
improved efficiency and performance.
As the container body 12 is mounted into the head component 14, the lips of
the front
end of the container body 12 pass axially through the axial channel sections
92 until they
abut on the bottom surface of the channels. At the same time, the tongue 112
is inserted
into the slot 120 (with the ribs housed in the cylindrical portions) of the
engagement unit
40. In this position, the head component 14 and the container body 12 are in a
fluid
containment mode. Preferably, the head and container body are provided with
additional
coupling means for snapping or otherwise holding them together in this
position. The
liquid dispensing applicator may be sold in this pre-assembled form.
The channels allow the lips to rotationally slide therein, when the head
component is
rotated relative to the container body. Preferably, the channels and lips are
provided with
locking elements, such that once the handle is rotated within the head
component the
lips are locked in the rotated position.
22
The liquid dispensing applicator is assembled as appreciated by referring to
the figures,
particularly Figs 1, 2, and 32, among others. The container body is inserted
into the head
component such that the slot receives the tongue or the offset projections as
the case
may be. In addition, the container body and the head component are provided
with
corresponding coupling elements, preferably an annular ridge and an annular
groove,
such that when the handle component is inserted into the head component the
ridge
snaps into the groove and axially locks the two components together. This is
to prevent
the components from being pulled apart. The ridge and groove are arranged in
order to
lock the components axially while allowing rotational movement with respect to
each
other. In operation, when the head and container body components are rotated
with
respect to each other, a rupture is caused in the container body. The rupture
is achieved
by deflection shearing in the case of the offset projections and by at least
partially
rotationally shearing in the case of the tongue which is torn away from the
front end to
expose apertures which preferably align at the end of rotation with the
passages
provided in the engagement unit. Liquid is thus released through the
apertures, and
flows through the passages into the lower cavity of the head component. The
fluid flows
into the base, which acts as a housing to the sponge. The base has inset
region that is
preferably spaced away from the absorbent material, which allows the fluid to
then flow
into that inset region to improve even distribution over the absorbent
material. The
absorbent material is mounted to the base, preferably around the perimeter
using an
adhesive. Once the fluid penetrated through the absorbent material it can be
dispensed
by the absorbent material.
In operation, the user rotates the container body relative to the head
component.
Consequently, this causes the lips to slide within the channels and the
engagement unit
to engage and exert forces on the tongue or offset projections, as the case
may be,
which are fixedly mounted to the rest of the front end of the container body.
At a certain
point, the proximal portion of the tongue or offset projection, engaged within
the slot, is
broken by this rotation. Preferably, a snap signifies the user of the
completion of the
tongue or offset projection break. The breaking of the tongue or offset
projection away
from the rest of the handle component creates fluid communication allowing the
liquid to
flow through the passageway and into the absorbent material. To facilitate
this liquid
flow, the engagement unit is preferably constructed to have passages which
directly
communicate with the exposed cavity of the container body after rotation.
Preferably, the
engagement unit comprises various walls that are designed to define the slot
and
CA 2796699 2019-03-20
CA 02796699 2012-11-14
,
23
passages within the handle component. In some embodiments, the slot and
passages
may extend in a substantially same direction as illustrated.
As the container body is locked in place with the lips engaged into the
channels, a fixed
connection is made between the container body and the head component. This
connection provides reliability and security for the liquid dispensing
applicator during
liquid application, the head and handle components being secured together and
acting
as an integral unit. In addition, by providing a locking mechanism between the
head and
container body components once rotated to the liquid dispensing position,
single-use of
the liquid dispensing applicator is facilitated since the head and container
body
components cannot be detached, refilled or reused. Once rotation has taken
place the
broken tongue or offset projections may remain within the slot and the two
apertures are
exposed (see Fig 25). The passages of the engagement unit are preferably sized
and
configured in relation to the channels and lips such that after full rotation
the exposed
apertures are aligned and communicate with the passages, thus ameliorating
liquid flow.
The container body is preferably moulded such that the ribs of the tongue cap
the
apertures, which are then exposed with the breaking of the ribs away from the
surrounding region. The ribs or offset projections may be sized as a function
of the
desired aperture size and engagement with the slot to effect adequate shearing
upon
rotation. It should also be noted that the tongue and exposable apertures may
have a
variety of forms and configurations, as long as the breaking of the tongue
causes fluid
communication between the cavity of the container and the tubular member. In
one non-
illustrated variant, the cross sections of the passages and the apertures are
very similar,
e.g. circular, and their alignment enables the fluid communication. It is not
imperative
that the tongue be completely broken away from the handle component and remain
housed within the slot upon rotation; the tongue may be only partially broken
away at its
lateral ends to expose the apertures while remaining attached at its central
portion. It
should also be noted that while the preferred method of breaking the tongue is
via
torsion forces by opposed rotation of the head and container body components
along
generally longitudinal axes, the head and container body components could also
be
constructed and arranged such that the tongue and slot engage and are
displaced or
rotated relative to each other along other axes or vectors to effect the break
and enable
liquid to be released. The liquid is released from the two apertures into the
cavity of the
tubular member according to the pressure given by the user by squeezing the
container.
CA 02796699 2012-11-14
24
The tongue and slot engagement provides a number of advantages for the liquid
dispensing applicator. One advantage is improved reliability and consistency
when
breaking the tongue. While known applicators depended on subjective deflection
applied
by a given user to break the tongue, various embodiments of the dispensing
applicator
of the present invention allow consistent and recognizable breaking by any
user, reliable
breaking and positioning of the tongue away from the apertures and reliable
positioning
of the exposed apertures to ensure consistent and proper liquid flow toward
the
absorbent material. The slot and tongue arrangement is also covered and
protected by
the surrounding tubular component, which can help improve sterility and
hygiene by
limiting or eliminating contact with the environment or the user.
The liquid flowing into the cavity of the head component is dispensed through
the
absorbent material fitted into the base portion. The cavity of the tubular
member is in
fluid communication with the absorbent material, preferably around the middle
of the
base portion. This arrangement helps to improve even distribution of the
liquid into the
absorbent material for improved application. In addition, the angle (about
450), between
the upper surface of the base portion and the tubular member, offers an easy
and
ergonomic handling of the applicator and efficient squeezing of the container
body to
allow fluid dispensing. This arrangement provides proper liquid flow through
the
absorbent material which can be easily maintained in contact with the surface
on which
the liquid is to be applied.
In another embodiment, as described above, the applicator has "double-lock"
functionality. The first lock axially holds the components together and is
achieved when
the front end of the container body is inserted into the head component. This
first locking
may be snap action by a groove-ridge engagement. The second lock radially
holds the
components in a position of fluid release. Upon rotating the components with
respect to
each other and causing fluid communication between the components, the second
lock
holds the components in the desired aligned fluid flow position, e.g. with the
apertures of
the container body aligned with the passages of the head component. It should
be
understood that many different locking mechanisms or means of achieving the
"double-
lock" functionality may be used.
In another optional aspect, the container body may be constructed such that
the second
end is a separate component which has threads for engaging with the main
container
CA 02796699 2012-11-14
portion to form the container body. In another aspect, the container body may
be
constructed such that the second end is glued, adhered, melt bonded,
ultrasonically
joined or otherwise attached onto the rest of the main container portion. In
another
aspect, the container body may be constructed as a moulded structure without
the offset
projections or without the tongue element, as the case may be. The container
body may
in this case have two openings at the second end and the offset projections or
tongue
element is then glued, adhered, melt bonded, ultrasonically joined or
otherwise attached
into place over the openings. In such embodiments, when the container body is
rotated
in relation to the head component, the offset projections or tongue element
may be
allowed to break off due to rupture or disconnection of the glue, adhesive,
welded region
or other attachment means.
In another optional aspect, the liquid dispensing applicator is constructed to
provide flow
control once the fluid communication has been established. The container body
and
head component engagement may be so as to establish abutment surfaces to allow
a
relatively sealed engagement avoiding air re-entry. Surface abutment and
alignment of
the broken openings and the fluid passageway upon rotation improve the flow
control of
the applicator.
In another optional aspect, referring to Figs 28a-28d, the offset projections
26 may also
have support tabs 130 which may have a variety of configurations. There may be
support tabs 130 on either side or on a single side of each offset projection.
The support
tabs may extend above the tip of each offset projection as in Figs 28c and
28d, or may
end midway up the offset projection as in Figs 28a and 28b. The support tabs
130 are
preferably configured, sized and given sufficient thickness to provide support
to the
offset projections 26. Added support can aid during manufacture, packaging,
transport
and operation of the device to avoid premature or unwanted breakage of the
offset
projections, for example. It is also preferred, as illustrated, that the
support tabs 130 are
unitary with the corresponding offset projections 26 and do not span across
the rotation
axis 24.
In another optional aspect, the liquid is a substance with a viscosity
allowing it to flow out
of the container body in response to pressure thereon. The liquid may be a
substantially
Newtonian fluid such as aqueous based fluids for surgical application. The
liquid may
also be a thicker fluid, semi-liquid fluid, or another fluid for application
onto a surface.
CA 02796699 2012-11-14
26
Referring now to Fig 29, a possible process for making an applicator is
illustrated. In this
case, there are two main parts: a container body and a head component.
Referring to Figs 30 and 31, the container body 12, which may be identical or
similar to
one or more of the container body example described herein or have a different
configuration, may be used with a sponge 134 that is affixed to the neck of
the container
body 12. The sponge 134 has an inner cavity into which the liquid dispensing
end of the
container body 12 may be inserted, and an adhesive may be used to connect the
two
elements. An adhesive band 136 adhesive may be applied around the
circumference of
the tubular container body 12 and the sponge 134 may have a correspondingly
shaped
connection region 138 may be brought into contact with the adhesive band 136
in order
to connect the elements. In operation, a user may use an object or hand to
cause the
fluid to flow, for example by pinching and twisting through the sponge 134 to
engage the
tongue or projection or another elements that may be provided to cause
breakage and
formation of a fluid communication breach. The fluid in the container body 12
can thus
flow into the sponge and the applicator can be used. The breakage may be in
response
to a twisting, a shearing, a bending or another mechanism depending on the
structure of
the liquid dispensing end of the container body.
Referring to Figs 32 to 34b, the head component 14 may have various other
features
and configurations. For example, the head component 14 may include at least
one wing
element 140 that may be part of the one piece head component structure or
otherwise
attached to the head component.
Referring to Fig 32, there may also be two wing elements 140 that are
configured in an
opposed and generally parallel orientation, extending from a side wall of the
head
component 14 beyond the distal surface 62 of the engagement unit 40. The
engagement
unit 40 may be similar or different from the engagement units described and/or
illustrated
herein. Each wing element 140 may thus have an attachment region 142 connected
for
example to the side walls of the head component 14 and free ends 144. The
sponge 34
may include a single sponge piece with a lower slot for receiving the wing
elements 140
or two opposed distinct sponge pieces that are attached to opposing sides of
the wing
elements 140. The sponge 34 may have flat surfaces that are placed along the
flat
surfaces of the wing elements 140. The sponge 34 may be attached to the wing
elements and/or other regions of the head component using adhesive, molding
CA 02796699 2012-11-14
27
techniques (e.g. ultrasonic molding) or other techniques. The applicator of
Fig 32 can
have one of more of the features of the other applicators described herein.
Referring to Figs 32 to 34b, the wing elements 140 may have a variety of
configurations
and structures, such as tapering toward the free ends, curved free ends (as in
Fig 32),
square free ends (as in Figs 33 to 34b), attached to the pouter surface of the
conical part
of the head component along a thin edge (as in Figs 32 and 33), or attached
over a
larger surface of the conical part of the head component and having a block
element 146
as the attachment region 142 (as in Figs 34a and 34b).
Referring to Figs 34a and 34b, the block element 146 may encircle the
periphery of the
distal surface 62 of the engagement unit 40. In addition, the wing elements
140 may
have a first side surface 148 having a first colour and a second side surface
150 having
a second colour different from the first colour. The colours may be provided
to be visible
through the sponge so as to act as indicia to indicate to a user to use one
side of the
sponge for an initial application of fluid followed by another side of the
sponge for a
subsequent application of the fluid.
The sponge may be provided so as to completely or partially enclose and cover
the head
component 14.
In another optional aspect, the invention may also include a one-handed method
of
applying liquid using a liquid dispensing applicator in which a user, such as
a pre-
operative nurse, grasps the container body of the applicator, twists it
relative to the head
component causing the projection to break and fluid to be flowable, locks the
container
body with respect to the head component in the fluid flow position, and then
commences
application of the liquid onto a surface. All of the steps are easily
performable with one
hand due to the breaking by rotation and the radial locking mechanism.
