Title of Invention

"PUMP-ACTION NOZZLE DEVICE"

Abstract This invention relates to pump-action dispenser nozzle adapted to dispense fluid in the form of a spray and methods of making the same. The dispenser nozzles of the invention comprises a body which defines an internal chamber having an inlet through which fluid may be drawn into said chamber and an outlet through which fluid present in the chamber may be expelled from the nozzle. The inlet comprises an inlet valve and the outlet comprises an outlet valve. Fluid is dispensed from the dispenser nozzles by resiliently deforming or displacing a portion of the body of the device that defines the chamber, thereby compressing the chamber and actuating the dispensing of fluid. In preferred embodiments, the outlet comprises an outlet passageway that extends from the chamber to an outlet orifice. One or more spray-modifying features are preferably formed within the outlet passageway. The dispenser nozzle may be adapted to be fitted to a container or integrally formed there with.
Full Text The present invention relates to pump-action spray nozzle.
This invention relates to a spray nozzle and, more particularly but not exclusively, this invention relates to a pump-action spray nozzle and methods of making the same.
Pump-action spray nozzles are commonly used to provide a means by which fluids can be dispensed from a non-pressurised container, or other fluid source, in the form of a spray.
Conventional pump-action spray nozzles tend to be extremely complex in design and typically comprise numerous component parts (usually between 8 and 10 individual components in pump nozzle devices and between 10 and 14 individual components in trigger-actuated nozzle devices). As a consequence, these nozzle devices can be extremely costly to manufacture due to the amount of material required to form the individual components and the assembly processes involved. In addition, many of the conventional nozzle devices tend to be bulky (which again increases the raw material costs) and a proportion of this bulk is invariably disposed inside the container to which the device is attached. This is a further drawback because the nozzle takes up a proportion of the internal volume of the container, which can be a particular problem in small containers where the available space inside the container is limited. Finally, the size of the pump-action device is also dictated to certain extent by the size of the container to which it is attached. Thus, the size of the device is usually restricted in small containers, and especially in small containers with narrow necks, and this limits the amount of pressure that can be generated by the device as well as the volume of fluid that can be dispensed, and, for this reason, can be detrimental to the performance of the device.
Therefore, there is a desire for a pump-action spray nozzle device that is: (i) simple in design;

(ii) utilises less component parts; and
(iii) is easy to operate and functions effectively.
The present invention provides a solution to the problems associated
with conventional nozzle devices by providing, in a first aspect, a pump-action
nozzle device configured to enable fluid to be dispensed from a container in the
form of a spray, said nozzle having a body which defines an internal chamber
having an inlet through which fluid may be drawn into said chamber and an
outlet through which fluid present in the chamber may be expelled from the
nozzle, said inlet comprising an inlet valve adapted to only permit fluid to flow
into the chamber through the inlet when the pressure within the chamber falls
below the pressure within the container by at least a predetermined minimum
threshold amount and said outlet comprising an outlet valve configured to only
permit fluid to flow out of the chamber and be expelled from the nozzle when
the pressure within the chamber exceeds the external pressure at the outlet by at
least a predetermined threshold amount, and wherein at least a portion of the
body which defines said chamber is configured to:
(i) resiliency deform from an initial resiliency biased configuration to a
distended or deformed configuration in response to the application of a
pressure, whereby the volume of said chamber defined by said portion of the
body is reduced as said portion of the body is deformed from said initial
configuration to said distended or deformed configuration, said reduction in
volume causing the pressure within the chamber to increase and fluid to be
ejected through the outlet valve; and
(ii) subsequently return to its initial resilientiy biased configuration
when the applied pressure is removed, thereby causing the volume of the
chamber to increase and the pressure therein to fall such that fluid is drawn into
the chamber through the inlet valve;
characterised in that the outlet of the device is adapted to generate a
spray of the fluid ejected through the outlet valve during use.
The nozzle device of the present invention solves the aforementioned
problems associated with many conventional pump-action spray nozzle devices
by providing a device which is extremely simple in design and which will
typically comprise no more than six separate component parts that are fitted
together to form the assembled nozzle device. In preferred embodiments the
device will comprise no more than three component parts or, more preferably,
two separate component parts or, even more preferably, the device is formed
from a single, integrally formed component. By "separate component parts" we
mean that the parts are not linked in any way, i.e. they are not integrally formed
with one another (but each separate component part may comprise one or more
integral parts or portions). The key to reducing the number of components lies
hi the formation of the necessary features integrally within the body of the
device. For instance, the chamber, inlet, inlet valve, outlet, and outlet valve can
all be defined by the body, thereby reducing the need to include separate
components with all the consequential increases in component and assembly
costs.
The outlet of the device may be adapted to generate a spray by any
suitable means known in the art. For instance, the outlet orifice of the outlet
may be a fine hole configured such that fluid flowing through it under pressure
is caused to break up into droplets.
Preferably, the outlet comprises an outlet orifice and an outlet
passageway that connects the chamber to the outlet orifice. The outlet valve is
preferably disposed within the outlet passageway. It is especially preferred that
the outlet passageway comprises one or more internal spray-modifying features
that are adapted to reduce the size of liquid droplets dispensed through the
outlet orifice of the nozzle device during use. Examples of internal spray
modifying features that may be present in the outlet passageway include one or
more expansion chambers, one or more swirl chambers, one or more internal
spray orifices (adapted to generate a spray of fluid flowing through within the
outlet passageway), and one or more venturi chambers. It is known that the
inclusion of the aforementioned features, either alone or in combination,
contributes to the break up or "atomisation" of liquid droplets cased to flow
through the outlet passageway during use. The net effect is the production of
finer sprays at the outlet of the nozzle device. These spray-modifying features,
and the effect that they impart on the properties of the spray produced, are
known hi the art and are described in, for example, International Patent
Publication Number WO 01/89958, the entire contents of which are
incorporated herein by reference. It shall be appreciated that the provision of
the outlet valve upstream from the outlet passageway and the outlet orifice
ensures that the fluid enters the outlet passageway with sufficient force for the
liquid to be broken up into droplets and form a spray.
The body of the device
The chamber defined by the body may be defined between two or more
interconnected parts of the body. It is especially preferred that the chamber of
the nozzle device is defined between two interconnected parts, which may be
separately formed component parts that fit together to define the chamber or,
more preferably, the two parts will be integrally formed with one another as a
single component In the latter case, it is preferred that the two parts are
connected together by hinge or foldable connection element which enables the
two parts to be moulded together in the same mould and then brought into
contact with one another to define the, chamber.
In preferred embodiments of the invention in which the outlet comprises
the outlet valve, an outlet orifice and an outlet passageway that connects the
outlet valve to the outlet orifice, it is also preferred that the at least two
interconnected parts that define the chamber also define at least a portion of the
outlet passageway. Most preferably, the two interconnected parts form the
outlet valve between them and also define the entire outlet passageway and the
outlet orifice.
The outlet passageway is preferably defined between an abutment
surface of one of said parts and an opposing abutment surface of another of said
parts. One or more of the abutment surfaces preferably comprises one or more
grooves and/or recesses formed thereon which define the outlet passageway
when the abutment surfaces are contacted together. Most preferably, each of
said abutment surfaces comprises a groove and/or recesses formed thereon
which align to define the outlet passageway when the abutment surfaces are
contacted together. The grooves and/or recesses preferably extend from the
chamber to an opposing edge of the abutment surfaces where, when the
abutment surfaces are contacted together, an outlet orifice is defined at the end
of the outlet passageway. In preferred embodiments where one or more spray
modifying features are present in the outlet passageway, the features may be
formed by aligning recesses or other formation formed on the abutment
surfaces, as illustrated and described in International Patent Publication
Number WO 01/89958.
The two parts of the body may be permanently fixed together by, for
example, ultrasonically welding or heat welding. If the base and upper part are
to be moulded or welded together, then it is preferable that they are made from
compatible materials. As previously indicated above, however, it is preferable
that the body if formed from a single material.
Alternatively, the two parts may be configured to fit tightly/resistively to
one another to form the nozzle (e.g. by the provision of a snap-fit connection)
in the absence of any welding. For instance, the edges of one part may be
configured to fit into a retaining groove of the other part to form the nozzle
device.
As a further alternative, the two parts could be connected together within
the moulding tool and a plastic or other suitable material could then be moulded
over the join to the two parts together. This can be achieved by moulding the
two components simultaneously in a tool, joining them together in the tool to
form the nozzle device and then moulding a suitable plastic material around
them to hold the two parts together.
In certain embodiments, the two parts may remain releasably attached to
one another so that they can be separated during use to enable the chamber
and/or the outlet to be cleaned.
It is most preferred that the two parts of the body of the nozzle device
that define the chamber are a base part and an upper part. The base part is
preferably adapted to be fitted to the opening of a container by a suitable
means, such as, for example, a screw thread or snap fit connection.
Furthermore, in addition to forming a portion of the body that defines the
chamber, the base part also preferably defines the inlet as well as a portion of
the outlet passageway leading from the chamber to the outlet orifice in
preferred embodiments.
The upper part is adapted to be fitted to the base so that between then|
they define the chamber and, in preferred embodiments, the outlet valve, outlet
passageway and/or outlet orifice. In certain preferred embodiments of the
invention, the base and upper part also define the outlet orifice. It is also
preferred that the upper part forms the resiliency deformable portion of the
body defining the chamber.
Material
The body of the nozzle arrangement may be made from any suitable
material.
In preferred embodiments where the body comprises two interconnected
parts which fit together to define the chamber, the two parts may be made from
either the same or different materials. For instance, one of the parts may be
made from a flexible/resiliently deformable material, such as a resiliently
deformable plastic or rubber material, and the other of said parts may be made
from a rigid material, such as a rigid plastic. Such embodiments are preferred
for some applications because the flexible/resiliently deformable material forms
the resiliently deformable portion of the body defining the chamber and can
readily be depressed by an operator to actuate the ejection of fluid present in the
chamber in the form of a spray. The flexible material can also provide a soft
touch feel for the operator. Preferably, the base part will be formed from a
rigid plastic and the upper part will be formed from a resiliently deformable
material. Such embodiments can be made by either moulding the two parts
separately and then connecting them together to form the assembled nozzle
arrangement, or moulding the two parts in the same tool using a bi-injection
moulding process. In the latter case, the two parts could be moulded
simultaneously and then fitted together within the moulding tool or,
alternatively, one part could be moulded first from a first material and the
second part made from a second material could be moulded directly onto the
first part.
Alternatively, the two parts may both be made from either a rigid or a
flexible material. The rigid and flexible material may be any suitable material
from which the nozzle device may be formed. For instance, it may be formed
from metallic material such as aluminium foil or a flexible material such as
rubber. Preferably, however, the body of the device is formed entirely from a
rigid plastic material or a flexible plastic material.
The pump-action nozzle device is preferably formed from a single rigid
or flexible plastic material.
The expression "rigid plastic material" is used herein to refer to a plastic
material that possesses a high degree of rigidity and strength once moulded into
the desired form, but which can also be rendered more flexible or resiliently
deformable in portions by reducing the thickness of the plastic. Thus, a thinned
section of plastic can be provided to form the at least a portion of the body that
defines the chamber and which is configured to resiliently deform.
The term "flexible plastic" is used herein to denote plastics materials
which are inherently flexible/resiliently deformable so as to enable the resilient
displacement of at least a portion of the body to facilitate the compression of
the chamber. The extent of the flexibility of the plastic may be dependent on
the thickness of the plastic in any given area or region. Such "flexible plastic"
materials are used, for example, in the preparation of shampoo bottles or
shower gel containers. In the fabrication of a nozzle device of the present
invention, portions of the body may be formed from thicker sections of plastic
to provide the required rigidity to the structure, whereas other portions may be
composed of thinner sections of plastic to provide the necessary deformability
characteristics. If necessary, a framework of thicker sections, generally known
as support ribs, may be present if extra rigidity is required in certain areas.
Forming the body of the device from a single material provides and
advantage in that the entire nozzle device can be moulded in a single tool in a
single moulding operation, as discussed further below.
The formation of the nozzle device from a single material, particularly in
preferred embodiments where the two parts are integrally formed and
connected to one another by a foldable connection element or a hinged joint so
that the upper part can be swung into contact with the base part to form the
assembled nozzle device, avoids the requirement for the assembly of multiple,
separate component parts. Furthermore, forming the nozzle device from a
single material provides the possibility of possibility of welding the two parts
together (e.g. by heat or ultrasonic welding) or, if the plastic material is a rigid
plastic material, then a snap-fit connection can be formed between the upper
part and the base. The latter option also enables the upper part and base to be
disconnected periodically for cleaning.
For most applications the nozzle device would need to be made from a
rigid material to provide the necessary strength and enable the two-parts to be
either snap fitted or welded together. In such cases, the deformable portion of
the body tends to deform only when a certain minimum threshold pressure is
applied and this makes the pump action more like the on/off action associated
conventional pump-action nozzle devices. However, in certain applications, a
flexible material may be preferred.
The portion of the body configured to resiliency deform could be a
relatively thin section of a rigid plastic material which elastically deforms to
compress the chamber when a pressure is applied and then subsequently returns
to its initial resiliency biased configuration when the applied pressure is
removed. Alternatively, the portion of the body concerned may comprise a
substantially rigid portion surrounded by a deformable portion such that
pressure applied to the rigid portion causes the surrounding resiliently
deformable portion of deform and thereby enables the rigid portion to be
displaced to compress the chamber. For example, the surrounding resilientiy
deformable portion could resemble a bellows, i.e. a rigid portion is surrounded
by a deformable side wall that comprises a number of folded segments of rigid
plastic which is configured such that applying a pressure to the rigid portion
causes the folds of the sidewall to resiliently compress together to reduce the
volume of the chamber. Once the applied pressure is removed, the side walls
return to their original configuration.
In all cases, however, it is preferable that the abutment surfaces that
define the outlet passageway of the outlet are formed from a rigid plastic
material. Although flexible/resiliently deformable materials could be used for
this purpose they are generally less preferred because any spray-modifying
features present will typically need to be precisely formed from a rigid material.
Thus, in some embodiments of the invention, one of the two parts that defines
the outlet and the chamber may be formed from two materials, namely a rigid
material that forms the abutment surface that defines the outlet passageway and
the outlet orifice, and a resiliently deformable material that defines the
chamber.
Outlet Valve
In order to function optimally, it is necessary that the outlet of the
chamber is provided with, or is adapted to function as, a one-way valve. The
one-way valve enables product stored in the chamber to be dispensed through
the outlet only when a predetermined minimum threshold pressure is achieved
within the chamber (as a consequence of the reduction in the volume of the
internal chamber caused by the displacement of the resiliency deformable wall
from its initial resiliently biased configuration), and closes the outlet at all other
times to form an airtight seal. The closure of the valve when the pressure in the
chamber is below a predetermined minimum threshold pressure prevents air
being sucked back through the outlet into the chamber when the applied
pressure to the resiliently deformable portion of the body is released and the
volume of the chamber increases as the resiliently deformable wall re-assumes
its initial resiliently biased configuration.
Any suitable one-way valve assembly that is capable of forming an
airtight seal may be provided in the outlet. However, it is preferable that the
valve is formed by the component parts of the body of the nozzle device. Most
preferably, the valve is formed between the abutment surfaces that define outlet
passageway.
In certain embodiments of the invention, the outlet valve is formed by
one of the abutment surfaces being resiliency biased against the opposing
abutment surface to close off a portion of the length of the outlet passageway.
In this regard, the valve will only open to permit fluid to be dispensed from the
chamber when the pressure within the chamber is sufficient to cause the
resiliency biased abutment surface to deform away from the opposing abutment
surface and thereby form an open channel through which fluid from the
chamber can flow. Once the pressure falls below a predetermined minimum
threshold value, the resiliently biased surface will return to its resiliency biased
configuration and close off the passageway.
In certain embodiments of the invention, it is especially preferred that
the resilientiy biased abutment surface is integrally formed with the resiliently
deformable portion of the body, which defines the chamber.
In embodiments where the body is made entirely from a rigid plastic
material, the resilience of the resiliency biased surface (which will be a thin
section of rigid plastic) may not be sufficient to achieve the required minimum
pressure threshold for the optimal functioning of the device. In such cases, a
thickened rib of plastic, which extends across the passageway, may be formed
to provide the necessary strength and resistance in the ouCet passageway/valve.
Alternatively, a rigid reinforcing rib could be provided above part of the ouCet
passageway/valve.
In an alternative preferred embodiment, the outiet valve is formed by a
resiliently deformable member formed on one of said abutment surfaces which
extends across the outlet passageway to close off and seal the passageway. The
member is mounted to the device along one of its edges and has another of its
edges (preferably the opposing edge) free, the free end being configured to
displace when the pressure within the chamber exceeds a predetermined
minimum threshold value. The free end abuts a surface of the outlet channel to
form a seal therewith when the pressure is below the predetermined minimum
threshold value. However, when the pressure exceeds the predetermined
minimum threshold value, the free end of the member is displaced from the
abutment surface of the channel to form an opening through which the fluid
present in the chamber can flow to the outlet. Preferably, the resilienfly
deformable member is positioned within a chamber formed along the length of
the outlet channel or passageway. Most preferably, the abutment surface,
which forms the seal with the free end of the member at pressures below the
minimum threshold, is tapered or sloped at the point of contact with the free
end of the member. This provides a point seal contact and provides a much
more efficient seal. It will of course be appreciated that the slope or taper of
the abutment surface must be arranged so that the free end of the resilientiy
deformable member contacts the slope when the pressure within the chamber is
below the predetermined minimum threshold, but distends away from it when
the predetermined minimum threshold is exceeded.
Alternatively, the valve may be a post or plug formed on the abutment
surface of one of the base or upper parts and which contacts the opposing
abutment surface to close off and seal the passageway. The post or plug will be
mounted to a deformable area of the base or upper part so that when the
pressure within the chamber exceeds a predetermined threshold value, the post
or plug can be deformed to define an opening through which fluid can flow
through the outlet.
The predetermined minimum pressure that must be achieved within the
chamber in order to open the outlet valve will depend on the application
concerned. A person skilled in the art will appreciate how to modify the
properties of the resilientiy deformable surface by, for example, the selection of
an appropriate resiliently deformable material or varying the manner in which
the surface is fabricated (e.g. by the inclusion of strengthening ridges).
Inlet valve
To ensure that fluid is only ejected through outlet when the chamber is
compressed by displacing the resiliently deformable portion of the body into the
chamber from its initial resiliently biased configuration, it is necessary to
provide a one-way inlet valve disposed at or in the inlet of the nozzle device.
Any suitable inlet valve may be used.
The inlet valve may be adapted to only open and permit fluid to flow
into the chamber when the pressure within the chamber falls below a
predetermined minimum threshold pressure (as is the case when the pressure
applied to the resiliently deformable portion of the chamber to compress the
chamber is released and the volume of the chamber increases as the resiliently
deformable portion reassumes it's initial resiliently biased configuration). In
such cases, the inlet valve may be a flap valve which consists of a resiliently
deformable flap positioned over the inlet opening. The flap is preferably
resiliently biased against the inlet opening and adapted to deform so as to allow
fluid to be drawn into the chamber through the inlet when the pressure within
the chamber falls below a predetermined minimum threshold pressure. At all
other times, however, the inlet will be closed, thereby preventing fluid flowing
back from the chamber into the inlet. It is especially preferred that the
resilientiy deformable flap is formed as an integral extension of the resiliently
deformable portion of the body which defines the chamber. It is also especially
preferred that the base defines the inlet and the resiliently deformable portion of
the body is formed by the upper part. It is therefore the preferred that the upper
part comprises the resiliently deformable flap that extends within said chamber
to cover the inlet opening to the chamber and form the inlet valve.
Alternatively, the flap may not be resiliently biased against the inlet
opening and may instead be disposed over the inlet opening and configured
such that it is pressed against the inlet only when the chamber is compressed
and the pressure therein increases.
Problems can arise, however, with the simple provision of a flap valve
that is resiliently biased over the inlet opening. Specifically, over time the
elastic limit of the material from which the flap is formed may be exceeded,
which may cause it to not function properly. This problem applies particularly
to embodiments of the invention in which the flap is formed from a thin section
of a rigid material, although it also applies to a lesser extent to flexible
materials and can occur due to deformation of the flap when the chamber is
compressed, as well as when the flap deforms to open the valve. As a
consequence, fluid could leak from the chamber back into the container through
the inlet.
For these reasons it is preferable that flap valve comprises a number of
further adaptations. In particular, it is preferred that the inlet has a raised lip
extending around the inlet orifice that the resiliently deformable flap abuts to
create a tight seal around the inlet. The provision of a lip ensures a good
contact is obtained with the flap. In embodiments where the lip is very small it
may be necessary to provide one or more additional support ribs at either side
of the inlet opening to ensure that a proper seal is formed and to also prevent
the lip from damage.
A further preferred feature is that the flap possesses a protrusion or plug
formed on its surface. The protrusion or plug extends a short way into the inlet
opening and abuts the side edges to further enhance the seal formed.
It is also preferred that the inlet opening to the chamber is disposed at an
elevated position within the chamber so that fluid flows into the chamber
through the inlet and drops down into a holding or reservoir area. This prevents
fluid resting on the top of the inlet valve over prolonged periods by effectively
distancing the inlet opening from the main fluid holding/reservoir area of the
chamber and thereby reduces the likelihood of any leaks occurring over time.
It is also preferred that a second reinforcing flap or member contacts the
opposing surface of the resiliently deformable flap to urge it into tight abutment
with the inlet opening. It is also preferred that the second reinforcing flap
contact the opposing surface of the resiliently deformable flap at or close to the
portion of the opposing surface that covers the inlet orifice to maximise the
vertical pressure of the main flap over the hole. Again this helps to maintain
the integrity of the seal.
Lock
The nozzle device may also be provided with a locking means to prevent
the fluid being dispensed accidentally.
In such embodiments the lock will be integral part of the body and will
not be a separate component connected to the body. For instance, the locking
means may be hinged bar or member that is integrally connected to a part of the
body (e.g. either the base or upper part) and which can be swung into a position
whereby the bar or member prevents the outlet valve from opening.
The locking means may also comprise a rigid cover that can be placed
over the resiliently deformable portion of the body to prevent it being
compressed. The cover may be connected to the nozzle device by a hinge to
enable it to be folded over when required. Alternatively, the rigid cover may be
a slidable over cap that can be slid downwards to compress the chamber during
use. The cover can be twisted to lock it and thereby prevent the accident
actuation of the device.
Air Release/leak Valve
The device may further comprise an air leak through which air can flow
to equalise any pressure differential between the interior of the container and
the external environment. In some cases, the air leak may simply occur through
gaps in the fitting between the dispenser nozzle and the container, but this is not
preferred because leakage may occur if the container is inverted or shaken. In
preferred embodiments, the dispenser nozzle further comprises an ah- leak
valve, i.e. a one-way valve that is adapted to permit air to flow into the
container, but prevents any fluid leaking out of the container if it is inverted.
Any suitable one-way valve system would suffice. It is preferred, however, that
the air leak valve is integrally formed within the body of the dispenser or, more
preferably, between two component parts of the body of the dispenser.
Most preferably, the air leak valve is formed between the upper part and
base which define the chamber of the dispenser nozzle.
Preferably, the air leak valve comprises a valve member disposed within
a channel that is defined by the body of the device and connects the interior of
the fluid supply to the external environment. Most preferably, the valve
member is resiliently biased so as to contact the sides of the channel and forms
a sealing engagement therewith to prevent any liquid from leaking out of the
container, the valve member being further adapted to either resiliently deform
or displace from the sealing engagement with the sides of the channel to define
an opening through which air can flow into the container when pressure within
the container falls below the external pressure by at least a minimum threshold
amount. Once the pressure differential between the interior and the exterior of
the container has been reduced to below the minimum threshold pressure, the
valve member returns to it position in which the channel is closed.
Preferably, the valve member is in the form of a plunger that extends
into the channel and comprises an outwardly extending wall that abuts the sides
of the channel to form a seal. Preferably, the outwardly extending wall is
additionally angled towards the interior of the container. This configuration
means that a high pressure within the container and exerted on the wall of the
valve member will cause the wall to remain in abutment with the sides of the
channel. Thus, the integrity of the seal is maintained thereby preventing liquid
from leaking out through the valve. Conversely, when pressure within the
container falls below the external pressure by at least a minimum threshold
amount, the wall is deflected away from the sides of the container to permit air
to flow into the container to equalise or reduce the pressure differential.
It is especially preferred that the plunger is mounted on to a deformable
base or flap which is capable of some movement when the dome is pressed to
displace any residue that may have accumulated in the air leak valve. In
addition, the provision of a moveable (e.g. resiliently deformable) element
within the air leak valve is preferred because it helps to prevent the valve
becoming clogged during use.
In certain embodiments of the invention it is also preferred that a
protective cover is provided over the opening of the female tube on the internal
surface of the device to prevent liquid present in the interior of the container
from contacting the valve member with a high or excessive force when the
container is inverted or shaken aggressively. The cover will allow air and some
fluid to flow past, but will prevent fluid impacting on the seal formed by the
flared end of the plunger directly, and thus will prevent the seal being exposed
to excessive forces.
In an alternative embodiment, the channel of the air leak valve may be
resiliently deformable instead of the male part. This arrangement can be
configured so that the side walls of the channel distort to permit air to flow into
the container.
The valve member and channel could be made from the same material or
different materials. For instance, they may both be made from a semi-flexible
plastic or the female element may be made from a rigid plastic and the male
part made from a resiliency deformable material.
With certain products stored in containers over time there is a problem
associated with gas building up inside the bottle over time. To release the build
up of pressure, which can inevitably occur, a release valve is required. The air
leak valve described above can be modified to additionally perform this
function by providing one or more fine grooves hi the side of the channel.
These fine groove(s) will permit gas to slowly seep out of the container, bypassing
the seal formed by the contact of the valve member with the sides of the
channel, but prevent or minimise the volume of liquid that may seep out.
Preferably, the groove or grooves formed in the side walls of the channel is/are
formed on the external side of the point of contact between the valve member
and the sides of the channel so that it/they are only exposed when the pressure
inside the container increases and acts on the plunger to cause it to deform
outwards (relative to the container). The plunger will return to its resiliency
biased position in which the grooves are not exposed once any excess gas has
been emitted. No liquid product should be lost during this process.
Alternatively, the gas pressure within the container could urge the valve
member outwards so that it is displaced from the channel and defines an
opening through which the gas could flow.
Seal
In preferred embodiments of the invention comprising at least two
component parts, it is preferred that a seal is disposed at the join between the at
least two interconnected parts to prevent any fluid leaking out of the nozzle
device. Any suitable seal would suffice. For instance, the two parts could be
welded to one another or one part could be configured to snap fit into a sealing
engagement with the other part or have possess a flange around its perimeter
that fits tightly around the upper surface of the other part to form a seal
therewith.
Preferably, the seal comprises a male protrusion formed on the abutment
surface of one of the at least two parts that is received in a sealing engagement
with a corresponding groove formed on the opposing abutment surface of the
other part when the two parts are connected together.
The seal preferably extends around the entire chamber and the sides of
the outlet passageway so that fluid leaking from any position within the
chamber and or outlet passageway is prevented from seeping between the join
between the two component parts.
In certain embodiments that comprise an outlet passageway the
protrusion member may extend across the passageway and form the resiliently
deformable valve member of the outlet valve. This portion of the protrusion
will usually be thinner to provide the necessary resilience in the valve member
to permit it to perform its function.
In certain embodiments of the invention, the male protrusion may be
configured to snap fit into the groove or, alternatively, the male protrusion may
be configured to resistively fit into the groove in a similar manner to the way in
which a plug fits into the hole of a sink.
Dip Tube
In most cases, a dip tube may be integrally formed with the nozzle
device, or alternatively the body of the nozzle device may comprise a recess
into which a separate dip tube can be fitted. The dip tube enables fluid to be
drawn from deep inside the container during use.
Alternatively, it may be desirable with some containers, particularly
small volume containers, such as glues, perfume bottles and nasal sprays, to
omit the dip tube, because the device itself could extend into the container to
draw the product into the nozzle during use, or the container could be inverted
to facilitate the priming of the dispenser with fluid. Alternatively, the device
may further comprise a fluid compartment formed as an integral part of device
from which fluid can be drawn directly into the inlet of the nozzle without the
need for a dip tube.
Chamber
The chamber of the nozzle device may be of any form and it shall of
course be appreciated that the dimensions and shape of the dome will be
selected to suit the particular device and application concerned. Similarly, all
the fluid in the chamber may be expelled when the dome is compressed or,
alternatively, only a proportion of the fluid present in the chamber may be
dispensed, again depending on the application concerned.
In certain preferred embodiments of the invention, the chamber is
defined by a generally dome-shaped resilientiy deformable region of the body.
Preferably, the dome-shaped region is formed on the upper surface of the body
so that it is accessible for operation by a person using the nozzle. One problem
with dome-shaped chambers can be that a certain amount of dead space exists
within the chamber when it is compressed by an operator, and for some
applications it will be preferable that the dead space is minimised or virtually
negligible. To achieve this property, it has been found that flattened domes or
other shaped chambers whereby the resiliency deformable wall of chamber can
be depressed such that it contacts an opposing wall of the chamber and thereby
expels all of the contents present therein are generally preferred. For this
reason, a flattened dome is especially preferred because it reduces the extent
with which the dome needs to be pressed inwards in order to compress the
chamber and actuate the dispensing of fluid stored therein. It also reduces the
number of presses required to prime the chamber ready for the first use.
In some cases, the resiliently deformable portion of the body may not be
sufficiently resilient to retain its original resiliency biased configuration
following deformation. This may be the case where the fluid has a high
viscosity and hence tends to resist being drawn into the chamber through the
inlet In such cases, extra resilience can be provided by the positioning of one
or more resiliently deformable posts within the chamber, which bend when the
chamber is compressed and urge the deformed portion of the body back to its
original resiliently biased configuration when the applied pressure is removed.
Alternatively, one or more thickened ribs of plastic could extend from the edge
of the resilientiy deformable area towards the middle of this portion. These ribs
will increase the resilience of the resiliently deformable area by effectively
functioning as a leaf spring which compresses when a pressure is applied to the
resilientiy deformable portion of the body, and urges this portion back to its
initial resilientiy biased configuration when the applied pressure is removed.
Yet another alternative is that a spring or another form of resilient means
is disposed in the chamber. As above, the spring will compress when the wall
is deformed and, when the applied pressure is removed, will urge the deformed
portion of the body to return to its original resilientiy biased configuration and,
in doing so, urges the compressed chamber back into its original "noncompressed
configuration".
Two or more chambers
The nozzle device of the invention may comprise two or more separate
internal chambers.
Each individual chamber may draw fluid into the nozzle device through
a separate inlet from different fluid sources, e.g. separate fluid-filled
compartments within the same container.
Alternatively, one or more of the additional chambers may not comprise
an inlet. Instead a reservoir of the second fluid may be stored in the chamber
itself and the additional chamber or its outlet may be configured to only permit
a predetermined amount of the second fluid to be dispensed with each
actuation.
As a further alternative, one or more chambers of the additional
chambers may draw air in from outside the nozzle device. Whether the
additional chamber or chambers contain air or some other fluid drawn from a
separate compartment within the container, the contents of the two or more
chambers can be ejected simultaneously through the outlet by simultaneously
compressing both chambers together. The contents of the respective chambers
will then be mixed within the outlet, either on, after or prior to, ejection from
the nozzle device. It shall be appreciated that varying the relative volumes of
the separate chambers and/or the dimensions of the outlet can be used to
influence the relative proportions of constituents present in the final mixture
expelled through the outlet. Furthermore, the outlet passageway may be
divided into two or more separate channels, each channel extending from a
separate chamber, and each separate channel may feed fluid into a spray nozzle
passageway as discussed above where it is mixed prior to ejection.
Where an additional chamber for the expulsion of air is present, it shall
be appreciated that, once the expulsion of air is complete and the applied
pressure is removed thereby allowing the chamber to deform back to its original
expanded configuration, more air needs to be drawn into the chamber to
replenish that expelled. This can be achieved by either sucking air back in
through the outlet (i.e. not providing this additional chamber with an airtight
outlet valve) or, more preferably, drawing air in though an inlet hole in the body
defining the chamber. In the latter case, the inlet hole is preferably provided
with a one-way valve similar to the inlet valve discussed above. This valve will
only permit air to be drawn into the chamber and will prevent air being expelled
back through the hole when the chamber is compressed.
In most cases, it is desirable to co-eject the air and fluid from the
container at approximately the same pressure. This will require the air chamber
to be compressed more (e.g. 3-200 times more - depending on the application
concerned) than the fluid/liquid-containing chamber. This may be achieved by
positioning the chambers so that, when a pressure is applied, the compression
of the air-containing chamber occurs preferentially, thereby enabling the air and
liquid to be ejected at the same or substantially the same pressure. For
example, the air-containing chamber may be positioned behind the liquidcontaining
chamber so that, when a pressure is applied, the air chamber is
compressed first until a stage is reached when both chambers are compressed
together.
As an alternative, the nozzle device may also be adapted in such a way
that the air pressure may be higher or lower than the liquid pressure, which may
be beneficial for certain applications.
The chambers may be arranged side by side or one chamber may be on
top of another. In a preferred embodiment where one of the additional
chambers contains air, the additional air chamber is positioned relative to the
chamber of the nozzle device so mat the compression of the air chamber causes
the resiliency deformable portion of the body to deform and compress the
chamber of the nozzle device.
Preferably, the fluid present in each chamber are ejected simultaneously.
However, it shall be appreciated that one chamber may eject its fluid before or
after another chamber in certain applications.
In alternative embodiments, air and fluid from the container may be
present in a single chamber, rather than separate chambers. In such cases, fluid
and air is co-ejected and may be mixed as it flows through the outlet For
example, where the outlet comprises an expansion chamber, i.e. a widened
chamber positioned in the outlet passageway, the contents ejected from the
chamber could be split into separate branches of the channel and enter the
expansion chamber at different locations to encourage mixing.
Spray insert
In an alternative embodiment of the invention, the outlet passageway and
outlet orifice may be in the form of a separate unit or insert, which can be
connected to the outlet of the chamber to form the outlet of the nozzle device.
The unit or insert may also be connected to the body of the device by a hinge so
as to enable it to be optionally swung into the required position for use and
swing out of position when it is not required.
Integrally formed with the container
In most cases it is preferable that the nozzle device is adapted to be fitted
to container by some suitable means, e.g. a snap fit or a screw thread
connection. In certain cases, however, the nozzle device could be incorporated
into a container as an integral part. For instance, the nozzle device could be
integrally moulded with various forms of plastic container, such as rigid
containers or bags. This is possible because the device is preferably moulded
as a single material and, therefore, can be integrally moulded with containers
made from the same or a similar compatible material.
According to a second aspect of the present invention, there is provided
a container having a pump-action nozzle device as hereinbefore defined fitted
to an opening thereof so as to enable the fluid stored in the container to be
dispensed from the container through said nozzle device during use.
According to a third aspect of the present invention, there is provided a
container having a pump-action nozzle device as hereinbefore defined
integrally formed therewith so as to enable the fluid stored in the container to
be dispensed from the container through said nozzle device during use.
According to another aspect of the present invention, there is provided a
pump-action nozzle device configured to enable fluid to be dispensed from a
container in the form of a spray, said nozzle having a body which defines an
internal chamber having an inlet through which fluid may be drawn into said
chamber and an outlet through which fluid present in the chamber may be
expelled from the nozzle, said inlet comprising an inlet valve adapted to only
permit fluid to flow into the chamber through the inlet when the pressure within
the chamber falls below the pressure within the container by at least a minimum
threshold amount and said outlet comprising an outlet valve configured to only
permit fluid to flow out of the chamber and be expelled from the nozzle when
the pressure therein exceeds the external pressure at the outlet by at least a
predetermined threshold amount, and wherein at least a portion of the body
which defines said chamber is configured to:
(i) be displaceable from an initial resiliently biased configuration to a
distended or deformed configuration in response to the application of a
pressure, whereby the volume of said chamber defined by said portion of the
body is reduced as said portion of the body is deformed from said initial
configuration to said distended or deformed configuration, said reduction in
volume causing the pressure within the chamber to increase and fluid to be
ejected through the outlet valve; and
(ii) subsequently return to its initial resiliently biased configuration
when the applied pressure is removed, thereby causing the volume of the
chamber to increase and the pressure therein to fall such that fluid is drawn into
the chamber through the inlet valve;
characterised in that the outlet of the device is adapted to generate a
spray of the fluid ejected through the outlet valve during use.
Preferably the nozzle device is as defined above.
In addition, it is also preferable, the part of the body that can be
displaced inwards to reduce the volume of the chamber and thereby cause fluid
present in said chamber to be ejected through the outlet is a piston mounted
within a piston channel. The piston channel may form the entire chamber or,
alternatively, just a portion thereof.
Preferably, the nozzle device comprises a means for displacing the
piston inwards from its initial position and then subsequently returning it is
initial position. This may be achieved by any suitable means, such as, for
example, a trigger or over cap connected to the piston which can be operated to
displace the piston, when desired. Preferably, the means for displacing the
piston inwards from its initial position is resiliently biased so that the piston
will be returned to its initial position after use.
Method of manufacture
The nozzle devices of the present invention may be made by any suitable
methodology know in the art.
As previously described, preferred embodiments of the invention
comprise a body having two parts (a base and upper part) which fit together to
define at least the chamber of the device and, more preferably, the chamber and
at least a portion of the outlet.
According to a further aspect of the present invention, there is provided
a method of manufacturing a nozzle device as hereinbefore defined, said nozzle
device having a body composed of at least two interconnected parts and said
method comprising the steps of:
(i) moulding said parts of the body; and
(ii) connecting said parts of the body together to form the body of the
nozzle device.
Each part of the body may be a separate component part, in which case
the component parts are initially formed and then assembled together to form
the nozzle device.
Alternatively, and more preferably, the two parts of the body or one of
the parts of the body and the trigger actuator may be integrally formed with one
another and connected by a bendable/foldable connection element. In such
cases, the connected parts are formed in a single moulding step and then
assembled together with the remaining part to form the nozzle device. For
instance, the base and upper part of the preferred embodiments of the device
may be integrally formed and connected to one another by a foldable/bendable
connection element. Thus, the entire device will be formed in a single
moulding step from a single material. Once formed, the upper part can be
folded over and connected to the base to form the assembled nozzle device.
As an alternative, the nozzle device may be formed by a bi-injection
moulding process whereby a first component part the body is formed and a
second part is then moulded onto the first part. Each part may be moulded from
the same or a different material. As before, the trigger actuator may be a
separate component part that is then fitted to the body of the nozzle device, or it
may be integrally formed with one of the parts of the body.
Once the two parts of the body are connected to one another to form the
assembled body of the device, the two parts may be over moulded with another
plastic to hold the two parts together
According to a further aspect of the present invention, there is provided
a method of manufacturing a nozzle device as hereinbefore defined, said nozzle
device having a body composed of at least two interconnected parts and said
method comprising the steps of:
(i) moulding a first of said parts of the body in a first processing
step; and
(ii) over-moulding the second of said parts onto the first of said parts
in a second processing step to form the body of the nozzle device.
The at least two parts are preferably moulded within the same moulding
tool in a bi-injection moulding process. Usually the first part will be the base
part of the nozzle device and the second part will be the upper part.
According to a further aspect of the present invention, there is provided
a method of manufacturing a nozzle device as hereinbefore defined, said nozzle
device having a body composed of at least two interconnected parts and said
method comprising the steps of:
(i) moulding a first of said parts of the body in a first processing step
together with a framework or base for a second of said parts; and
(ii) over-moulding onto the framework or base to form the second of
said parts of the assembled nozzle device.
The framework for the second part may be fitted to the base prior to the
over-moulding step.
Alternatively, the over-moulding may take place before the framework
for the second part is fitted to the first part.
The over-moulding may be the same material to that of the first part and
the framework of the second part or it may be a different material.
It is especially preferred that the base is moulded first from a rigid
plastic material together with the framework support for the upper part. The
framework for the upper part is preferably connected to the base by a hinged or
foldable connection member, which enables the framework to be folded over
and fitted to the base during the assembly of the final product. The framework
is over moulded with a compatible flexible, resiliently deformable plastic
material which forms the resiliently deformable portion of the body that defines
the chamber. The resiliently deformable plastic material may also form
resiliently deformable valve members for the outlet valve and the inlet valve. It
may also extend over other parts of the nozzle surface to provide a soft-touch
feel to the device when an operator grips it. The rigid framework of the upper
part may form an outer edge of the upper part, which forms the point of
connection with the base and, in embodiments where a spray nozzle
passageway is present, the framework may also form an upper abutment surface
which contacts a lower abutment surface formed the base to define the spray
passageway and outlet orifice.
According to a further aspect of the present invention, there is provided
a method of manufacturing a nozzle device as hereinbefore defined, said nozzle
device having a body composed of at least two interconnected parts and said
method comprising the steps of:
(i) moulding a first of said parts of the body in a first processing step
together with a framework or base for a second of said parts; and
(ii) positioning an insert portion of the body such that said insert is
retained within the framework of the second part of the body
when said framework is connected to the first parts of the body,
said framework and insert forming the second part of the body.
According to a further aspect of the present invention, there is provided
a method of manufacturing a nozzle device as hereinbefore defined, said nozzle
device having a body composed of at least two interconnected parts and
wherein said parts are connected to one another by a connection element such
that said parts are moveable relative to one another, said method comprising the
steps of:
(i) moulding the parts of the body together with said connection
elements in a single moulding step; and
(ii) moving said parts of the body into engagement with one another
to form the body of the nozzle device.
The dispenser nozzles of the present invention may be made by a
number of different moulding techniques.
Blowing Agent
Preferably, a blowing agent is incorporated into the mould together with
the plastic material. The blowing agent produces bubbles of gas within the
moulded plastic that prevent the occurrence of a phenomenon known as sinkage
from occurring. The problem of sinkage and the use of blowing agents in the
manufacture of blowing agents to address this problem is described further in
the applicant's co-pending International Patent Publication No. WO03/049916,
the entire contents of which are incorporated herein by reference.
How the invention may be put into practice will now be described by
way of example only, in reference to the accompanying drawings, in which:
Figure 1A is a perspective view of a nozzle device of the present
invention in which the two component parts of the body are separated to
illustrate the internal features of the device;
Figure IB is a further perspective of the device shown in Figure 1A;
Figure 2 is a cross-sectional diagrammatic view of the further
embodiment of the present invention;
Figure 3 is a perspective view of the upper part 102 shown in Figure 1;
Figure 4 is a cross-sectional diagrammatic view of an alternative
construction of an outlet valve that may be present in the nozzle devices of the
present invention;
Figure 5 is a cross-sectional view of a dispenser nozzle comprising a
piston assembly for compressing the chamber;
Figure 6 is a perspective view of a dispenser nozzle of the present
invention comprising two internal chambers; and
Figure 7 is a perspective view of further embodiment of the invention
that comprises two internal chambers.
In the following description of the figures, like reference numerals are
used to denote like or corresponding parts in different figures, where
appropriate.
The embodiment of a nozzle device shown in Figures 1A and IB
comprises a body 100 formed of two parts, namely a base part 101 and an upper
part 102, which are connected to one another by a foldable connection element
103.
In this embodiment the body 100 is formed from a single rigid plastic
material in a single moulding operation. The device will be moulded in the
configuration shown in Figures 1A and IB and then the upper part 102 will be
folded over about the connection element 103 and fitted to the upper surface of
the base 101 to form the assembled nozzle arrangement. Once the base 101 and
the upper part 102 are fitted together, the portion 102a of the under surface of
the upper part 102 abuts the abutment portion/surface lOla of the upper surface
of the base 101. The elevated portion lOlb of the upper surface of the base 101
is received within recess 102b formed in the under surface of the upper part 102
to define an internal chamber.
A groove 104 formed in the elevated portion of the base lOlb forms an
initial portion of an outlet passageway in the assembled nozzle arrangement that
leads from the internal chamber to an outlet valve. The outlet valve is formed
by a resiliency deformable flap 105 formed on the under surface of the upper
part 102 which is received within a recess 106 formed in the opposing abutment
surface 10la of the base. The flap 105 extends over the end of the groove 104
when the base and upper parts are connected together to close the outlet
passageway. The flap 105 is configured to resiliently deform away from the
snd of the groove 104 when the pressure within the internal chamber exceeds a
predetermined minimum threshold to define an open passageway, as described
further below. The flap 105 is also formed as a continuation of the ridge
protrusion 112 discussed further below.
The remainder of the fluid flow passageway is defined by the alignment
of grooves and or recesses 104a, 104b and 104c formed in the abutment surface
101 a of the base 101 with corresponding grooves and/or recesses 107a, 107b
and 107c, respectively. The portions 104c and 107c are semicircular recesses
which align to form a circular swirl chamber which induces rotational flow into
liquid passing through the outlet passageway during use. Liquid is ejected from
this chamber during use through an outlet formed by the alignment of grooves
104d and 107d respectively.
The base 101 also defines an inlet orifice 108, which is positioned within
a recess 108a formed in the elevated portion lOlb. A resiliency deformable
flap 109 formed on the under surface of the upper part 102 is received within
the recess 108a in the assembled nozzle arrangement and is resiliently biased
against the inlet opening to close off the inlet. The flap 109 is configured to
resiliently deform away from the inlet opening to permit fluid to be drawn into
the chamber when the pressure therein falls below the pressure in the attached
container by at least a predetermined minimum threshold amount. The opening
of the inlet 108 is provided with a lip against which the flap 109 abuts to form a
seal. Supporting ribs 108b and 108c prevent the flap 109 exerting too much
force on the lip.
Locating posts HOa and 11 Ob formed on the under surface of the upper
part 102 are received within holes Ilia and 11 Ib formed in the base and assist
in holding the base and the upper part in tight abutment with one another. In
addition, a ridge protrusion 112, which extends around the recess 102b is
received within, and forms a sealing engagement with, a correspondingly
shaped groove 113, which is formed in the upper surface of the base 101 and
extends around the elevated portion lOlb. The ridge 112 and groove fit tightly
together to assist in holding the base 101 and the upper part 102 in tight
abutment with one another. The ridge and groove also form a seal that prevents
any fluid leaking out of the chamber and seeping between the upper part and
the base. This seal also extends to encompass the outlet passageway and the
outlet orifice by virtue of portions 112a and 113a.
The body also comprises an air leak valve which consists of a resiliency
deformable member 115 formed on the under surface of the upper part 102,
which is received within an opening 116 formed on the abutment surface 101 a
of the base when the nozzle arrangement is assembled. The opening 116,
together with the groove 115 defines a passageway through which air may flow
into the container from the outside in the assembled nozzle arrangement. The
tip of the resiliency deformable member 115 is provided with a flared rim, the
edges of which abut the internal walls of the opening 116 to form an airtight
seal. If a reduced pressure exists in the container as a consequence of expelling
fluid through the nozzle arrangement, the pressure differential between the
interior of the container and the external environment causes the flared rirn of
the member 115 to deform inwards, thereby permitting air to flow into the
container from the external environment. Once the pressure differential has
been equalised, the flared rim returns to its original configuration resiliently
biased configuration to prevent any further flow through the opening 116. It
shall also be appreciated that if the container is inverted, the product cannot
leak past the rim of the resiliently deformable member 115 and any pressure
that is applied, by squeezing the container for example, simply pushes the flared
rim into tighter abutment with the walls of the opening 116.
In an alternative embodiment, the air leak valve may be a post or flap
positioned within a hole which can resiliently deform to open the passageway
when a pressure differential exists, thereby allowing air to flow into the
container from the external environment.
In a further alternative, the resiliency deformable upper part 102 could
comprise a fine slit above an opening similar to opening 116. This slit could be
configured to open when a pressure differential exists.
In yet another alternative, the air release may be positioned closer to the
resiliency deformable upper part 102 and configured such that, when the upper
part is pressed downwards to expel the contents present in the chamber, the
resilientiy deformable member deforms in such a way that the air valve is
opened, and air may flow into or out of the chamber to equalise any pressure
differential that may exist.
During use, an operator will press the outer surface of the portion 102b
of the upper part inwards, which is the resiliently deformable portion of the
body defining the chamber. This portion of the upper part can be easily pressed
into abutment with the upper surface of the portion lOlb of the base and
thereby compresses the internal chamber defined there between and causes the
pressure therein to increase. When the pressure exceeds a predetermined
minimum threshold value, the flap 105 will be displaced from its resiliently
biased position to define an opening through which liquid can flow through the
remainder of the outlet passageway to the outlet orifice where it is ejected in the
form of a spray. As soon as the pressure within the chamber falls back below
the predetermined minimum threshold value, the flap 105 will return to its
resiliently biased configuration to close of the outlet passageway. When the
applied pressure is removed from portion 102b of the upper part 102 it will
return to its resiliently biased position and the volume of the chamber will
increase. This causes the pressure within the chamber to decrease and the flap
109 of the inlet valve to be displaced to permit more liquid to be drawn into the
chamber through the inlet valve.
A further alternative embodiment of the invention is shown in Figure 2.
In this embodiment, only the internal chamber 201 and outlet passageway 202
are shown for the purpose of illustration. An inlet, although not shown, would
usually be present in practice.
The embodiment shown in Figure 2 comprises a base made from a rigid
plastic and an upper part 102 which comprises an abutment surface portion
102a formed from a rigid plastic, and a resiliently deformable portion 102b,
which defines the chamber 201 together with portion lOlb of the base 101 is
made from a resiliently deformable material. This embodiment of the nozzle
device may be formed by a bi-injection moulding process whereby the base and
the portion 102a of the upper part 102 are moulded from a rigid plastic and the
portion 102b, which is formed from a resiliently deformable plastic is then
moulded onto the portion 102a. The base 101 and upper part 102 are then fitted
together to form the assembled nozzle device. Optionally, the portion 102a and
the base may be moulded from, the same material and connected to one another
by a foldable connection element.
In the embodiment shown in Figure 2, the outlet valve again comprises
flap 105 received within a recess 106 formed on the opposing abutment surface
of the upper part. The side 106a of the recess is angled so that the flap 105 is
resiliently biased to abut the edge to form a tight seal at its lower end.
The flap is deflected from the side 106a to define an opening through
which fluid can flow when the required pressure is achieved in the chamber
201. Fluid then flows along the outlet passageway to the outlet orifice (not
shown) and on its way passes through an expansion chamber 204 formed by
aligned recesses formed on the opposing abutment surfaces 102a and 101 a.
Figure 3 shows the upper part 102 and base 101 of the embodiment
shown in Figure 2. Again, although not shown, the upper part also comprises a
flap projection 109 which covers an inlet 108 formed in the base 101 to form
the inlet valve, as discussed above. In this embodiment, the upper part 102
comprises a frame of rigid plastic material, which forms portion 102a of the
upper part and which surrounds a region of resiliently deformable material,
which forms portion 102b of the upper part 102, as previously described. The
rigid plastic portion 102a abuts the portion 10 la of the base (as shown in Figure
2) to define the outlet passageway. As can be seen in Figure 35 outlet
passageway 202 comprises a first expansion chamber 204 formed by the
alignment of recesses 301 and 302, and a second outlet chamber formed by the
alignment of recesses 303 and 304.
The clip 305 formed on the abutment surface of the upper part 102
engages with the recess 306 formed in the abutment surface lOla of the base to
locate and secure the upper part and the base together.
Figure 4 is a cross-sectional view of an alternative outlet valve assembly
that may be incorporated into the nozzle devices of the present invention.
Instead of a flap 105, the alternative valve comprises a plug 401, which is
received within a recess 106 formed in the base 101. A feed channel 402 is
formed in the recess so that fluid can flow from the chamber as far as the
member 403 formed in the base, which closes of the feed channel. If the
pressure within the chamber, and hence the feed channel 402, exceeds a
predetermined minimum threshold value, then the plug will either resiliently
deform to define a channel between it and the member 403 through which fluid
can flow, or the member 403 will be resiliently deformed/deflected away from
the plug to define a channel, or both. The cavity 404 formed by the cut-out
portion 405 of the base provides a spray modifying expansion chamber as well
as a space into which the member 403 can be resiliently deformed/deflected.
Figure 5 shows a further alternative embodiment of the invention that,
instead of utilising a resilientiy deformable portion of the body to enable the
chamber to be compressed, incorporates a piston cylinder 501 as an integral
portion of the body defining the chamber. A piston 502 is slidably mounted
within the piston cylinder 501. Movement of the piston to compress the
chamber 201, and thereby expel the contents stored therein, is facilitated in the
embodiment shown in Figure 5 by depressing arm portion 503, to which the
piston 502 is mounted, in the direction of arrow 510. The arm portion is
connected to the base 101 by a resilient deformable hinge 504. When the
pressure applied to the arm portion 503 is subsequently released, it will return
to the position shown in Figure 5 due to the inherent resilience of the hinge
504.
Figure 6 shows another embodiment of a dispenser nozzle of the present
invention. The device, which is adapted to dispense fluids in the form of a
spray, comprises a body 600 formed of two parts, namely a base part 101 and
an upper part 102. The base 101 and upper part 102 are connected to one
another by a foldable connection element 103.
The base 101 is adapted to be fitted to a container (not shown) to permit
fluid stored in said container to be drawn to, and dispensed from, said device
during use.
In this embodiment, the body 600 is formed from a single rigid plastic
material in a single moulding operation. The device will be moulded in the
configuration shown in Figure 6 and then the upper part 102 will be folded over
about the connection element 103 and fitted to the upper surface of the base
101 to form the assembled nozzle device. Once the base 101 and the upper part
102 are fitted together, the portion 102a of the under surface of the upper part
102 abuts the abutment portion/surface 10la of the upper surface of the base
101. The recessed portions lOlb and lOlc of the upper surface of the base 101
are aligned with corresponding recessed portions 102b and 102c respectively,
that formed in the under surface of the upper part 102 to define two separate
internal chambers.
Each chamber comprises an inlet orifice 108 formed in the base. Each
inlet orifice is disposed within a respective recess 108a, as shown in Figure 6.
When the upper part 102 is fitted to the base 101, the resiliently deformable
flaps 109 are received within the respective recesses 108a. The flaps 109 are
resiliently biased against the respective openings of the inlet orifices 108 to
form inlet valves. Thus, fluid is only drawn into the two chambers when the
pressures within the inlet orifice exceeds the pressure within the chamber such
that said flaps are displaced away from the openings of the Met orifices 108 to
permit fluid to flow into chambers. Each inlet orifice 108 will be connected to
different fluid supplies, such as separate compartments within the container to
which the device is attached. Alternatively, one of the chambers may draw air
(or any other form of gas) from the container or the external environment. In
the latter case, an air inlet could simply be formed within the body of the device
to permit air to be drawn in form the external environment.
The outlet comprises an outlet passageway and outlet orifice defined by
the abutment surfaces 10la and 102a when they are contacted together. The
passageway is formed by the alignment of grooves 606, 607 and 608 with
grooves 609, 610 and 611 respectively, and chambers formed within the outlet
passageway are formed by the alignment of recesses 612 and 613 with recesses
614 and 615 respectively.
Therefore, fluid dispensed from the chamber formed by recesses
101b/102b during use travels through the chamber formed by the alignment of
recesses 612/614 and then into the chamber formed by the alignment of
recesses 613/615 before being ejected through the outlet orifice. Fluid
dispensed from the chamber formed by recesses 101c/102c during use travels
through to the chamber formed by the alignment of recesses 613/615, where it
mixes with the fluid dispensed from the other chamber prior to ejection through
the outlet orifice.
The provision of the chambers formed within the passageway has been
found to contribute to the break up of liquid droplets dispensed from the
dispenser nozzle, thereby enabling a fine spray to be produced.
The outlet passageway leading from each chamber will also comprise an
outlet valve (not shown) positioned up stream from the chambers so that fluid
will only be ejected when the pressure within the chamber exceeds a
predetermined minimum threshold value. The valve can be formed by the
provision of a resiliency deformable flap or other member in the outlet
passageway, which can deform from an initial resiliently-biased position in
which the passageway is closed to define an opening through which fluid can
flow when the pressure within the chamber is at or exceeds the predetermined
threshold value.
The device would also preferably comprise sealing means to ensure that
the upper part and base are tightly bound together. In the embodiment shown in
Figure 6, a plastic can be moulded over the join to create a suitably tight seal.
Alternatively, one of the parts may be provided with a ridge protrusion, which
encircles the recesses and the sides of the grooves/recesses that define the outlet
passageway, and which forms a sealing engagement with a correspondingly
shaped groove formed on the opposing abutment surface. The ridge protrusion
and corresponding groove will fit tightly together to assist in holding the base
101 and the upper part 102 in tight abutment with one another. The ridge and
groove also form a seal that prevents any fluid leaking out of the chambers or
outlet passageways and seeping between the upper part 102 and the base 101.
In an alternative embodiment, the air leak valve may be a post or flap
positioned within a hole which can resiliency deform to open the passageway
when a pressure differential exists, thereby allowing air to flow into the
container from the external environment.
During use, fluid is dispensed from the dispenser nozzle by depressing
the portions 102b and 102c on the upper surface of the assembled device.
These portions form the resiliently deformable portion of the body. When the
applied pressure is removed, the portion 102b and 102c return to their initially
biased configurations, thereby causing the volume of the chambers to increase
and fluid to be drawn into each chamber through the respective inlets 108.
In embodiments where one chamber, for instance the chamber formed by
the alignment of recesses 101c/102c, contains air, the compression of the
chambers together causes the air stream ejected from this chamber to mix with
a liquid dispensed from the other chamber. This mixing will break up the
droplets of liquid and assist in the formation of a fine spray when the liquid is
dispensed through the outlet.
Figure 7 shows an alternative embodiment of the invention adapted to
dispense two liquids simultaneously in the form of a spray. This embodiment is
in many respects similar to that shown in Figure 6 (as shown by the like
reference numerals). However, there are some differences. Firstly, the upper
part 102 is connected to the base 101 at the front, rather than at the side, as
shown in Figure 7. The upper part 102 is therefore simply flipped over by
bending/folding the connection element 103 and fitting it to the base 101 to
form the assembled dispenser nozzle.
The device shown in Figure 7 is also configured to dispense two liquids
separately so that they only mix outside of the dispenser nozzle by the merging
of the two separate sprays, which is desirable for certain applications. It shall
of course be appreciated that in alternative embodiments, the outlet
passageways could be configured to merge in a similar manner to the outlet
passageways of the embodiment shown in Figure 6.
The outlet passageways also differ in that a passageway is formed by the
alignment of grooves 701 and 702. The passageway extends to a swirl chamber
formed by the alignment of semi-circular recesses 703 and 704. Thus, fluid
dispensed from each chamber during use flows along the passageway and into
the swirl chamber whereby rotational flow is induced into the fluid stream prior
to ejection through the outlet orifice. Swirl chambers are known in the art and
are again used to break up fluid droplets prior to ejection through the outlet.
A further difference over the embodiment shown in Figure 6 is that the
embodiment shown in Figure 7 also comprises two air release valves. The air
release valves are formed by valve members 115a and 115b formed on the
under surface of the upper part 102 being received within openings 116a and
116b respectively formed on the abutment surface 10la of the base when the
nozzle device is assembled. The openings 116a and 116b both define
passageways through which air may flow into separate compartments of the
container from the outside in the assembled nozzle arrangement. The tip of the
resiliently deformable member is provided with a flared rim, the edges of which
abut the internal walls of the opening to form an airtight seal. If a reduced
pressure exists in the container as a consequence of expelling fluid through the
nozzle arrangement, the pressure differential between the interior of the
container and the external environment causes the flared rim of the member to
deform inwards, thereby permitting air to flow into the container from the
external environment. Once the pressure differential has been equalised, the
flared rim returns to its initial resiliently biased configuration to prevent any
further air flow through the opening. It shall also be appreciated that if the
container is inverted, the product cannot leak past the rim of the resiliently
deformable member and any pressure that is applied, by squeezing the container
for example, simply pushes the flared rim into tighter abutment with the walls
of the opening.
It shall be appreciated that the description of the embodiments of the
invention described in reference to the figures is intended to be by way of
example only and should not construed as limiting the scope of the invention.






WE CLAIM:
1. A pump-action nozzle device configured to enable liquid to be dispensed from a container, said nozzle having a body (100) which defines an internal chamber having an inlet (108) through which, in use, liquid is drawn into said chamber and a separate outlet (104) through which liquid present in the chamber is expelled from the nozzle, said inlet comprising an inlet valve (108a, 109) adapted to only permit liquid to flow into the chamber through the inlet when the pressure within the chamber falls below the pressure within the container by at least a minimum threshold amount and said outlet comprising an outlet valve (105, 106; 401) configured to only permit liquid to flow out of the chamber and be expelled from the nozzle when the pressure therein exceeds the external pressure at the outlet by at least a predetermined threshold amount, the body of the device comprising two parts (101, 102) connected together to define the chamber and wherein least a portion (102b) of one (102) of the two parts which defines said chamber is configured to:
(i) resiliently deform from an initial resiliently biased configuration to a distended or deformed configuration in response to the application of a pressure, whereby the volume of said chamber defined by said portion of the body is reduced as said portion of the body is deformed from said initial configuration to said distended or deformed configuration, said reduction in volume causing the pressure of liquid present within the chamber to increase and the liquid to be ejected through the outlet valve; and
(ii) subsequently return to its initial resiliently biased configuration when the applied pressure is removed, thereby causing the volume of the chamber to increase and the pressure therein to fall such that liquid is drawn into the chamber through the inlet valve;
the device further comprising an outlet orifice (104d, 107d) and an outlet passageway (202) that connects the chamber and the outlet orifice, the device being adapted to generate a spray of the liquid ejected through the outlet orifice during use,

characterised in that both of said parts (101, 102) of the body which define the chamber are injection-moulded from plastics material, with one of said parts (102) of the body integrally comprising a rigid framework (102a), said resiliency deformable portion (102b, 102c) and at least one resiliency deformable valve member (105; 401; 109), the framework being formed from a first, rigid plastics material and said resiliency deformable portion and said at least one resiliency deformable valve member being formed from a second, resiliency deformable plasCcs material over moulded onto the framework, the framework (102a) defining a first abutment surface portion which contacts a corresponding rigid abutment surface portion (101a) on the other of the parts, at least part of the ouCet passageway (202) being defined between the abutment surface portions.
2. A nozzle device as claimed in claim 1, wherein the ouCet valve (105, 106; 401) is disposed within said ouCet passageway (202).
3. A nozzle device as claimed in claim 1 or claim 2, wherein the outlet passageway (202) having one or more internal spray-modifying features, excluding the final spray orifice and/or a final swirl chamber, said spray modifying features being configured to reduce the size of the liquid droplets dispensed through the ouCet orifice of the nozzle device during use.
4. A nozzle device as claimed in claim 3, wherein the internal spray-modifying features are selected from the group consisting of one or more expansion chambers (204) , one or more swirl chambers, one or more internal spray orifices (adapted to generate a spray of liquid flowing through within the outlet passageway), and one or more venturi chambers.
5. A nozzle device as claimed in any one of the preceding claims, wherein said nozzle is adapted to be fitted to an opening of a container so as to enable liquid stored in said container to be dispensed during use.

6. A nozzle device as claimed in any one of claims 1 to 4, wherein said nozzle device is integrally formed with said container so as to enable liquid stored in said container to be dispensed during use.
7. A nozzle device as claimed in any one of the preceding claims, wherein said parts having at least two integral resiliently deformable valve members, both of said integral valve members being formed from said second resiliently deformable plastics material.
8. A nozzle device as claimed in any one of the preceding claims, wherein one or both of the abutment surfaces (101a, 102a) having one or more grooves (104, 107) and/or recesses (301, 302, 303, 304), formed thereon which define the outlet passageway when the abutment surfaces are contacted together.
9. A nozzle device as claimed in claim 8, wherein the whole of the outlet passageway (202) is defined by means of said one or more grooves and/or recesses in one or both of the abutment surfaces.
10. A nozzle device as claimed in any one of the preceding claims, wherein said one of said parts (102) is an upper part and the other of said parts (101) is base part.
11. A nozzle device as claimed in claim 10, wherein said base part (101) is adapted to be fitted to the opening of a container.
12. A nozzle device as claimed in claim 10 or claim 11, wherein said base part (101) also defines the inlet (108) as well as a portion of the outlet passageway (202) leading from the chamber (201) to the outlet.
13. A nozzle device as claimed in any one of claims 10 to 12, wherein the upper part (102) having the resiliently deformable portion (102b) of body defining the chamber (201).

14. A nozzle device as claimed in any one of the preceding claims, wherein a resiliently deformable valve member forming part of the outlet valve (105, 106; 401) is integrally formed with said one of said parts (102) of the body of the nozzle device.
15. A nozzle device as claimed in claim 14, wherein the resiliently deformable outlet valve member (105; 401) is resiliently biased against the other of said parts (101) to close the outlet orifice or the outlet passageway (202) leading thereto, said resiliently deformable valve member being configured to deform away from the other of said parts to open the outlet orifice or passage leading thereto when the pressure within the chamber exceeds the external pressure by at least a minimum threshold amount.
16. A nozzle device as claimed in claim 15, wherein said valve member is in the form of a flap (105) or a plug (401).
17. A nozzle device as claimed in any one of the preceding claims, wherein the inlet valve is a flap valve consisting of a resiliently deformable flap (109) positioned over the inlet opening (108), said flap being adapted to deform so as to allow liquid to be drawn into the chamber (201) through the inlet when the pressure within the chamber falls below a predetermined minimum threshold pressure, and subsequently return to its resiliently biased configuration at all other times.
18. A nozzle device as claimed in claim 17, wherein the resiliently deformable flap (109) is formed as an integral extension of the resiliently deformable portion (102b) of the body which defines the chamber (201).
19. A nozzle device as claimed in claim 17 or claim 18, wherein a second reinforcing flap or member contacts the opposing surface of the resiliently deformable flap (109).

20. A nozzle device as claimed in any one of the preceding claims wherein the
nozzle device having a locking means configured to prevent liquid being
dispensed accidentally, said locking means being integrally formed with the
body (100).
21. A nozzle device as claimed in any one of the preceding claims, wherein
the device having an air leak valve through which air can flow to equalise any
pressure differential between the interior of the container and the external
environment, but prevents any liquid leaking out of the container through the
air leak valve if it is inverted, said air leak valve being integrally formed within
the body (100) of the nozzle device.
22. A nozzle device as claimed in claim 21, wherein the air release valve is defined between the two parts of the body (101, 102) which define the chamber (201) of the nozzle device.
23. A nozzle device as claimed in claim 22, wherein the air leak valve having a valve member (115) formed integrally with one of the parts (102) and a channel (116) defined in the other of the parts (101) which connects the interior of the container to the external environment, the valve member being disposed in the channel when the parts are assembled.
24. A nozzle device as claimed in claim 23, wherein the valve member (115) is resiliently biased so as to contact the sides of the channel (116) and forms a sealing engagement therewith to prevent any liquid from leaking out of the container, said valve member (115) being further adapted to either resiliently deform or displace from the sealing engagement with the sides of the channel (116) to define an opening through which air can flow into the container when pressure within the container falls below the external pressure by at least a minimum threshold amount.

25. A nozzle device as claimed in claim 23 or claim 24, wherein the valve member (115) is in the form of a plunger that extends into the channel (116) and having an outwardly extending wall that abuts the sides of the channel to form a seal.
26. A nozzle device as claimed in claim 25, wherein the plunger (115) is mounted on to a deformable base or flap which is capable of some movement when pressure is applied to the resiliently deformable portion of the body to reduce the volume of the chamber so as to prevent the build up and hardening of any residue in the air release valve.
27. A nozzle device as claimed in any one of claims 23 to 26, wherein a protective cover is provided over the internal opening of the channel to prevent liquid present in the interior of the container from contacting the valve member (115) with a high or excessive force when the container is inverted or shaken aggressively.
28. A nozzle device as claimed in any one of claims 21 to 27, wherein said air leak valve is further adapted to permit a gas to flow out of the container when the pressure therein exceeds the predetermined threshold value.
29. A nozzle device as claimed in any preceding claim, wherein a sealing means is disposed between said two parts (101, 102) of the body that define the chamber (201) to prevent any liquid leaking out of the nozzle device.
30. A nozzle device as claimed in any one of the preceding claims, wherein said two parts (101, 102) of the body are welded to one another.
31. A nozzle device as claimed in any one of the preceding claims, wherein said two parts (101, 102) of the body are configured to snap fit into a sealing engagement with the one another.

32. A nozzle device as claimed in claim 29, wherein one of said two parts possesses a flange that fits tightly around a surface of the other part to form a seal therewith.
33. A nozzle device as claimed in claim 29, wherein the seal having a male protrusion (112, 112a) formed on the abutment surface of one of said two parts (102) that is received in a sealing engagement with a corresponding groove (113, 113a) formed on the opposing abutment surface of the other part (101) when the two parts are connected together, the seal extending around the entire chamber and also the outlet.
34. A nozzle device as claimed in claim 33, wherein the protrusion member (112, 112a) of said seal extends across the outlet passageway (202) and forms a resiliently deformable valve member (105) of the outlet valve.
35. A nozzle device as claimed in any one of the preceding claims, wherein the body is adapted to receive, or is integrally formed with, a dip tube to enable liquid to be drawn from deep inside the container during use.
36. A nozzle device as claimed in any preceding claim, wherein said device consists of a maximum of three separate component parts (101, 102) that are interconnected to form the assembled nozzle device.
37. A nozzle device as claimed in claim 36, wherein said device consists of two separate component parts (101, 102) that are interconnected to form the assembled nozzle device.
38. A nozzle device as claimed in claim 36, wherein said device consists of a single integrally formed component.
39. A nozzle device as claimed in claim 38, in which the integrally formed component having two or more parts (101, 102) interconnected by means of flexible hinge members (103) that enables the parts to be assembled to each other to form the completed nozzle device.

40. A nozzle device as claimed in any one of the preceding claims wherein part of the outlet passageway and the outlet orifice are provided in a separate unit or insert, which is connected to the outlet of the chamber to form the outlet of the nozzle device.
41. A nozzle device as claimed in claim 40, wherein said insert is connected to the body (100) of the device by a hinge so as to enable it to be optionally swung into the required position for use and swing out of position when it is not required.
42. A nozzle device as claimed in claim 1, wherein the two parts (101, 102) are permanently fixed together after assembly by over moulding the join with a compatible material.
43. A nozzle device as claimed in any one of claims 1 to 42, wherein the framework (102a) of said one of the parts (102) of the body and the other of the parts (101) of the body are formed from the same rigid plastics material.
44. A container for a liquid having a pump-action nozzle device as claimed in any one of claims 1 to 43 fitted to an opening thereof or integrally formed therewith so as to enable the liquid stored in the container to be dispensed from the container through said nozzle device during use.

Documents:

3270-DELNP-2005-Abstract-(16-07-2008).pdf

3270-delnp-2005-abstract.pdf

3270-delnp-2005-claims (23-01-2009).pdf

3270-DELNP-2005-Claims-(16-07-2008).pdf

3270-delnp-2005-claims.pdf

3270-delnp-2005-complete specification (granted).pdf

3270-DELNP-2005-Correspondence-Others-(16-07-2008).pdf

3270-delnp-2005-correspondence-others.pdf

3270-delnp-2005-description (complete)-16-07-2008.pdf

3270-delnp-2005-description (complete).pdf

3270-DELNP-2005-Drawings-(16-07-2008).pdf

3270-delnp-2005-drawings.pdf

3270-DELNP-2005-Form-1-(16-07-2008).pdf

3270-delnp-2005-form-1.pdf

3270-delnp-2005-form-18.pdf

3270-DELNP-2005-Form-2-(16-07-2008).pdf

3270-delnp-2005-form-2.pdf

3270-delnp-2005-form-3.pdf

3270-delnp-2005-form-5.pdf

3270-DELNP-2005-GPA-(16-07-2008).pdf

3270-delnp-2005-gpa.pdf

3270-DELNP-2005-Others-Document-(16-07-2008).pdf

3270-delnp-2005-pct-101.pdf

3270-delnp-2005-pct-105.pdf

3270-delnp-2005-pct-304.pdf

3270-delnp-2005-pct-332.pdf

3270-delnp-2005-pct-409.pdf

3270-delnp-2005-pct-416.pdf

3270-DELNP-2005-Petition-137-(16-07-2008).pdf


Patent Number 228028
Indian Patent Application Number 3270/DELNP/2005
PG Journal Number 07/2009
Publication Date 13-Feb-2009
Grant Date 27-Jan-2009
Date of Filing 22-Jul-2005
Name of Patentee INCRO LIMITED
Applicant Address 35 FAIRFIELD RISE, WOLLASTON, STOURBRIDGE, WEST MIDLANDS DY8 3PQ, GREAT BRITAIN.
Inventors:
# Inventor's Name Inventor's Address
1 TIMOTHY RODD CHART HOUSE, SANDY LANE, LYNDHURST, HANTS SO43 7DN, GREAT BRITAIN.
2 KEITH LAIDLER 35 FAIRFIELD RISE, WOLLASTON, STOURBRIDGE, WEST MIDLANDS DY8 3PQ, GREAT BRITAIN.
PCT International Classification Number 17/02/2004
PCT International Application Number PCT/GB2004/000637
PCT International Filing date 2004-02-17
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 0310244.9 2003-05-03 U.K.
2 0327423.0 2003-11-25 U.K.
3 0303698.5 2003-02-18 U.K.
4 0320720.6 2003-09-04 U.K.
5 0305597.7 2003-03-12 U.K.