Abstract:
A diaphragm bottle pump system for dispensing a personal care product includes a bottle, a pump body, and a plurality of valves. The bottle holds the product. Further, the pump body includes a lower pump body and an upper pump body that define a diaphragm chamber therebetween that is acted on by a diaphragm. A first valve allows the product to pass from the bottle to the diaphragm chamber and prevents the product from passing to the bottle from the diaphragm chamber. A second valve allows the product to pass from the diaphragm chamber to an outside of the system and prevents the product from passing to the diaphragm chamber from the outside of the system. Additionally, a third valve allows air to pass from the outside of the system to the bottle and prevents the air from passing to the outside of the system from the bottle.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to a diaphragm-style bottle pump. 
         [0003]    2. Description of the Related Art 
         [0004]    Commercialized personal care products can be sold in a bottle having a pump attached thereto. Conventionally, such bottle pumps are vertically-oriented positive displacement pumps. These pumps must be actuated in a linear fashion along the vertical axis. Conventional vertical displacement pumps generally extend well above the top of a bottle to which they are attached. Additionally, such conventional pumps have many components, generally including a piston and a return spring. The conventional pumps can also include a closure, piston, piston seal, actuator, sometimes ball valves, and thus can be difficult and expensive to produce and assemble. Further, conventional pumps generally include metal components, which can become corroded and contaminate the product dispensed from the bottle. 
       SUMMARY OF THE INVENTION 
       [0005]    The present invention relates to a diaphragm bottle pump system for dispensing a fluid personal care product. The system includes a bottle, a pump body, and a plurality of valves. The bottle holds the product. A lower pump body is attached to the bottle and has an air inlet. An upper pump body is attached to the lower pump body and has a flexible diaphragm positioned on a top part thereof. Further, the lower pump body and the upper pump body define a diaphragm chamber therebetween. A first valve allows the product to pass from the bottle to the diaphragm chamber and prevents the product from passing to the bottle from the diaphragm chamber. A second valve allows the product to pass from the diaphragm chamber to an outside of the system and prevents the product from passing to the diaphragm chamber from the outside of the system. Additionally, a third valve allows air to pass from the outside of the system to the bottle and prevents liquid from escaping the bottle. 
         [0006]    A method of dispensing a personal care product according to the present invention comprises holding the product in a bottle attached to a diaphragm pump including a diaphragm in an original position on a top of the diaphragm pump. The diaphragm is pressed a first time such that the diaphragm is changed from the original position to a depressed position to expel air from a diaphragm chamber through a first valve. The expelled air is prevented from returning to the diaphragm chamber from the outside of the diaphragm pump through the first valve. Then, the diaphragm is released a first time such that the diaphragm returns to the original position from the depressed position to create a negative pressure in the diaphragm chamber. By releasing the diaphragm, the product is drawn from the bottle to the diaphragm chamber through a second valve. The drawn product is prevented from returning to the bottle from the diaphragm chamber through the second valve. During the uptake phase ambient air enters the bottle through a third valve to equalize pressure. Additionally, the drawn air and the product in the bottle are prevented from passing through the third valve to the outside of the bottle. Further, the diaphragm is pressed a second time such that the diaphragm is changed from the original position to the depressed position to expel the drawn product held in the diaphragm chamber to the outside of the diaphragm pump through the first valve. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein: 
           [0008]      FIG. 1  is a perspective view of an exemplary embodiment of the bottle pump; 
           [0009]      FIG. 2  is a top view of an exemplary pump; 
           [0010]      FIG. 3  is a bottom view of an exemplary pump; 
           [0011]      FIG. 4  is a sectional side view of an exemplary pump; 
           [0012]      FIG. 5  is a front view of an exemplary pump; 
           [0013]      FIG. 6  is an exploded view of an exemplary pump; 
           [0014]      FIG. 7  is an assembled view of the exemplary pump shown in  FIG. 6 ; 
           [0015]      FIG. 8  is an perspective view of an exemplary pump; 
           [0016]      FIG. 9  is a sectional side view of an exemplary pump; 
           [0017]      FIG. 10  is a sectional side view of an exemplary pump; 
           [0018]      FIG. 11  is a sectional side view of an exemplary pump; and 
           [0019]      FIG. 12  is a sectional side view of an exemplary pump. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0020]    Certain terminology may be used in the following description for convenience only and is not limiting. The words “top,” “bottom,” “above,” “below,” “lower,” and “upper” designate directions in the drawings to which reference is made. The terminology includes the words noted above as well as derivatives thereof and words of similar import. Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views. 
         [0021]      FIG. 1  shows an exemplary embodiment of the diaphragm-style bottle pump  10  (hereinafter “pump  10 ”), which is a positive displacement pump. The pump  10  can be attached to a bottle  20  to form a system to dispense personal care products. The bottle  20  can contain a product to be dispensed, such as shampoo, conditioner, lotion, or other skin or facial care products. The bottle  20  could also be used to dispense soap, such as hand soap. The pump  10  can be engaged with the bottle  20  via male and female threads or the pump  10  can be snap fit on the bottle  20 . Such a snap fit may be preferable as the orientation of the pump  10  with respect to the bottle  20  can be adjusted without compromising the seal formed between the pump  10  and the bottle  20 . Thus, the connection of the pump  10  to the bottle  20  can create an atmospherically closed system such that the product does not escape the system other than in the intended manner through the outlet valve  62  described below. The pump  10  and the bottle  20  can be disposable. Alternatively, the pump  10  can be reusable either with the same bottle  20  or with a new bottle  20  attached thereto. 
         [0022]      FIG. 2  shows an exemplary embodiment of the pump  10 . The pump  10  includes a diaphragm  30  on a top portion thereof. The diaphragm can be made of, for example, a thermoplastic elastomer or a thermoset elastomer. An exemplary thermoplastic elastomer from which the diaphragm  30  can be made is DYNAFLEX® G2701-1000-02 produced by GLS Corporation. The diaphragm  30  can be non-transparent or at least a portion of the diaphragm  30  can be translucent such that the user can see the product through the translucent portion of the diaphragm  30 . The diaphragm  30  can have an oval shape. Further, the minor axis of the oval can be approximately the width of a user&#39;s thumb. Thus, due to the size, shape, and material composition of the diaphragm  30 , the diaphragm  30  can be easily pressed by the user. 
         [0023]      FIG. 3  shows the bottom view of an exemplary embodiment of the pump  10 . As will be discussed in greater detail below, the pump  10  includes an air valve  34  that allows air to enter the bottle  20 . The air valve  34  is a one-way valve that can be, for example, an umbrella valve or a mushroom valve preferably made of silicone. The air valve  34  could also be a ball and spring valve. Because the air valve  34  is a one-way valve, air can be drawn into the bottle  20  but air cannot escape and the product cannot spill out of the bottle  20  through the air valve  34 . The pump  10  also includes a dip tube  38  that serves as a passageway for the product to be dispensed to enter the diaphragm chamber  42  (see  FIG. 4 ) from the bottle  20 . Thus, the dip tube  38  can extend downward from the pump  10  into the bottle  20 . The dip tube  38  can be made of a linear low-density polyethylene, for example. In another exemplary embodiment, the dip tube could also be injected with the body to reduce assembly.  FIG. 3  also shows a product outlet  46  from which the product is ultimately dispensed from the pump  10  to the user. 
         [0024]      FIG. 4  is a side section view of an exemplary embodiment of the pump  10 . The grooves  50  in the pump  10  can be used to attach the pump  10  to the bottle  20 . As discussed above, the grooves  50  could contain the male or female thread, or could have a lip or a groove that is used to snap fit the pump  10  and the bottle  20  together. 
         [0025]    The pump  10  includes an air inlet  54  that is upstream of the air valve  34 . The air inlet  54  communicates with an outside of the pump  10  such that air can be drawn in through the air inlet  54 , pass through the air valve  34  positioned downstream of the air inlet  54 , and then enter the bottle  20 . 
         [0026]    As can be seen in  FIG. 4 , a product valve  58  is positioned downstream of the dip tube  38 . The product valve  58  is a one-way valve that allows the product to be dispensed to pass therethrough into the diaphragm chamber  42 . Thus, the product valve  58  does not allow any air or product to pass from the diaphragm chamber  42  back into the dip tube  38  or the bottle  20 . The product valve  58  can be a flapper valve as shown in  FIG. 9  or a duck bill valve The product valve  58  can be made of, for example, an elastomer, such as the thermoplastic elastomer that comprises the diaphragm  30 . 
         [0027]    The diaphragm chamber  42  is a pump chamber that is formed downstream of the product valve  58 . The diaphragm chamber  42  comprises the area under the diaphragm  30  and is bounded by the body of the pump  10 . The diaphragm chamber  42  includes an entrance from the product valve  58  and an exit to the product outlet  46 . 
         [0028]    Downstream from the diaphragm chamber  42  is the product outlet  46 .  FIG. 9  shows the path the product takes from the diaphragm chamber  42  to the product outlet  46 . An outlet valve  62  is housed in the product outlet  46 . The outlet valve  62  is another one-way valve that allows the product to be dispensed from the product outlet  46  without drawing air or dispensed product from outside the pump  10  back into the pump  10 . The outlet valve  62  can also be a flapper valve or a duck bill valve that is made of, for example, an elastomer. Further, the outlet valve  62  can be held in the product outlet  46  by an outlet cap such as a hinged fixture  66 . The hinged fixture  66  can be positioned on an end of the product outlet  46  such that that outlet valve  62  is fixed by the outlet cap  66  with respect to the product outlet  46 . 
         [0029]      FIG. 5  is a front view of an exemplary embodiment of the pump  10 . As discussed above, air can enter the pump  10  through the air inlet  54  and the product can be dispensed from the product outlet  46  by passing through the outlet valve  62  and the outlet cap  66 . 
         [0030]    Operation of the pump  10  will now be described with reference to  FIG. 4 . 
         [0031]    As discussed above, the diaphragm  30  can be approximately the width of a user&#39;s thumb. Thus, a user can hold the bottle  20  in his or her hand and operate the pump  10  by pressing the diaphragm  30  with his or her thumb. Accordingly, the pump  10  is convenient to use with a single hand. Alternatively, the user can set the bottle  20  on a support, such as a table top, and press the diaphragm  30  with one or more of their fingers. 
         [0032]    When the user presses the diaphragm  30 , as shown in  FIG. 1 , in the downward direction, the diaphragm  30  is moved from the original position to a depressed position in which the diaphragm  30  decreases the size of the diaphragm chamber  42  such that the contents of the diaphragm chamber  42  are expelled through the product outlet  46  to an outside of the pump  10 . Thus, pressing the diaphragm  30  exerts a force on the contents of the diaphragm chamber  42  that is sufficient to expel the contents through the outlet valve  62 . The exerted force can be, for example, about four to eight pounds. As discussed above, the product valve  58  is a one-way valve that does not allow the contents of the diaphragm chamber  42  to pass through the product valve  58  back into the dip tube  38  and the bottle  20 . Thus, the first time the diaphragm  30  is pressed, air in the diaphragm chamber  42  will pass through the outlet valve  62 . 
         [0033]    In the exemplary embodiment shown in  FIG. 4 , the diaphragm chamber  42  is angled such that it is raised on the outlet side. This helps evacuate air during the initial priming. 
         [0034]    Once the user releases the diaphragm  30  from its depressed position, the elastic diaphragm  30  will attempt to return to its original shape. Additionally, the pump  10  may contain a semi-rigid support structure, such as the fingers  70  positioned under the diaphragm  30 , that contacts the diaphragm  30  and are deflected when the diaphragm  30  is pressed. In one exemplary embodiment, the fingers  70  only come in contact with the diaphragm  30  after the diaphragm  30  is pressed. Then, when the diaphragm  30  is released, the elasticity of the fingers  70  produces an upward force on the diaphragm to help return the diaphragm  30  to its original position. Thus, a conventional metal spring is not required to return the diaphragm  30  to its original position. Accordingly, corrosion can be avoided in the pump  10 . 
         [0035]    Alternatively, the diaphragm  30  may be provided with a means for assisting return of the deformed diaphragm  30  to its original position such as by a spring. Exemplary embodiments of the spring include a helical spring  86  as shown in  FIG. 10  or an eye-shaped spring  90  as shown in  FIG. 11 . In an exemplary embodiment, a cantilevered structure could be molded to the bottom half of the diaphragm cavity  42  and help return the deformed diaphragm  30  to its original position. Additionally, the thickness of the diaphragm  30  can be biased in certain regions to help return the deformed diaphragm  30  to its original position. For example, the diaphragm  30  could be thicker around the perimeter and thinner in the center. 
         [0036]    As the diaphragm  30  returns to its original position, a reduced pressure is created in the diaphragm cavity  42 . Because the outlet valve  62  is a one-way valve that prevents anything from entering the diaphragm cavity  42  through the outlet valve  62 , the partial vacuum due to the negative pressure is filled by drawing in the contents of the dip tube  38  through the product valve  58  into the diaphragm cavity  42 . 
         [0037]    If the pump  10  has not been previously used, then one or more strokes will likely be required to prime the pump  10 . These initial priming strokes of the diaphragm  30  draw the air out of the dip tube  38 , such that a strong enough vacuum is created to draw the product to be created up through the dip tube  38  into the diaphragm cavity  42 . For example, a vacuum of four pounds per square inch could draw the product into the diaphragm cavity  42 . 
         [0038]    Because the product is drawn up into the dip tube  38  and then passed through the product valve  58 , a reduced pressure is created in the bottle  20 . Thus, as the diaphragm  30  is released and returning to its original position, the vacuum due to the reduced pressure created in the bottle  20  causes air to be drawn into the bottle  20  through the air inlet  54  and the air valve  34  to equalize the internal pressure of the bottle  20  with the outside atmosphere. 
         [0039]    Thus, repeated pressing and releasing of the diaphragm  30  will cause the product in the bottle  20  to pass into the diaphragm chamber  42  via the dip tube  38  and then be dispensed from the product outlet  46 . Additionally, air will be drawn into the bottle  20  via the air inlet  54  to replace the dispensed product. Accordingly, because it can be automatically ventilated during use, the bottle  20  can be a solid bottle that can stand on its own and is not required to contract when the product is removed from the bottle  20 . Thus, a pump  10  and bottle  20  that is convenient to use can be provided. 
         [0040]    The diaphragm  30  can be pressed from many different angles in many different directions. Thus, the pump  10  can be actuated in a non-linear and off-axis fashion that deviates from the vertical actuation of conventional pumps and resulting in improved ergonomics. 
         [0041]    In an exemplary embodiment, the pump  10  can include a lever  94  to shut off passage of the product from the dip tube  38  to the diaphragm chamber  42 . As can be seen in  FIG. 12 , the lever  94  can fit between the upper half of the pump body  74  and the lower half of the pump body  78 . Further, the lever  94  includes a portion that projects outside of the pump body  74 ,  78  to allow the lever  74  to be rotated between an open position and a closed position. In the open position, product can be dispensed as discussed above. In the closed position, the lever  94  blocks the dip tube  38  to prevent the product from passing from the dip tube  38  to the diaphragm chamber  42  when the diaphragm  30  is pressed. Thus, accidental discharge of the product can be prevented. 
         [0042]    As discussed above, the pump  10  can be used with a personal care product. Accordingly, regulating the amount of each dose may be important. When the diaphragm  30  is the size of a thumb, the product dosage amount for every non-priming pump is approximately less than 3.6 milliliters and more than 1 milliliter. Preferably, the dosage amount is two milliliters. Other dosage amounts can be achieved depending on the size and shape of the diaphragm  30  and the diaphragm chamber  42 . The size and shape of the pump  10  can be adjusted to achieve a target dosage that depends on the product to be dispensed. 
         [0043]      FIG. 6  shows an exploded view of an exemplary embodiment of the pump  10  and  FIG. 7  shows the pump  10  for  FIG. 6  in an assembled view. To assemble the pump  10 , the diaphragm  30  is inserted into the underside of the upper half of the pump body  74 . Alternatively, the diaphragm  30  can be co-molded with the upper half of the pump body  74 . The outlet valve  62  is held against the pump body  74  by the outlet cap  66  attached thereto. Additionally, as can be seen in the exemplary embodiment shown in  FIG. 8 , a backplate  82  can be positioned upstream of the outlet valve  62  (not shown in  FIG. 8 ) to help prevent air from entering the diaphragm chamber  42  through the outlet valve  62  on the upstroke. The product valve  58  is held to the lower half of the pump body  78  by the dip tube  38 . Further, the air valve  34  is also attached to the lower half of the pump body  78 . Then, the upper half of the pump body  74  is attached to the lower half of the pump body  78  via snap fit, heat stake or threading. The upper half of the pump body  74  and the lower half of the pump body  78  can be molded of, for example, polypropylene and thermoplastic elastomer. Alternatively, the upper half of the pump body  74  and/or the lower half of the pump body  78  can be made by another suitable material or by another suitable process. The upper half of the pump body  74  and the lower half of the pump body  78  can be molded in a single piece, and can be connected by a hinge. When the upper half of the pump body  74  and the lower half of the pump body  78  are molded in a single piece, they can be snap fit together. The lower half of the pump body  78  can include two stacked annular rings, and one of the rings may be molded with the elastomer to form a critical seal between the two halves of the pump body. The above-described order of assembly in a non-limiting order of assembly and the pump  10  can be assembled in a different order without departing from the scope of the present invention. 
         [0044]    Accordingly, it can be seen that the pump  10  does not require many parts. Thus, assembly of the pump  10  is easier and less costly than conventional vertical displacement pumps. 
         [0045]    Additionally, because a diaphragm  30  is used instead of the conventional vertical displacement pump, the pump  10  requires minimal height to function, and thus is a discrete addition to the top of the bottle  20 . As discussed above, such a pump  10  can also allow the product in the bottle  20  to be dispensed with one hand. Such a product can have a viscosity of up to 28,000 centipoise or higher. Additionally, a minimum viscosity can be, in an exemplary embodiment, around 20,000 centipoise. 
         [0046]    Further, because the pump  10  uses the diaphragm  30 , which is not pressed against any sliding parts, there can be less frictional losses than in conventional pumps. Accordingly, the pump  10  can require less force to actuate. 
         [0047]    Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.