Abstract:
A curved dip tube for sprayer heads that solves the problem of spraying air as a container&#39;s contents are dispensed and reduced to a level that allows the tip of a straight dip tube to become disengaged with the liquid as the container is tilted downward. As the user of a sprayer head tilts or tips it from a vertical to a horizontal position to spray the intended target the liquid level pools at the lowest point in the container. It then becomes advantageous for the tip of the curved dip tube to be positioned on the lowest point where the bottom meets the wall. This is accomplished by lengthening the dip tube and then curving it to direct the tip toward the side. Once installed onto a sprayer head and inserted into a container the curved dip tube extends toward the bottom of the container, curves and follows the contour of the bottom of the container, pointing in the same direction as the sprayer head output nozzle. The liquid contents of the container can now be fully consumed without spraying air during operation as the consumer uses the product in its entirety.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefits of provisional patent application serial number 61138801 filed Jan. 5, 2009 by the present inventor. 
       FEDERALLY SPONSORED RESEARCH 
       [0002]    Not applicable 
       SEQUENCE LISTING OR PROGRAM 
       [0003]    Not applicable 
       BACKGROUND 
       [0004]    1. Field 
         [0005]    This application relates to sprayer heads, specifically to the design of the dip tube used to pick up the contents of spray bottles. 
         [0006]    2. Prior Art 
         [0007]    For the purpose of clarity in this application the term “dry fire” is defined as: When a spray bottle still contains liquid but the dip tube extending from the sprayer head becomes disengaged with the liquid and the sprayer head pumps air instead of liquid. 
         [0008]    The prior art can be broken up into 4 groups. Common sprayer heads, designs using flexible dip tubes, designs deflecting the dip tube to a corner of the bottle and designs in which the sprayer head is redesigned to allow inverted spraying. 
         [0009]    Currently common sprayer heads use straight dip tubes or slightly-extended straight dip tubes. U.S. Pat. No. 5,762,236 indicates the straight dip tube is the most commonly used means to reach the liquid at the bottom of a spray bottle. When the bottle is full of liquid the straight dip tube works just fine. But when the bottle begins to empty, if the bottle is tipped downward or upward, the user experiences dry fire and it is difficult to use all the contents of spray bottles. 
         [0010]    The slightly extended dip tube is a recent addition to spray bottles. Like U.S. Pat. No. 3,301,438 some manufacturers have beveled the bottom of spray bottles and extended the dip tube. When the dip tube is inserted, the bevel on the bottom of the bottle pushes the tip of the dip tube to one side or the other. Unfortunately, for many end users the dip tube is pointing in the wrong direction. Since many spray bottles are colored or opaque, instead of clear, the end user has no idea the dip tube is on the wrong side and it exasperates the problem of dry fire and the inability to use all the contents. 
         [0011]    Prior art has seen the use of flexible dip tubes in place of semi ridged dip tubes such as US Pat. No. 2008/0047982 and U.S. Pat. No. 5,195,664. Whenever flexible dip tubes are used it either carries a weight on the end or a bobber. The flexible dip tube with a weight or bobber is designed to keep the tip of the dip tube in contact with the contents of a spray bottle in an effort to stop dry fire. But many spray bottles are now designed with a bevel on the bottom and the weight or bobber can easily be caught on the wrong side of the bevel. Whether the bottle has a bevel bottom or a flat bottom neither the weight nor bobber can ensure the tip of the flexible dip tube would stay in contact with the lower corner of the bottle to help the user avoid dry fire. 
         [0012]    There are other limitations of flexible dip tubes integrated onto sprayer heads. In order for a material to be flexible enough it must contain rubber which has a different chemical compatibilities. Nylon and Polyethylene are the common semi ridged material used for dip tubes and they have a wide range of chemical compatibility. Also, the rubber material combined with the weight or bobber, have a higher cost then nylon or polyethylene dip tubes used in spray bottles. 
         [0013]    Prior art also includes changes to the bottle design. Like U.S. Pat. No. 6,834,815 and U.S. Pat. No. 6,742,677 some designs exist in which the spray bottle has a deflection piece built in to the inside of the bottle to deflect the dip tube into the corner of the bottle. Although it allows for the more common ridged or semi-ridged dip tube and helps eliminate dry fire; the change is to the bottle or mechanism and has increased the price of manufacturing the bottle. 
         [0014]    Finally prior art has brought changes to sprayer head design such as U.S. Pat. No. 5,462,209. There are design changes to the sprayer heads that allows a, sprayer head to be sprayed upright, at 90 degrees and inverted. These designs are much more complicated than standard sprayer heads as they incorporates multiple 
         [0000]    check valves, multiple fluid entry points and a larger housing. Although this design does help eliminate dry fires and allows the user to spray inverted, these complex designs have a higher cost to manufacture and as a result tend to be offered as specialty sprayer heads. 
         [0015]    Curved dip tube for sprayer heads has many features to address the shortcomings of the groups presented as prior art. The curved dip tube can be made from the exact same materials already used by the industry. The common materials used now for dip tubes has a semi ridged quality which ensures the tip of the curved tube will stay positioned even if the bottle is shaken or dropped. In addition it can be made in a variety of ways to accommodate the height, width and dimensions of all spray bottles. That means spray bottles and sprayer heads will not have to be redesigned. In addition the curved dip tube can be used on trigger sprayers, pump sprayers, aerosol cans, electric pumps or any devise in which the contents can be picked up by a tube. 
       SUMMARY 
       [0016]    The curved dip tube for sprayer heads will assist in dispensing the contents of a spray bottle in a continuous flow without dry fire and utilizing the entire contents of the bottle while the bottle is tilted downward between 0 and 90 degrees. 
     
    
     
       DRAWINGS 
       Figures 
         [0017]      FIG. 1  shows a curved dip tube aligned with a standard sprayer head. 
           [0018]      FIG. 2  shows a curved dip tube aligned with a standard sprayer head inserted into a flat bottomed oval spray bottle. 
           [0019]      FIG. 3  shows a curved dip tube aligned with a standard sprayer head inserted into a flat bottomed circular spray bottle. 
           [0020]      FIG. 4  shows an integral curved dip tube aligned with a standard sprayer head inserted into a bevel bottomed circular spray bottle. 
           [0021]      FIG. 6  shows a curved dip tube aligned with a standard sprayer head inserted into an oval spray bottle tipped downward to show the contents pooling in the lower corner. 
           [0022]      FIG. 7  shows a curved dip tube reverse aligned with a standard sprayer head inserted into a circular spray bottle tipped upward to show the contents pooling in the lower corner. 
           [0023]      FIG. 10   a - d  shows how to bend ridged tubing to the correct dimensions. 
           [0024]      FIG. 11   a - b  shows how attach the guide bracket to the bent ridged tubing. 
           [0025]      FIG. 12   a - b  shows a plastic type tube and a sprayer head with an integral dip tube preparing to be inserted into the form. 
           [0026]      FIG. 13   a - d  shows a straight dip tube and a sprayer head with an integral dip tube inside the forms preparing to be inserted into hot and cold baths. 
           [0000]    
         
           
                 
               
                 
                 
                 
                 
               
             
                 
                     
                 
                 
                   DRAWINGS - REFERENCE NUMERALS 
                 
                 
                     
                 
               
               
                 
                     
                 
               
            
             
                 
                   10 
                   Sprayer head 
                   11 
                   Sealing cap. 
                 
                 
                   12 
                   Dip tube connection point. 
                   13 
                   Integrated dip tube. 
                 
                 
                   14 
                   Full length curved dip tube. 
                   15 
                   Aligned curved section. 
                 
                 
                   16 
                   Reverse aligned curved section 
                   17 
                   The tip of the curved dip tube. 
                 
                 
                   18 
                   Bevel bottom of spray bottle. 
                   19 
                   Contents of spray bottle. 
                 
                 
                   20 
                   Oval shaped bottle. 
                   21 
                   Circular bottle. 
                 
                 
                   30 
                   Ridged tubing. 
                   31 
                   Mark for the bend line. 
                 
                 
                   32 
                   Tube bender. 
                   33 
                   Long arm of tube bender. 
                 
                 
                   34 
                   Short arm of tube bender. 
                   35 
                   Bent ridged tube. 
                 
                 
                   36 
                   Guide bracket. 
                 
                 
                   37 
                   Point where the tip of bent 
                 
                 
                     
                   ridged tube meets the 
                 
                 
                     
                   guide bracket. 
                 
                 
                   38 
                   The weld point. 
                 
                 
                   39 
                   The form. 
                 
                 
                   40 
                   Plastic type tube. 
                 
                 
                   41 
                   Sprayer head with the 
                 
                 
                     
                   integral dip tube. 
                 
                 
                   42 
                   Hot water bath. 
                 
                 
                   43 
                   Cold water bath. 
                 
                 
                   45 
                   Bottom tip of the form. 
                 
                 
                     
                 
               
            
           
         
       
       
    
    
     DETAILED DESCRIPTION 
     FIG.  1 , FIG.  2  and FIG.  3 —First Embodiment 
       [0027]    One embodiment of the curved dip tube is illustrated in  FIG. 1 ,  FIG. 2  and  FIG. 3 .  FIG. 1  shows the curved dip tube  14  and a sprayer head  10 . The sprayer head  10  is a 1.0 ml sprayer head—available through Unisan Products of Los Angeles, Calif. The relevant variations on sprayer heads related to this application are sealing cap size and dip tube connection size or integral dip tube. The sealing cap size  11  preferred by most sprayer head manufacturers is 28-400, although there are other sizes used in industry such as 28-410 and 28-415. The sealing cap size  11  need only fit the bottle  20  ( FIG. 2 )  21  ( FIG. 3 ) to be used. The dip tube connections  12  size can vary. The curved dip tube  14  outer diameter need only match the inner diameter of the dip tube connection  12 . Once matched the curved dip tube  14  can be inserted into the dip tube connection  12  beneath the sealing cap  11 . The preferred material for the curved dip tube  14  is nylon or polyethylene as they are inexpensive and possess good chemical compatibility characteristics. Both nylon and polyethylene tubing are available through Hudson Extrusion of Hudson Ohio. Although nylon and polyethylene are the most common materials used for dip tubes many other materials can be used including but not limited to polyvinyl chlorine, polypropylene, polystyrene, Nitrile, Ethylene propylene, Teflon, Polyurethane and Viton. The preferred radius of the curved section  15  of this embodiment is a 1.25 inch radius. Although the curve radius can vary, it need only be smaller than the diameter of a circular bottle  21  ( FIG. 3 ) or the long diameter of an oval bottle  20  ( FIG. 2 ). The bottles  20  ( FIG. 2 )  21  ( FIG. 3 ) are available through Indiana Bottle Company in Scottsburg, Ind. Bottles  20  ( FIG. 2 )  21  ( FIG. 3 ) are available in many different sizes, shapes and materials. The material need only be chemically compatible with the contents and the connection size should match the sprayer head  10  sealing cap  11 . The length and width of the curved dip tube  14  can be altered to fit the variations in the size and shape of the bottles  20  ( FIG. 2 )  21  ( FIG. 3 ). 
       OPERATION 
     FIG.  6  and FIG.  7   
       [0028]    The elimination of dry fire and utilization of all the contents while spraying down is illustrated in  FIG. 6 . When spraying down the elimination of dry fire and utilization of all the contents  19  of the spray bottle  20  is obtained when the curved section  15  is aligned with the sprayer head  10 . This is achieved when the curved dip tube  14  is pushed into the dip tube connection  12  on the sprayer head  10  such that the tip  17  is pointing in the same direction as the sprayer head  10 . The tip  17  of the curved dip tube  14  is now positioned in the lowest position of the spray bottle  20 . When the spray bottle is tipped downward anywhere between 0 and 90 degrees the contents  19  pools at the Tip  17  of the curved dip tube  14  allowing the sprayer head  10  to continue to spray the contents  19  without dry fire until all the contents  19  are used. 
         [0029]    The elimination of dry fire and utilization of all the contents while spraying upward is illustrated in  FIG. 7 . When spraying up the elimination of dry fire and utilization of all the contents  19  of the spray bottle  20  is obtained when the curved section  16  is reverse aligned with the sprayer head  10 . This is achieved when the curved dip tube  14  is pushed into the dip tube connection  12  on the sprayer head  10  such that the tip  17  is pointing in the opposite direction as the sprayer head  10 . The tip  17  of the curved dip tube  14  is now positioned in the lowest position of the spray bottle  20 . When the spray bottle is tipped upward anywhere between 0 and 90 degrees the contents  19  pools at the Tip  17  of the curved dip tube  14  allowing the sprayer head  10  to continue to spray the contents  19  without dry fire until all the contents  19  are used. 
       FIG.  4   
     Additional Embodiments 
       [0030]    Other embodiments are illustrated in  FIG. 4 . This figure illustrates an integral curved dip tube  14  as an assembly component of the sprayer head  10  and a circular bottle  21  with a beveled bottom  18 . When the curved dip tube  14  is manufactured it is done with the sprayer head  10  attached so the bottle  21  dimensions and bevel  18  configuration must be specified to achieve the proper length, width and curve diameter of the curved dip tube  14 . 
       FIG.  10 - 14  Technique for Making the Curved Dip Tube  14  (FIG.  1 ) 
       [0031]    The technique used for making the curved dip tube  14  ( FIG. 1 ), out of plastic type tubing, begins with making a form  39  ( FIG. 12 ) for the curved shape. Instructions for how to make the form  39  ( FIG. 12 ) is illustrated in  FIG. 10  and  FIG. 11 . The preferred way is to use 0.375 inch stainless steel tubing  30  ( FIG. 10   a ) cut to 11.25 inches, although a variety of materials can be used. Place a mark  31  on the tubing  30  ( FIG. 10   a ) 8 inches from the end. Use a tube bender  32  ( FIG. 10   b ) with a 1.25 inch bend radius. Open the short arm  34  ( FIG. 10   c ) by pushing the end away from long arm  33  and insert the tubing  30  so the mark  31  lines up with the start position on the long arm  33  and the short arm  34 . Pull the end of the short arm  34  ( FIG. 10   d ) toward the end of the long arm  33  in a smooth motion. Stop the motion when the mark on the short arm  34  lines up with the end mark on the long arm  33 . The tubing  30  is now bent to 90 degrees. Release the short arm  34  and remove the tubing  30 . The stainless steel tubing and tube bender can be obtained at Home Depot in Centennial Colo. 
         [0032]    The bracket  36  ( FIG. 11   a ) is 5 inches long, 2 inches wide, ⅛ th  inch thick stainless steel flat bar stock. Four 90 degree bends are added. The first bend is started 1 inch from the end and each subsequent bend is 1 inch further from the previous bend to give the desired shape. The bracket  36  ( FIG. 11   b ) is positioned such that tip  37  of the bent tubing  35  is flush with top of the first bend  37  on the bracket  36  and the fiat edge of the bracket to be welded should be pointing in the same direction as the tip  45  of the bent tubing  35 . Weld the bent tube  35  to the bracket  36  at the contact point  38  to create the form  39  ( FIG. 12   a ). 
         [0033]    Instructions on how to make the curved dip tube is illustrated in  FIG. 12  and  FIG. 13 . The hot water bath  42  ( FIG. 13   c ) should be filled to within an inch of the top with 212 degree Fahrenheit water. The cold water bath  43  ( FIG. 13   d ) should be filled to within an inch of the top with 60 degree Fahrenheit water. The plastic type tubing in this example is three sixteenths inch nylon tubing although a variety of materials and sizes can be used. Cut the tubing  40  ( FIG. 12   a ) to a length of 11.5 inches and insert into the top of the form  39  ( FIG. 12   a ) until the tip of the tubing  40  is flush with the bottom end  45  of the form  39 . With the tubing  40  ( FIG. 13   a ) inserted into the form  39  ( FIG. 13   a ) drop the form  39  into the hot water bath  42  ( FIG. 13   c ) using the guide bracket  36  to hang the form  39  on the edge of the hot water bath  42 . After 30 seconds remove the form  39  from the hot water bath  42  and insert into the cold water bath  43  ( FIG. 13   d ) using the guide bracket  36  to hang the form  39  on the edge of the cold water bath  43 . Wait 30 seconds and remove the form  39  from the cold water bath  43 . When you remove the tubing  40  from the form  39  you now have a curved dip tube  14  ( FIG. 1 ) with a vertical long length of 9.5 inches and a horizontal short length of 3 inches. 
         [0034]    Instructions on how to make a sprayer head with an integral curved dip tube is illustrated in  FIG. 12  and  FIG. 13 . The hot water bath  42  ( FIG. 13   c ) should be filled to within an inch of the top with 212 degree Fahrenheit water. The cold water bath  43  ( FIG. 13   d ) should be filled to within an inch of the top with 60 degree Fahrenheit water. The plastic type tubing in this example is integrated into the sprayer head as a part of the assembly. In this example the integral dip tube is three sixteenths inch nylon tubing and cut to 11.5 inches, although a variety of materials and sizes can be used. Insert the sprayer head with the integral dip tube  41  ( FIG. 12   b ) into the top of the form  39  ( FIG. 12   b ) until the tip of the integral dip tube  41  is flush with the bottom end  45  of the form  39  and the sprayer head  41  is pointing in the same direction as the tip  45 . With the sprayer head with the integral dip tube  41  ( FIG. 13   b ) inserted into the form  39  ( FIG. 13   b ) drop the form  39  into the hot water bath  42  ( FIG. 13   c ) using the guide bracket  36  to hang the form  39  on the edge of the hot water bath  42 . After 30 seconds remove the form  39  from the hot water bath  42  and insert into the cold water bath  43  ( FIG. 13   d ) using the guide bracket  36  to hang the form  39  on the edge of the cold water bath  43 . Wait 30 seconds and remove the form  39  from the cold water bath  43 . When you remove the sprayer head with the integral dip tube  41  from the form  39  you now have a sprayer head with the integral curved dip tube  14  ( FIG. 1 ) with a vertical long length of 9.5 inches and a horizontal short length of 3 inches. 
       ADVANTAGES 
       [0035]    From the description above, a number of advantages of embodiments of the curved dip tube for sprayer heads become evident. 
         [0036]    The materials used are the same as the materials already in use by the industry. There are no new chemical compatibility issues. Due to the semi ridged nature of the standard materials use for dip tubes the tip of the curved dip tube will stay in the optimal position even if the bottle is shaken or dropped. The effectiveness can be obtained for only a fraction of a penny making it a cost effective alternative. The curved dip tube for sprayer heads can be made separate of the sprayer head or formed with the dip tube integrated into the sprayer head. The improvement requires no new product changes by the spray bottle and sprayer head industries and it can be used in a variety of applications. 
       CONCLUSION, RAMIFICATIONS AND SCOPE 
       [0037]    Accordingly, the reader will see the curved dip tube for sprayer heads and its embodiments offer the users of sprayer bottles a vast improvement in effectiveness toward eliminating dry fire and assist in utilizing all the contents of a spray bottle. In addition, the curved dip tube for sprayer heads has these additional advantages:
       a) The tubing can be made of a variety of materials including the common materials used by spray bottle and sprayer head manufacturers. These manufacturers need only increase the length of the tubing they already buy in large quantities. For common use materials the increase in material costs would add a fraction of a penny to the cost of the product.   b) Since all the same materials are being used there is no chemical compatibility issues that don&#39;t already exist with the materials used by manufactures today.   c) The common materials used for dip tubes have a semi ridged quality. This ensures the tip of the curved dip tube will stay in the optimal position even if the bottle is shaken or dropped.   d) The curved dip tube for sprayer heads can be made in variety of ways to accommodate all bottles regardless of height, width and shape.   e) The curved dip tube can be manufactured separate of the sprayer heads or formed with the dip tube integrated into the sprayer head.   f) Spray bottle and sprayer head manufacturers will not have to redesign their products to accommodate the curved dip tube for sprayer heads.   g) The curved dip tube can be used on trigger sprayers, pump sprayers, aerosol cans, electric pumps or any devise in which the contents can be picked up by a dip tube.       
 
         [0045]    Although the description above contains many specifications, these should not be construed as limiting the scope of the embodiments but as merely providing illustrations of some of the presently preferred embodiments. For example the material for the form and guide bracket can be stainless steel, copper, brass, aluminum or steel. Or, the heat source for the process of curving the tubing can be air, water or steam and the form can be inserted into the hot source and cold source for shorter or longer periods of time. Also, the curve radius of the tubing can vary depending on the forms used to manufacture the curved dip tube. 
         [0046]    Thus the scope of the embodiments should be determined by the appended claims and their legal equivalents rather than by the examples given.