Trigger sprayer

A trigger sprayer having six parts: (i) a dip tube, (ii) a valve, (iii) a flexible pump diaphragm having a circumferential valve lip, (iv) a shroud having a trigger, an element which engages the diaphragm, and front and rear mating elements, (v) a body having a closure for a container, an inlet coupled to the dip tube, a valve seat for the valve, an element which engages the valve lip, a discharge barrel having a proximal opening into which the valve lip seats, a vent chamber, a vent barrel coupled to the vent chamber, a rear mating structure coupling to the rear mating element of the shroud so that the shroud can pivot, and a forward mating element, and (vi) a combination nozzle and door assembly with a nozzle which couples to the fluid discharge barrel of the molded body, and has a trigger locking element.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates broadly to hand-held and hand-operated liquid sprayers typically called trigger sprayers.

2. State of the Art

A common trigger sprayer may be seen with reference to commonly-owned U.S. Pat. No. 4,747,523 to Dobbs. The trigger sprayer of Dobbs is seen to be comprised of numerous parts including (i) a pump housing or body having a pump chamber, (ii) an inlet passageway and an outlet passageway, (iii) a closure cap which mounts the pump body to a container, (iv) a dip tube coupled to the inlet passageway, (v) a check (ball) valve in the inlet passageway, (vi) a trigger which mounts to and rotates relative to the pump housing, (vii) a pump piston which is actuated by the trigger, (viii) a coil spring seated in the pump chamber, (ix) a discharge valve located at the entrance of the outlet passageway, (x) a nozzle coupled to the outlet passageway of the pump body, and (xi) a shroud which covers the pump housing. The trigger sprayer of Dobbs includes additional elements as parts of the above-listed elements. For example, the pump piston of Dobbs includes chevron seals for sealing against the pump chamber and for acting as a vent port seal. Many trigger sprayers include additional parts to implement venting. Likewise, many sprayers utilize additional parts in the nozzle to implement spraying options.

SUMMARY OF THE INVENTION

A functional trigger sprayer according to the invention has only six easily assembled parts. In a preferred embodiment the six parts of the trigger sprayer of the invention include (i) a dip tube, (ii) a ball valve, (iii) a molded flexible pump diaphragm having a circumferential flange and a valve lip, (iv) a molded shroud which includes a trigger, an actuation element which engages the pump diaphragm, a front mating element, a rear mating element, (v) a molded body having a closure for a container, a fluid inlet coupled to the dip tube, a valve seat for the ball valve, an engaging element for engaging the circumferential flange of the flexible diaphragm, a fluid discharge barrel having a proximal opening into which the valve lip of the pump diaphragm seats, a vent chamber, a vent barrel coupling the vent chamber to the ambient atmosphere, a body section having a mating element for coupling to the rear mating element of the shroud so that the shroud can pivot at the coupling point, and a forward mating element, and (vi) a molded combination nozzle and door assembly with a nozzle which couples to the fluid discharge barrel of the molded body and a flange which mates with the forward mating element of the body, a live hinge, and a door having a first plug which plugs the nozzle, a second plug which plugs the vent barrel, and trigger locking elements which mate with the front mating element of the molded shroud in order to lock the trigger when the door is closed.

In the preferred embodiment, the integral trigger shroud has a forward finger trigger, two shroud arms which extend rearwardly from their front mating elements which are adjacent the nozzle and can be locked by the trigger locking elements of the door arms, an upper shroud portion which joins the shroud arms and includes downwardly directed actuation ribs for engaging the diaphragm, and rear trunnions which snap into the valve body so that the entire trigger shroud can pivots relative to the body. Thus, pushing backward on the trigger will cause the trigger shroud to pivot about the rear trunnions slightly downward, which will in turn cause the actuation ribs to depress the pump diaphragm. When the trigger is released, the elasticity of the pump diaphragm will cause movement of the trigger shroud back to its at-rest position.

With the entire trigger sprayer having only six pieces including the ball, the dip tube, and four molded pieces, assembly of the trigger sprayer is simple and overall costs are reduced. Assembly may be accomplished in five simple steps: placing the ball valve into the body; snapping the diaphragm into the body; snapping the trigger trunnions into the valve body with the trigger shroud over the diaphragm; snapping the nozzle and door assembly into the valve body; and pushing the dip tube into the body.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Turning now toFIGS. 1a-1d, a trigger sprayer10having six easily assembled parts is provided. In a preferred embodiment the six parts of the trigger sprayer10include a dip tube12, a ball valve14, a flexible pump diaphragm20, a molded combination trigger shroud30, a molded body50, and a molded combination nozzle and door assembly80. As seen best inFIG. 1d, the dip tube12is coupled to the molded body50, the ball valve14sits in the molded body50, the diaphragm20sits atop the molded body50, and the combination nozzle and door assembly80is coupled to the molded body50. As seen best inFIGS. 1aand1b, the shroud trigger30mates with the body50.

Turning now toFIGS. 2aand2b, the molded flexible pump diaphragm20is shown with a circumferential flange22and a valve lip or skirt24. The diaphragm20is preferably formed from a copolymer ELVALOY (a trademark of DuPont), although other materials could be utilized such as by way of example only and not by way of limitation ethylene copolymers or acrylate copolymers. In an at rest position the diaphragm is a generally hemispherical body. The circumferential flange22essentially constitutes a double tongue and groove seal. More particularly, flange22has a first finger or tongue26which defines a first recess or groove27between the finger26and the diaphragm body, and a second finger or tongue28which defines a second recess or groove29between the first finger26and the second finger28. As described hereinafter, the recesses receive corresponding elements of the molded body50which help hold the diaphragm20in place. The open end of the hemispherical body constitutes the valve lip or skirt24, which as hereinafter described, at least partially sits in a fluid path and acts as a valve therein.

Referring now toFIGS. 3athrough3d, the combination trigger shroud30in a preferred embodiment is an integral piece of polypropylene, although other materials could be utilized such as by way of example only and not by way of limitation high density polyethylene (HDPE). The trigger shroud30has finger trigger32located at the nozzle end of the trigger sprayer10, two shroud arms33a,33b, an upper shroud portion34which joins the shroud arms33a,33band includes on its underside (FIG. 3c) downwardly directed actuation ribs35for engaging the top of the diaphragm20, and a rear section36defined by the arms33a,33band the upper shroud portion34. The forward portion of the shroud arms33a,33bextend above the finger trigger32and are provided with front locking elements36a,36b(seeFIGS. 3cand3d) which define trigger lock windows37a,37b. The front locking elements are adjacent the nozzle (as described hereinafter) and can be locked by the trigger locking elements of the door arms (as also hereinafter described). The shroud arms and the front edge38of the upper shroud portion34also define an opening39above the body50. Turning toFIGS. 1aand1bin conjunction withFIGS. 3a-3d, the rear section36of the trigger shroud30includes rear engagement elements, preferably in the form of trunnions41a,41b. The trunnions41a,41bhave axle-like portions42a,42bwhich terminate in larger disk portions44a,44bwhich extend towards each other from rear fins47a,47bof the arms33a,33b. The rear fins are coupled to the upper shroud portion34via oppositely extending wings46a,46bof the upper shroud portion which form windows43a,43bbetween them and the fins. The trunnions41a,41bengage or snap into a rear portion of the valve body50so that the entire trigger shroud30can pivot relative to the body. Thus, pushing backward on the trigger32will cause the trigger shroud30to pivot about the rear trunnions41a,41bslightly downward, which will in turn cause the actuation ribs35to depress the pump diaphragm20(as shown hereinafter with respect toFIGS. 4cand4d). When the trigger is released, the elasticity of the pump diaphragm20will cause movement of the trigger shroud back to its at-rest position.

A first embodiment of the molded body50of the invention is seen inFIGS. 4aand4c-4i. Broadly, molded body50has a closure52(FIG. 4a) for a container (not shown), a fluid inlet54(FIG. 4c) which receives the dip tube12, a valve seat56which receives the ball valve14, engaging elements58a,58bfor engaging the grooves27,29of the circumferential flange22of the flexible diaphragm20, a hollow fluid discharge barrel60having a proximal opening62into which the valve lip24of the pump diaphragm20seats, a hollow vent chamber64, a hollow vent barrel66(FIG. 4d) coupling the vent chamber to the ambient atmosphere, a rear body section68(FIGS. 4a,4b) having elements70a,71a,72a,70b,71b,72b(seeFIGS. 4aand4j) for coupling to the rear mating elements (trunnions) of the trigger shroud30so that the shroud can pivot at the coupling point, and forward mating elements75a,75b(FIG. 4e) for mating with and holding the combination nozzle door80. Molded body50is preferably molded from polypropylene, although other materials could be utilized such as by way of example only and not by way of limitation high density polyethylene (HDPE). More particularly, the external features of the body50are seen best with reference toFIG. 4a, while the internal features are seen with reference toFIGS. 4c-4j. As seen inFIG. 4a, the bottom of body50comprises a closure52. The internal features of the closure52are not shown but may include threads, bayonet locks, or any snap-on, threaded or other closure mechanism which will serve to attach the body50to a container which contains fluid in a fluid-tight manner. Above the closure52is the outer wall of the vent chamber64. Communicating with the vent chamber64is the hollow vent barrel66which preferably extends beyond the end of the fluid barrel60in the direction of the nozzle. Above the vent chamber64is a diaphragm receiving section. The top64aof the vent chamber64and the internal wall of finger58adefine a well59which receives the skirt valve24of the diaphragm. The fluid barrel60is in communication with one side of well59via the previously mentioned opening62. External to the well59are the fingers or retaining elements58a,58b, and58cwhich hold the diaphragm in place. Internal to the well is the valve seat56having ball-retention features which are described in more detail hereinafter with reference toFIG. 4c. On the other side of the body50relative to the fluid barrel60and the vent barrel66, the body has a section68which includes elements mating elements70a-72a,70b-72bwhich mate with the trunnions41a,41bof the trigger shroud30. These elements prevent the shroud from being removed from the body, but permit rotation of the shroud relative to the body.

A second embodiment of the body is seen inFIG. 4b, where like numbers relate to like parts. The only difference between the body50aofFIG. 4band the body50ofFIG. 4ais that the valve seat56ais formed differently. Whereas the valve seat56of body50involves molding four undercut retention fingers (discussed with reference toFIGS. 4cand4d), the valve seat56ais formed by a simple core pull with no undercuts and requires a secondary operation to skive or peel down four retention fingers substantially the same as those shown inFIGS. 4cand4d.

Turning now toFIGS. 4cand4d, certain internal features of body50are seen. In particular, a fluid inlet54having dip tube12is shown with a seat or stop54afor the tube12which also forms the start of the valve seat56. Valve seat56includes arms76with undercuts76aand top prongs76b. The prongs76bare flexible to permit the ball14to be pushed therethrough and into the undercut arm section during assembly. The undercuts and prongs are sized and shaped to receive the ball valve14. In a fluid intake position (FIG. 4d), the ball is lifted off of seat56and a fluid path is established between the arms (seeFIG. 4a), whereas in a fluid outflow (spraying) position (FIG. 4c), the ball14is seated in seat56where it blocks fluid flow through dip tube12. As seen inFIG. 4d, during fluid intake, air passes from the vent barrel66to the vent chamber64via hole66awhich is perpendicular to chamber64.

Details of the internal structure of the nozzle end of the body50are seen best with reference toFIGS. 4e-4i. The nozzle end of the body50is seen with the walls of hollow fluid barrel60and hollow vent barrel66defining a space therebetween74(see alsoFIG. 1cwhere the space is unnumbered). The distal end of the outer surface of fluid barrel60is shown with a wall60ahaving mating structure or ribs75a,75bwhich extend into space74and are used to mate with structure on the combination door nozzle80. The distal end of the fluid barrel60is also shown with walls60cand60d. Wall60cis an enlarged solid cylindrical wall which as discussed hereinafter with reference toFIGS. 4f-4ihas channels60ewhich define two fluid paths to an outlet. Wall60dis a supporting wall for a portion of wall60awhich forms a circle around wall60c(seeFIG. 4f).

As seen best inFIGS. 4f,4g, and4h, wall60cis provided with molded grooves, paths or channels60ewhich direct fluid from the fluid barrel60up the sides of solid cylindrical wall60c. The channels60ein the front face60bof wall60ceffectively constitute a fluid outlet out of the body50and into the nozzle portion of the nozzle door80as described hereinafter with reference toFIGS. 5a-5c.

Turning now toFIG. 4jin conjunction withFIGS. 1band4a, the rear portion68(FIG. 4a) of body50is seen. The rear portion68is provided with internal wall structures70a,70b,71a,71b,72a,72bwhich receive and mate with the trunnions41a,41bof the trigger shroud30so that the trigger shroud30cannot be easily detached from the body50, but is able to rotate relative to the body. Wall structures70a,71aand70b,71bextend below and above the axle portions42a,42bof the trunnions, and define a space which is narrower than the diameter of the disks44a44b, thereby preventing the trunnions from pulling out. Axles42aand42bare free to rotate on walls70a,70b. Wall structures72aand72bare flexible walls which permit the trunnions to be forced past them during assembly, and then act as front stops for the axles, thereby preventing the trunnions from pulling out in a forward direction.

Turning now toFIGS. 5a-5c, the molded combination nozzle and door assembly80is seen. The combination nozzle and door assembly is preferably made from HDPE, although other materials could be utilized such as by way of example only and not by way of limitation polypropylene, and has a first portion82which includes the nozzle and various mating elements which mate to the body50, a live hinge83and a second door portion84which includes various plugs and trigger locking elements. More particularly, and as seen in conjunction withFIGS. 1dand4e,4hand4i, first portion82includes a nozzle85which abuts the fluid outlet path60eof the body50with optional spin mechanics (not shown) and a nozzle opening86. The first portion82also includes an outer mating wall88which engages the outside of body wall60a. Outer mating wall88has ribs which engage the mating ribs75a,75bof body wall60a, and seen inFIG. 4e, the top of the outer mating wall88is notched (i.e., it is shorter in cross-section) so as to key its location, as wall60dof body50acts as a stop in the notch. The first portion82further includes an inner mating wall90which engages and plugs the fluid barrel60, thereby forcing fluid to enter the fluid paths60eas previously described. Walls88and90assure that the combination nozzle and door assembly are fixed to the body50. Finally, the first portion82includes walls93a,93bwhich define windows94a,94band bosses95a,95bfor releasably holding trigger lock bars of the door portion84.

The door portion84is hinged to the first portion82by live hinge83and is free to move relative thereto. The door portion84includes a nozzle plug96, a vent plug97, and trigger lock bars98a,98beach having a protrusion99a,99bfor engaging the bosses95a,95b. More particularly nozzle plug96is seen to be a hollow plug with an end wall. When the door is closed, the nozzle plug96fits inside the nozzle85of the first portion82in order to block fluid from exiting the sprayer. Similarly, vent plug96is seen to be a hollow plug with an end wall. When the door is closed, the vent plug96fits inside the hollow vent barrel66of the body50and thereby prevents fluid from exiting from the bottle via the vent chamber and vent barrel. Trigger lock bars98a,98bare formed such that when the door is closed, the trigger lock bars extend through the windows94a,94bof the first portion82of the combination nozzle and door assembly80, and into the trigger lock windows37a,37b(FIG. 3c,3d) of the trigger shroud, thereby locking the trigger shroud relative to the combination nozzle and door assembly80and the body50. This prevents accidental actuation of the trigger.

With the provided elements of the trigger sprayer, assembly may be accomplished in five simple steps. Particularly, the ball14is pushed into the valve seat56by pushing the ball past prongs76bof the valve seat. After the ball is inserted, the diaphragm20may be fixed in place on the body50with valve lip24in well59, and with tongues26,28of flange22extending between and engaging the engaging elements or walls58a,58b,58cof the body50. The trigger shroud is coupled to the body by forcing trunnions41a,41bpast flexible wall structures72a,72bsuch that the axles42a.42bof the trunnions are captured by structures by walls70a,70b,71a,71b,72a,72b. At any time, the nozzle and door assembly80may be attached into the valve body50by pushing walls88and90into respective mating locations on the valve body. The door84of the nozzle and door assembly80may be either open or closed when the assembly80is attached to the body50. If it is closed, the vent plug97will engage the vent barrel66during attachment, and the trigger lock bars98a,98bwill engage the trigger lock windows37a,37b. Also, at any time, the dip tube12can be pushed into the inlet path54of the body50.

There have been described and illustrated herein embodiments of a trigger sprayer and a method of assembly. While particular embodiments of the invention have been described, it is not intended that the invention be limited thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise. Thus, while particular materials for molding certain elements of the invention have been disclosed, it will be appreciated that other materials or combinations of materials could be used as well. In addition, while particular types of latching and mating mechanisms have been disclosed, it will be understood other latching and mating mechanism could be used. Also, while the invention was described as preferably utilizing a ball-type valve, it will be recognized that a flapper valve or other type of valve could be utilized. In fact, it is possible to reduce the parts by one by forming a flapper valve on the sprayer end of the dip tube, or by forming the flapper valve as part of the body. In those situations it may be desirable to co-inject materials, or to use a post-molding process to generate the flapper valve. It will therefore be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its spirit and scope as claimed.