Atomizing pump spray

The invention relates to a manual, self-priming precompression spray pump, which employs a minimal number of different parts. The assembly includes a container for the liquid, a cap, a conventional spray nozzle unit, a valve member, a piston, a spring and a cylinder for housing the piston and providing a compression chamber. The valve upper end functions as an outlet valve and the valve lower end functions as an inlet valve. The spring is a compound spring and serves to force the valve outlet end into a constant sealing engagement with the interior of the piston, and to resist the compression movement of the piston. The cylinder for housing the piston includes an inner, concentric valve cylinder. The inner cylindrical wall has an axial length which terminates short of the chevron valve when said valve member and said piston are fully biased away from said inlet valve, whereby said chevron valve is in a position outside of said inner cylindrical wall. Thus, at this extreme position, the inlet valve is fully open for cooperation with said piston cylinder inlet end to restrict liquid flow from out of said piston compression chamber and through said piston cylinder inlet end.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
This invention relates generally to a precompression pump sprayer, and more 
particularly to a pump chamber priming arrangement for such sprayer and a 
simplified component arrangement. 
2. Brief Description of the Prior Art 
Self priming precompression pumps have undergone changes over the years, 
primarily for the purpose of producing improved valve structures, more 
effective self priming, improved reliability, reduced cost, and ease of 
manufacture. Over the years, prior art pump designs have undergone 
improvement and provided enhanced features. 
It is an object of the present invention, to provide a new concept in pump 
designs, in order to provide a new advancement with respect to ease of 
use, reliability, reduced cost, and ease of manufacture. 
SUMMARY OF THE INVENTION 
The invention relates to a manual, self-priming precompression spray pump, 
which employs a minimal number of different parts. Consequently, the 
device is highly reliable and low in cost of manufacture. A pump sprayer 
of this type comprises a chamber where liquid is drawn by means of a 
piston or plunger into a sealed chamber, and then released under pressure 
through an outlet valve. In general the plunger is driven by a stainless 
steel spring, and in many cases the same spring force is used to seal the 
outlet valve. This occurs in varied configurations, having variations 
related to both the outlet and inlet valves. In other cases the outlet 
valve pressure is controlled separately, usually by a separate, smaller 
spring. There are advantages to controlling the outlet valve separately. 
Among them is the dispensing of a range of volumes and viscosities of 
liquids and gels, as well as better control over the dosage. The drawback 
with the separate control is the greater number of components, leading to 
higher cost of production and assembly. The present invention seeks to 
improve prior art by controlling separately the plunger and sealing forces 
in the pump by use of a novel design and a single dual action spring, 
using a minimum number of parts. 
The entire assembly includes a container for the liquid which is to be 
dispensed, a cap for closing the open end of the container, a conventional 
spray nozzle unit, a valve member, a piston, a spring and a cylinder for 
housing the piston and providing a compression chamber. The valve upper 
end functions as an outlet valve and the valve lower end functions as an 
inlet valve. The spring is a compound spring and serves two, independently 
variable functions. It serves both to force the valve outlet end into a 
constant sealing engagement with the interior of the piston, and to resist 
the compression movement of the piston. The user applies pressure to the 
spray nozzle cap that is in contact with the piston thus putting it 
through the compression cycle and the spring returns the piston to its 
rest position. 
The cylinder for housing the piston includes an inner, concentric valve 
cylinder. The inlet valve end of the valve member is dimensioned to 
slidably receive the inlet valve end of the valve member. The compound 
spring has one end seated on the seat which is formed where the inner 
concentric valve cylinder is joined to the outer cylinder, the piston 
housing cylinder. 
The pump assembly includes a piston cylinder, a piston, a valve, and a 
compound spring. The compound spring has a first region and a second 
region, with the first region being compressible independent of the second 
region. The first region has a first end loop and a second end loop, and 
the second region also has a first end loop and a second end loop. 
The piston is adapted for reciprocal motion within the piston cylinder. The 
piston cylinder has an interior compression chamber and a valved leading 
from outlet the compression chamber. The valve member is positioned within 
the piston cylinder and has an outlet valve end adapted for fluid tight 
engagement with the piston cylinder valved outlet. The compound spring has 
a first end biased against the piston cylinder. The compound spring first 
region first loop end is in engagement with said valve member outlet valve 
end and biases the valve member for engagement with the piston valved 
outlet, and said second end is biased against the compound spring second 
region. The compound spring second region, first loop end is in engagement 
with the piston and the second region second loop end is biased against 
the piston cylinder. 
Thus, movement of the piston during a compression stroke is resisted by the 
compound spring second region and the movement of said valve member outlet 
valve end is independently biased toward said piston valved outlet by said 
compound spring first region. 
Another feature of the invention is providing the piston with an annular 
groove. The compound spring second region, first loop is mounted in the 
annular groove so as to provide a fixed engagement between the piston and 
the compound spring second region, allowing a constant and separate force 
of closure. 
A further feature of the invention is providing the valve member with an 
annular groove at its valve outlet end. The compound spring first region, 
first loop is mounted in the annular groove for fixed engagement between 
said compound spring first region and said valve member. 
In another feature of the invention, the piston cylinder has an inlet end, 
and the valve member has a valve inlet end. The valve member inlet end is 
adapted for cooperation with the piston cylinder inlet end to restrict 
liquid flow from out of said piston compression chamber and through said 
piston cylinder inlet end. The piston cylinder has an outer cylindrical 
wall and a concentric inner cylindrical wall, with the valve member inlet 
end being positioned for reciprocal movement within the piston cylinder 
inner cylindrical wall. 
Preferably, the valve member inlet end is a chevron valve having an annular 
skirt, such that the annular skirt has a increasing diameter in the 
direction away from said inlet end. 
A further feature of the invention relates to the spray pump assembly being 
self-priming. At least one vent groove is provided on the inner surface of 
the concentric inner cylindrical wall, such that at least one vent groove 
is positioned for cooperation with said chevron valve during the final 
portion of the reciprocal movement of said valve member within said piston 
cylinder inner cylindrical wall, to provide an air flow by pass around the 
inlet valve. Thus, during the priming step, air is forced into the 
container, rather than being vented to the atmosphere. Another feature of 
the invention is a dip tube entry placed eccentric to the upper cylinder 
to be in alignment with the priming grove. 
The inner cylindrical wall has an axial length which terminates short of 
the chevron valve when said valve member and said piston are fully biased 
away from said inlet valve, whereby said chevron valve is in a position 
outside of said inner cylindrical wall. Thus, at this extreme position, 
the inlet valve is fully open for cooperation with said piston cylinder 
inlet end to restrict liquid flow from out of said piston compression 
chamber and through said piston cylinder inlet end.

DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION 
The pump spray assembly 100, illustrated in FIG. 1, includes the essential 
elements of the invention. Not illustrated is the container, which 
component is well known in the art. The spray cap 102 is provided with a 
convex upper surface for receiving the finger of the user, and a spray 
nozzle 104. The interior of the nozzle is provided with a piston receiving 
notch 110 dimensioned to receive the piston head 618. The spray cap 102 
moveably sits within the container cap 120 that in turn is affixed to the 
container. The distal end of the container cap 120 is dimensioned to 
receive the lower edge of the spray cap 102. The downward vertical 
movement of the spray cap 102 is stopped by the cap ledge 124 while the 
upward vertical movement is controlled by the interaction between the 
spray cap 102 and the piston 600. The interior of the proximal end of the 
container cap 120 is provided with a flange indent 122 and to receive the 
flanged rim 510 as described hereinafter. A container seal 126 provides a 
secure seal. The spray cap 102 is mounted over the piston head 618 with 
the sides of the receiving notch resting on the seat 604. 
As best seen in FIG. 6, the piston 600 is an elongated member with the 
reduced diameter head 618 at the upper end and an upper compression 
chamber 616 at the lower end. The piston head 618 has a diameter less than 
that of the piston stem 602, thereby forming the piston seat 604. The 
compression chamber 616, as illustrated, is a half a decagon, however 
other configurations can be used that allow the valve system to function 
as described herein. It is critical, however, that the proximal end of the 
flow tube 622 be dimensioned to sealably engage the discharge valve 402. 
The sides 620 of the piston 600 have an outer diameter greater than the 
stem 602 to form the lateral extension 606. The open end of the chamber 
wall 620 is notched to form a piston spring seat 610. Although the 
interior diameter of the chamber 616, as formed by the interior chamber 
walls 608 is not critical, it must be dimensioned to interact with the 
spring 700 and valve 400, as described hereinafter. 
The piston 600 is slidably housed within the piston cylinder 500. The 
piston cylinder 500, as illustrated in detail in FIG. 5, is an elongated 
member open at each end. The distal end of the cylinder 500 has a flanged 
rim 510 that is dimensioned to interact with the flange indent 122 of the 
container cap 120. The flanged rim 510 is seated within the flange indent 
122. As well known in the art, air is permitted to leak into the 
container, between the flanged rim 510 and the flange indent 122, to 
prevent a vacuum from forming within the container as liquid is withdrawn 
from the container during successive cycles of the pump 
The vertical wall 502 reduces in diameter at the proximal end to form the 
cylinder neck 516. The valve cylinder wall 504 is parallel to, and set in 
from, the cylinder wall 502. The valve cylinder wall 504 is on the same 
plane as the cylinder neck 512 to permit the valve 400 to run smoothly 
within the valve cylinder 504. The space between the parallel valve 
cylinder wall 504 and cylinder wall 502 forms the spring seat 522. 
During the first stroke, or first few strokes of the piston, the pump must 
be primed. This is accomplished during the initial compression stroke of 
the piston, due to the groove 520 along the interior wall of the piston 
inner valve cylinder 504. The groove 520, illustrated in FIGS. 9a and 9b, 
permits the air to escape through the dip tube, which is placed of center 
in alignment with the groove. 
The design and dimension of the dual valve member 400, as shown in FIG. 4, 
allows it to be mounted within the piston cylinder 502 as well as move 
freely within the valve cylinder 504. The dual valve member 400 includes a 
conical upper discharge valve 402 at the distal end and a lower inlet 
valve at the proximal end. The discharge valve 402, in conjunction with 
the sealing edge 612 of the piston 600, precludes the flow of fluid, 
during compression, from the compression chambers 615 and 516 into the 
spray nozzle cap 102. 
The valve seal 414 functions as an inlet valve, and prevents the fluid 
which is being compressed within the compression chamber from leaking into 
the container. The lower inlet valve is a deformable annular seal 414 of 
the chevron valve type and is dimensioned to provide a fluid tight seal 
with the inner surface 506 of the valve cylinder 504. When the valve 400 
is at its uppermost position, the seal 414 is proximate the upper edge 508 
of the valve cylinder 504, thereby permitting liquid to flow between the 
seal 414 and the upper edge 508. The deformable annular seal 414 is 
dimensioned to enter into fluid tight sealing engagement with the inner 
surface 506 during the compression stroke of the piston 600. During the 
upward movement of the piston 600, fluid is drawn up the fluid tube and 
permitted to flow between the seal 414 and the upper edge 508 when the 
pump 100 is at rest. During the upward motion of the piston 600, the 
piston compression chamber 512 expands, producing a suction that draws 
fluid from the container, past the inlet valve 414, and into the piston 
compression chamber. Due to the outward flare of the inlet valve 414, in 
the direction away from the inlet side, fluid can pass the inlet valve 
414, under the reduced pressure in the compression chamber. The separation 
between the inlet valve seal 414 and the upper edge 508 provides a 
positive open passage for liquid. At the distal end of the valve 400 is a 
spring retaining groove 412 that is dimensioned to receive the spring 700 
as described hereinafter. The groove 412 must have a curvature slightly 
greater that the curvature of the spring 700 to prevent the spring from 
moving along the length of the valve body 410. 
Once primed, the discharge of compressed fluid is accomplished through the 
use of a novel compound spring 700. The use of a compound spring provides 
a unique advantage. The force that drives the piston 600 towards its 
maximum upward position and the force that drives the valve 400 into 
sealing engagement with the piston 600 can be independently varied. If the 
fluid contained within the container has a high viscosity, it is necessary 
to use a base spring having a resistance to compression greater than that 
required for a low viscosity fluid. Similarly, a higher volume of liquid 
requires a higher degree of force. If the force driving the valve into 
sealing engagement with the sealing edge 612 increased directly with 
stiffness of the spring 700, it would be difficult to obtain the required 
opening of the discharge valve during the spray discharge step. The use of 
the compound spring provides a single component that provides two, 
independently variable functions. The varying of the stiffness of a spring 
is well known in the art, and can be accomplished through changes in the 
coil diameter, distance between adjacent loops, or varying the 
characteristics of the spring material itself. Preferably, the change in 
stiffness is achieved by changes in the coil diameter, and/or changes in 
the distance between loops of the coil. Additionally the force of the 
spring varies proportionally with the amount of compression. The use of a 
separate and fixed compression spring element engages the outlet valve in 
a constant force of closure, regardless of the movement in the piston. 
The upper valve engaging loop 706, of the compound spring neck 704, 
illustrated in FIGS. 7 and 8, locks into the spring retaining groove 412. 
The inner diameter of the spring body 702 must be slightly greater than 
the inner valve cylinder 504 and less than the cylinder body 502 to permit 
the spring body 702 to be seated on the piston cylinder spring seat 522. 
The transitional rim 708 of the spring body 702, engages the piston spring 
seat 610. Thus, the stiff, spring body 702 of the spring 700 forces the 
piston 600 towards its uppermost position, while independently, the valve 
400 is forced towards its uppermost position. FIG. 6a shows clearance 
openings 626 in the seat 610. The clearance allows the transitional rim 
708 a horizontal seat and a continuation towards the reduced part of the 
coil. 
The preferred embodiment of the invention as described uses a pump 
configuration with a minimum number of parts. However, other embodiments 
can be accomplished by the variation of either the inlet and/or outlet 
valves, or by increasing the number of parts. The inlet valve can be of 
the type where there is a check valve. The valve member can be a simple 
rod to slidingly engage a movable sleeve or gasket, as in U.S. Pat. No. 
3,331,559. The inlet valve can be a member of a softer material that opens 
and closes due in part to pressure buildup, as in U.S. Pat. No. 4,389,003. 
The outlet valve usually has a valve member closing the outlet, and this 
may occur closer or farther from the dispensing point. Even the placement 
of the inlet valve may change. Indeed the embodiment of the pump can be 
completely different, and the dual action spring can still be applied to 
generally reduce the cost and improve the performance of any given 
embodiment. 
FIG. 10 shows an alternative embodiment of the invention. The main 
variation is the inclusion of a loss motion valve 1002, as the inlet 
valve. The design is as presented in copending Patent Application No. 
09/122,573, now U.S. Pat. No. 6,032,833, the disclosure of which is 
incorporated herein by reference, as though recited in full. The 
functioning is equivalent as the one described therein. The performance is 
however, improved by having separate force control over the piston up and 
down motion and the upper valve seal through the use of the dual action 
spring 1010. 
The dual action spring 1004, can be essentially identical to the dual 
action spring structure as shown in FIGS. 7 and 8. The lower end 1006, of 
the spring 1004, serves to limit the upward movement of the lost motion 
inlet valve 1002, and the ledge or seat 1008 serves to limit the downward 
movement of the lost motion valve 1002. The valve stem 1020 functions much 
in the same manner as the valve 410 of FIG. 1. The principal difference 
lies in that the valve stem 1020 carries the lost motion inlet valve 1002 
along with it, within the limits of the lower end 1006 of the spring 1004 
and the seat 1008. In this embodiment, the upper end of the inlet valve 
1002 breaks its liquid and air tight connection with the valve stem 1020, 
when the upper, reduced diameter section 1022 is positioned within the 
inlet valve. Thus, the reduced diameter section 1022 is dimensioned to be 
in sealing engagement with the main body section of the stem 1020, but to 
permit liquid or air flow between the inner valve 1002 and the reduced 
diameter section 1022. 
As in the case of the outlet valve structure of FIG. 1, the upper end 1024 
of the valve stem 1020 is biased against the outlet port 1026 by the upper 
section 1005 of the dual action spring 1004. The uppermost loop 1007, of 
the upper section 1005 of the dual action spring engages a lower surface 
1009, of the valve stem upper end 1024. It should be noted that the upper 
end of the valve stem 1020 can be of the configuration of the valve stem 
410 of FIG. 1, and the inlet valve of FIG. 1, can be in the form of the 
lost motion inlet valve of FIG. 10. 
METHOD OF OPERATION OF THE SPRAY PUMP 
The pump 100 at rest, is illustrated in FIG. 1. The spring neck 704 biases 
the conical valve 402 in the upward position, thereby placing the conical 
upper end 402 in sealing engagement with the sealing edge 612. The 
interior surface of the piston is provided with a groove 624 to engage and 
retain the end loop 708 of the wide section of the compound spring 700. 
Simultaneously, the lower spring body 702 biases the piston 600 to its 
uppermost position, maintaining the piston's lateral extension 606 in firm 
contact and sealing engagement with the container cap seal 109. 
The next stage of operation is illustrated in FIG. 2, wherein the spray cap 
102 has been depressed against the compression resisting force of the 
spring body 702. During the first few pumping cycles, this action serves 
to prime the pump, by forcing the compressible air past the valve seal 
414. As the valve seal 414 passes into the region of the groove 520, the 
air is forced through the groove 520, past the valve seal 414 and into the 
chamber 516. As well known in the art, air is a compressible fluid, and 
therefore it would merely compress and expand without an appropriate 
priming step. The venting of the compressed air into the container body, 
by permitting the air to leak past the valve annular seal 414, serves to 
discharge the air from the piston chamber through the dip tube into the 
container. Once the air is discharged from the compression chambers 516 
and 616, after one or two stroke cycles, liquid is drawn into the vacuum 
thus formed in chambers 516 and 616. 
The fully depressed position is attained when the spray cap edge 106 comes 
into contact with the spray container cap ledge cap seat 108. 
Alternatively, the movement of the spray cap 102 toward the container cap 
120 can be limited by the lower edge of the piston receiving notch 110 
coming into contact with the cap ledge 124. 
The compression chamber includes both the upper compression area 616 and 
the cylinder compression area 516. The compression areas are bound by the 
interior surface 608 of the chamber 620, between the sealing edge 612 and 
the lower most edge 614, as well as the interior walls of the cylinder 
502. Within the cylinder 516, the compression area is defined by the 
exterior walls of the inner valve cylinder 504, and the outer surface of 
the valve stem 410. 
The compression causes the valve seal 414 to enter into the inner valve 
cylinder 504 in sliding, fluid tight engagement with the inner surface 
506. As the piston 600 and valve 400 are compressed, air is forced from 
the container along groove 520. 
The spray nozzle cap 102 is depressed against the force of the spring body 
702, decreasing the volume of the compression chamber until, as 
illustrated in FIG. 3, the fluid pressure between the conical valve 402 
and the inner surface 618 is greater than the force exerted by the spring 
neck 704. As stated heretofore, the coils of the spring neck 704 offer 
less resistance to compression than the lower spring body 702. Thus, when 
a predetermined compressive force is developed within the compression 
chambers 616 and 516, the pressure between the inner wall of piston 
chamber 608 and the conical discharge valve 402, forces the valve 400 in a 
downward direction. Thus, the sealing surface of the conical discharge 
valve 402 is moved away from its engagement with the valve engaging edge 
612, thereby permitting the fluid under compression to pass between the 
conical discharge valve 402 and the piston edge 612, as shown by arrows 
302, into the spray cap 102, and out through the spray nozzle 104, in the 
form of a mist. 
It should be noted that there is an increase in volume of the compression 
chamber, as the inlet valve end of the valve 400 moves downwardly within 
the inner cylinder 504. Concurrently, there is a decrease in volume of the 
compression, as the piston moves downwardly, toward the upper end of the 
inner cylinder 504. The change in volume due to the movement of the inlet 
valve is minimal compared to the change in volume which results from 
movement of the piston. The outer diameter of the valve stem 410 is close 
in size to the inner diameter of the inner cylinder 504, and therefore the 
volume between these two elements is small. The dimension difference 
between the outer diameter of the valve stem 410 and the inner diameter of 
the inner cylinder 504, is merely sufficient to accommodate the valve seal 
414. 
Once the finger pressure on the spray nozzle cap is released, the cap 102 
is permitted to rise under the force of the piston spring section 702. 
During the upward movement of the piston 600, the volume of the 
compression chambers 616 and 516 increases. The vacuum formed by this 
expansion draws the liquid upwardly through a dip tube (not shown), past 
the inlet valve seal 414, into the expanding compression chambers 616 and 
516. 
The piston compression chamber is now filled with liquid and is primed and 
ready to dispense liquid in the form of a fine spray or mist. 
______________________________________ 
GLOSSARY OF TERMS 
______________________________________ 
100 pump assembly 
102 spray cap 
104 spray nozzle 
106 spray nozzle cap lower edge 
108 container cap seat 
109 container cap seal 
110 piston receiving notch 
120 container cap 
122 flange indent 
124 cap ledge 
126 container seal 
400 valve 
402 conical upper discharge valve 
404 seal surface for discharge valve end 404 
410 cylindrical valve stem 
412 spring retaining groove 
414 inlet valve 
500 piston cylinder 
502 piston cylinder body 
504 piston inner valve cylinder 
506 inner surface of inner valve cylinder 504 
508 upper edge of inner valve cylinder 504 
510 flanged rim 
512 cylinder neck 
516 piston compression chamber 
518 dip tube entry 
520 vent groove 
600 piston 
602 piston stem 
604 seat for nozzle cap 
606 lateral seat 
608 inner wall of piston chamber 
610 piston spring seat 
612 piston 600, valve engaging edge 
616 piston cylinder compression area 
618 piston head 
620 piston chamber 
622 piston flow tube 
624 piston skirt inner groove 
626 piston spring seat clearance 
700 compound spring 
702 piston spring section of compound spring 700 
704 valve section of compound spring 700 
706 spring retaining groove 
1004 dual action spring 
1005 upper section of dual action spring 
1007 upper loop of upper section 1005 
1008 seat for lower end of dual action spring 
1009 flange surface of outlet valve 1024 
1010 lost motion valve 
1020 valve stem 
1022 reduced diameter region of valve stem 
1024 outlet valve region at upper end of valve stem 1020 
1026 upper surface of outlet valve 1024 
______________________________________