PATENT ABSTRACT
A disposable dispensing device for storing and dispensing fluids, such as liquids and gels is disclosed. The dispensing device is a scalable packaging solution including an outer protective housing or shell, optionally a fluid reservoir, and an orifice from which the materials are expelled. The dispensing device can also include a dispensing button that activates an internal pumping system via an actuator mechanism that translates a force in a first direction into a force in a second direction. The dispensing device is particularly useful for liquids such as fragrances or colognes, gels, purified water, dry powders, creams, and pharmaceutical products such as eye ear drops or sprays. The device by design has many uses, is highly portable, and can include an outer reusable and decorative case.

PATENT DESCRIPTION
CROSS-REFERENCE TO RELATED APPLICATION 
   This application claims priority under 35 U.S.C. §371 to international application number PCT/US2004/032677, filed on Oct. 4, 2004, which in turn claims priority to U.S. Provisional application No. 60/508,533, filed on Oct. 2, 2003. The subject matters of these applications are incorporated herein by reference in their entireties. 
   This applications claims the benefit of priority of U.S. Provisional Patent Application No. 60/508,533, filed on Oct. 2, 2003, the contents of which is incorporated herein by reference in its entirety. 

   TECHNICAL FIELD 
   This invention relates to self-contained, portable dispensing systems that can store and dispense fluids such as fragrances, colognes, gels, and creams. 
   BACKGROUND OF THE INVENTION 
   Many consumer products, such as those used for personal care and hygiene, come in the form of liquids, creams, or gels that are sprayed or otherwise applied to the skin, eyes, or mouth. Such products are typically stored in jars, tubes, or bottles that contain sufficient quantities of the product to provide multiple applications, but are not always convenient or safe for travel or for being carried in a purse or pocket. 
   SUMMARY OF THE INVENTION 
   The invention provides a unique packaging solution in the form of a highly functional and portable dispensing system for commercially available consumer products by way of metered dose(s). The range of products that the new systems can store and dispense is limited only by their size and internal pump design(s). 
   In general, the invention features fluid dispensing devices that include a hollow housing comprising one or more walls; an orifice arranged to pass through a wall of the housing; an optional reservoir that fits into the hollow interior of the housing; a pump that fits into the reservoir and includes a nozzle that contacts the orifice; and an actuating mechanism that contacts the pump; wherein a force applied to a portion of the actuating mechanism in a first direction causes the actuating mechanism to move the pump in a second direction, and causing it to expel fluid from the reservoir through the nozzle and out of the device through the orifice. 
   In these devices, the housing can include a lower shell and an upper shell connected to the lower shell to enclose a hollow interior. The devices can further include a dispensing button arranged in a wall of the housing to contact a portion of the actuating mechanism. In certain embodiments, the pump and the reservoir move together as one unit upon actuation. 
   In some embodiments, the actuating mechanism can include one or more front arms that contact the pump via a pressure plate secured to the pump, and one or more rear arms that rest against the housing. For example, the one or more rear arms can rest against a recess in, or protrusion extending from, a wall (e.g., bottom wall or floor) of the housing. In other embodiments, the actuating mechanism can include a body having a front portion and a rear portion connected by a hinge, wherein the front portion includes a first cutout and two front arms, one front arm being located on each side of the first cutout, configured to fit over the pump, and wherein the rear portion includes a second cutout and two rear arms, one rear arm being located on each side of the second cutout, configured to fit over the pump. The actuating mechanism can further include a tab attached to the rear portion that extends through a third cutout in the front portion when the actuating mechanism is bent at the hinge. The actuating mechanism can be made of plastic, and the hinge can be a living hinge. 
   In other embodiments, the actuating mechanism can include two elongated parts, each part having a front arm, a rear arm, and hinge connecting the two arms, and wherein the two elongated parts are arranged one on each side of the pump. For example, the two elongated parts can be attached to each other by a connecting bar, and the parts can be made of plastic, with the hinge being a living hinge. 
   In these devices, the reservoir can include two fluid chambers arranged one on each side of the pump chamber, and that are in fluid communication with each other and the pump chamber. The reservoir can include at least one fluid chamber and a pump chamber, and the pump fits into the pump chamber. The pump can include a body, a nozzle, and a spring within the body to press the nozzle out of the pump when pressed into the body by an external force, wherein the body, nozzle, and spring are aligned along one central axis. The devices can further include an orifice cup configured to fit into the orifice, for controlling the dispensing pattern of the fluid as it is expelled from the nozzle, e.g., as a spray, stream, mist, or drop of fluid. 
   In certain embodiments, the actuating mechanism includes one or more actuating arms having an angled face; and the device further includes a pump mount connected to the pump having a wedge surface that is arranged to contact the angled face of the actuating arm. In this arrangement, pressure on a portion of the actuating mechanism in a first direction causes the one or more actuating arms to move, causing the angled face to press against the wedge surface, causing the wedge surface and the pump to move in a second direction, and causing the pump to expel fluid from the reservoir through the nozzle and out of the device through the orifice. 
   In these devices, the first and second directions can be at approximately 80 to 100 degrees, e.g., approximately 90 degrees, to each other. 
   In another aspect, the invention also includes cases for the new fluid dispensing devices. These cases include a container configured to enclose the dispensing device, and a cover configured to allow the dispensing device to be inserted into and removed from the container. The covers of these cases can further include a portion that covers a dispensing button of the dispensing device. The cases can have a round, square, or rectangular profile, or have the shape of an animal, a flower, a heart, or a face. 
   In another aspect, the invention includes methods of dispensing a fluid by obtaining one of the new dispensing devices and applying a force to a portion of the actuating mechanism to expel one measured dose of fluid in the device. The device can be obtained pre-filled with a fluid, or the user can fill a desired fluid into the device. In these methods, applying a force to a portion of the actuating mechanism includes applying a downward force on a hinged actuation mechanism that converts the downward force into a force in a second direction within the dispensing device, and causes the pump to move and to expel fluid through the nozzle and out of the device through the orifice. The methods can be used to dispense perfume, water, mouthwash, deodorant, antiperspirant, cologne, pepper spray, or skin lotion. 
   The new dispensing systems are relatively inexpensive and disposable and can be used for many different products and for many different occasions, and are thus ideal for mass-market distribution. Metal versions of the same designs can be made to be more durable and non-disposable. 
   Other embodiments include ornamental and/or fashion accessories, e.g., cases, as well as external designs of the device and/or case that are in the shape of animals or other “fun” shapes. These devices can be filled with, e.g., “younger” scents and/or aroma type products that are designed to appeal to children or teenagers. 
   The new devices have clear advantages over similar size sampling type dispensers, offering their users the convenience of multiple uses in metered doses in the form of a spray, mist, stream, or drops. The device can be personally stored between uses. In addition, the new devices offer a scalable design that can be altered for both functional and ornamental presentation. 
   Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described below. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the present specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting. 
   The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims. 

   
     DESCRIPTION OF DRAWINGS 
       FIG. 1A  is a cross-section of one embodiment of the new portable dispensing device. 
       FIGS. 1B to 1D  are side, top, and cross-sectional views, respectively, of the outer shell of the dispensing device of  FIG. 1A . 
       FIGS. 2A to 2C  are side, top, and cross-sectional views, respectively, of the outer shell lid and dispensing button. 
       FIGS. 3A to 3C  are front, top, and side views, respectively, of a pressure plate that fits over and contacts the end of a pump. 
       FIGS. 4A to 4C  are front, bottom, and side views, respectively, of a one-piece hinged actuating mechanism that fits over and is used to actuate the pump. 
       FIG. 4D  is a schematic view of an alternative embodiment of a hinged actuating mechanism with two separate parts, optionally attached to each other by a connecting bar. 
       FIGS. 5A and 5B  are front views of a reservoir cover and reservoir, respectively. 
       FIG. 5C  is a front view of the reservoir and cover as assembled. 
       FIG. 5D  is a top view of the reservoir. 
       FIG. 5E  is a back view of the reservoir. 
       FIG. 5F  is a side view of a suitable pump for use in the new dispensing devices. 
       FIG. 6A  is a side, cross-sectional view of a dispensing device in its resting position. 
       FIG. 6B  is a top, cut-away view of the dispensing device in its resting position. 
       FIG. 7A  is a side, cross-sectional view of the dispensing device at its end of stroke position. 
       FIG. 7B  is a top, cut-away view of the dispensing device at its end of stroke position. 
       FIGS. 8A to 8C  are side, top, and top with open case views, respectively, of a round case embodiment. 
       FIGS. 9A to 9C  are side, top, and top with open case views, respectively, of a rectangular case embodiment. 
       FIGS. 10A to 10C  are side, top, and top with open case views, respectively, of a square case embodiment. 
       FIG. 11  is a three-quarter view of the dispensing device minus the outer lid (cover or top “shell”) and dispensing button. 
       FIG. 12  is a three-quarter view of the actuating assembly with mounted pump. 
       FIG. 13  is a top-front view of the dispensing device without the cover (top “shell”) showing the orifice cup. 
       FIG. 14  is a side view of the actuating mechanism and pump minus reservoir and pump housing. 
       FIG. 15A  is a three-quarter view of an alternative embodiment of a portable dispensing device. 
       FIG. 15B  is an “exploded” view of the embodiment of  FIG. 15A . 
       FIG. 16  is a top view of the assembled device of  FIG. 15A . 
       FIG. 17  is a side cross-sectional view of the device of  FIG. 15A . 
       FIG. 18A  is three-quarter view of a dispensing actuator button of the device of  FIG. 15A . 
       FIG. 18B  is a side view of the dispensing actuator button as inserted in the device of  FIG. 15A . 
   

   Like reference numerals refer to like elements of the devices represented in these figures. Any dimensions shown in the figures are exemplary. 
   DETAILED DESCRIPTION 
     FIG. 1A  shows a side, cross-sectional view of dispensing device  20  having a housing  21  that in this embodiment includes a bottom shell  30 , a top shell  32  that connects to, e.g., fits into, the bottom shell, e.g., with a press fit (and/or glue or other mechanism, e.g., a heat seal), and a dispensing button  40  situated in the top shell. Bottom shell  30  has a sidewall  31  that includes an opening  26  at one end and recesses  28  at an end opposite the opening  26 . The bottom and top shells fit, e.g., snap, together to form the device  20  with a hollow interior  22 . All other parts of the device fit within this hollow interior  22 . Dispensing button  40  can also be hollow, and is arranged in top shell  32  so that it can be depressed into the device. Dispensing button  40  can be made of any elastic material, including rubber or neoprene, and can be fixed, e.g., glued, onto the top shell  32 . The top and bottom shells can be made of any plastic, e.g., polyolefin or polystyrene, and can be made by various known methods, such as injection molding or machining solid plastic. Housing  21 , e.g., shells  30  and  32 , can also be made of metal, e.g., by stamping and/or machining. 
   In other embodiments, housing  21  includes separate sidewalls (e.g., a cylinder), a bottom, and a top, that fit together to form a sealed container, which houses the other parts of the system. The top can be flexible or compressible, so that it forms dispensing button  40  without the need for a separate button. Instead, the user merely presses on the flexible top to contact and apply force to the actuating mechanism  60 , described in further detail below. 
   The contents of the dispensing device include a pump  50  including a nozzle  52  at one end (e.g., the “top”), and a pressure plate  45 , which fits over and is secured to the top of pump  50 . A reservoir  70  is also included within hollow interior  22  of device  20 . Pump  50  includes an internal spring  51  (as seen through the clear plastic of the pump in  FIG. 14 ). An orifice cup  35  fits into opening  26  in sidewall  31  of the bottom shell  30 , and has an opening at the bottom that fits snugly over nozzle  52  with a watertight seal (e.g., by glue or press fit). Orifice cup  35  controls the dispensing pattern of the dispensing device. The device can dispense the liquid as a fine mist, spray, stream, or droplets. 
   Interior space  22  also contains an actuating mechanism  60 , e.g., a hinged actuating mechanism, which will be described in further detail below for various embodiments.  FIGS. 1B-1C  show side, top, and side cross-sectional views of the bottom shell  30 .  FIG. 1C  shows the bottom shell having a round configuration, but various other shapes can be made.  FIGS. 2A-2C  show side, top, and side cross-sectional views of the top shell  32 .  FIG. 2C  shows how dispensing button  40  extends slightly beyond the plane of the top shell. In other embodiments, the button can be flush with the surface, or slightly below the surface. 
     FIGS. 3A-3C  show various views of pressure plate  45 . This plate is designed to fit over the standard pump  50 , and to provide a contact point for the front arms  62  of the hinged actuating mechanism  60 . Pressure plate  45  can be made of metal, e.g., stainless steel or aluminum, and can be manufactured by stamping and bending metal sheeting. Pressure plate  45  can also be made from stiff plastic, e.g., by injection molding or milling. 
     FIGS. 4A-4C  show various views of hinged actuating mechanism  60 . Mechanism  60  includes an upward jutting tab  66  that rests against the underside of dispensing button  40 . The mechanism also includes downward facing sidewalls  67  (that provide rigidity) and front and rear cutouts  68 A and  68 B that allow the mechanism to be bent at its hinge  63 , and still fit over pump  50 . In certain embodiments, actuating mechanism  60  is made of one part, e.g., of plastic, with a living hinge  63  in the middle, or can be made of two or more parts and connected, e.g., by glue or by melting the two parts together, to form hinge  63 . Tab  66  fits within cutout  61 . 
   Living hinges are thin sections of very flexible plastic, such as polyethylene or polypropylene, which connect two segments of a part to keep them together and allow the part to be bent repeatedly. These hinges must be processed properly. For example, the molecules of plastic in the hinge should be oriented along the hinge line for the hinge to have an acceptable life. For example, one can orient the gate location to allow the plastic to flow across the hinge for maximum strength. In addition, when the hinge is removed from a mold, it can be flexed a minimum of two times while it is still hot, for optimum strength. 
   The actuating mechanism  60  includes two front arms  62  and two rear arms  64  (as best seen in  FIG. 4B ). The front arms rest against pressure plate  45 . Rear arms  64  of the hinged actuating mechanism can rest within recesses  28  in sidewall  31  of the bottom shell  30 . In this embodiment, hinge  63  of the actuating mechanism  60  extends above the plane of the top shell  32  through an opening  33 . Dispensing button  40  is located over, or covers, hinge  63 . Actuating mechanism  60  can be made by injection molding or casting and/or machining. This part can also be made of metal. In other embodiments, all parts of actuating mechanism  60  are within, and do not extend beyond, housing  21 . 
   In alternative embodiments, actuating mechanism  60  can be formed of two separate elongated parts ( 60 A and  60 B), each with its own living hinge, e.g., as shown in  FIG. 4D . In this embodiment, each of the two parts comprises a front arm  62 A and a rear arm  64 A connected by living hinge  63 A. The two parts are inserted into housing  21  on either side of pump  50 . The front arms  62 A contact pressure plate  45  (e.g., with a cutout recess), and the rear arms  64 A can contact recesses  28 , much the same way as the front and rear arms of the one-piece design shown in  FIGS. 4A-C . The two separate parts can be attached to each other with connecting bar  69 . Alternatively, rear arms  64 A can contact a ridge or protrusion  64 B on the floor of bottom shell  30 . This approach can also be used with the one-piece actuating mechanism described above. 
   In both embodiments, the actuating mechanism translates force applied to the dispensing button  40  in a first direction (e.g., a downward force) into a force on the pressure plate  45  in a second direction (e.g., a lateral force) to move the pump towards a sidewall of the housing  21  and dispense liquid from the nozzle  52  and orifice cup  35 . The first direction can be about 70 to 110°, 75 to 105°, or 80 to 100°, e.g., about 90° (e.g., perpendicular), to the second direction. 
     FIGS. 5A to 5E  show different views of a reservoir  70 , which contains the liquid or gel consumer product, such as perfume, mouth wash, purified water, deodorant, antiperspirant, cologne, pepper spray, skin lotion, aroma therapy, or metered eye or nose sprays or drops. Reservoir  70  is made of hollow plastic or metal, has a cover  72 , and includes a pump chamber  55 , into which pump  50  is inserted, e.g., with a press fit, but that allows liquid from the other chambers of the reservoir to reach the back end of the pump. Reservoir  70  includes at least one, e.g., two, liquid chambers  70   a  and  70   b  (as best seen in  FIG. 5D ), and these are both in fluid communication with pump chamber  55 , so that when pump  50  is inserted into pump chamber  55 , and reservoir  70  is filled with a liquid, pump  50  is immersed in the liquid and can withdraw liquid from the reservoir though its back end  58 . The back end of the two liquid chambers and the pump chamber  55  are in fluid communication via cross-chamber  71 . Recesses  73  in the top of the reservoir provide space for the rear arms  64  of the actuating mechanism to contact recesses  28  in the lower shell  30 . In certain embodiments, the housing (which can be made watertight) itself forms the reservoir, and no separate reservoir is included. Thus, the reservoir is optional. 
   Pump  50  is a stock item, e.g., it can be a so-called “Replica™” pump made by Valois America. Other pumps of the appropriate size and configuration can be used. For example, the Replica pump is shown in  FIG. 5F . The neck gasket  56  and ferrule  57  of the pump are connected to pressure plate  45  and reservoir  70 . Pressure plate  45  has a hole and fits over the pump  50  from the rear and is stopped at the top of pump  50  by neck gasket  56 . Pump  50  and pressure plate  45  are then inserted into reservoir  70 , which secures the pressure plate  45 , e.g., by being “sandwiched.” Pump  50  dispenses liquids and gels from nozzle  52 , and liquids and gels enter into back end  58 . The main aspects of the pump are that it has a nozzle that extends into the orifice cup or out of the housing, and has an internal spring that allows the nozzle to be pressed into the pump and then be forced out of the pump by the spring. Pump  50  is pressure fitted into, glued, or otherwise connected to the hole at the front of reservoir  70  to form a liquid-tight seal. 
   The reservoir can be filled in the factory before the cover is secured to the reservoir (e.g., for disposable embodiments). Reusable embodiments of the device can include an access port and stopper, e.g., a threaded or press fit stopper (not shown) in the reservoir to enable consumers to fill various liquid or gel products into the reservoir. 
   From its resting position as illustrated in ( FIGS. 6A and 6B ) device  20  is operated by pointing the orifice cup  35  in the direction one wishes to manually release its contents, and pressing outer dispensing button  40 , mounted in the top shell  32  (or in some embodiments, by merely pressing on the top shell if it is flexible). This action starts the actuating process by means of pressure, e.g., downward pressure (arrow  80 ), applied to tab  66  of hinged actuating mechanism  60  (or directly on living hinge  63 ). The hinged actuating mechanism  60  moves in a downward motion causing it to flatten lengthwise and move pressure plate  45  towards the orifice cup  35  in the direction of arrow  81 . Rear arms  64  of hinged actuating mechanism  60  are securely seated in recesses  28  in the lower shell  30  (or contact projections  64 A in the floor of the housing), and thus cannot move laterally within the lower shell  30 . Front arms  62  are seated on the pressure plate  45 , which is fitted over horizontally mounted pump  50 , and when button  40  (or top shell  32 ) is pressed downwards, these arms are the only part of the actuating mechanism that can move laterally within the bottom shell  30 . As a result, pressure plate  45  moves laterally, and pulls the entire pump  50  and reservoir  70  with it, towards orifice cup  35  as shown in  FIGS. 7A and 7B . 
   This lateral movement causes the nozzle  52  to be pressed into pump  50 , causing it to expel one measured dose of the contents of reservoir  70  in a predetermine discharge pattern, e.g., a spring, stream, and drop, depending on the liquid and dosage or amount to be dispensed. By releasing dispensing button  40 , spring  51  inside pump  50  causes nozzle  52  to be pressed out of the pump, thereby moving pressure plate  45  laterally away from the orifice cup, and moving the pump and the reservoir away from the orifice cup as well. As a result, hinged actuating mechanism  60  is bent upwards, in preparation for the next actuation. Mounting the dispensing button  40  flush into the top shell  32  provides an accidental discharge safety feature. 
   The new dispensing devices offer high consumer portability and same package multi-application(s), with an ornamental design that can be cosmetically altered by way of production materials or methods and/or after market accessories. Thus, the housing  21  of the devices themselves can be circular, elliptical, rectangular, triangular, or other shapes. In addition, as shown in  FIGS. 8A-C , sturdy plastic or metal cases  80  can be manufactured to allow the new dispensing devices  20  to fit inside. Each case  80  includes a cover  82  that includes a portion  84  that covers dispensing button  40 , and can be provided with a company name, advertising slogan, or other insignia, e.g., by engraving or laser or other printing techniques. Dispensing devices  20  can be disposable or refillable, and case  80  can be reused over and over by inserting a new device  20 . Case  80  can be made of machined or stamped and bent metal, such as aluminum. Alternatively, case  80  can be made of clear or colored plastic using standard techniques. 
     FIG. 11  shows a view of a prototype of dispensing device  20  with top shell  32  and dispensing button  40  removed. Orifice cup  35  is inserted into opening  26  and rear arms  64  of actuating mechanism  60  are inserted into recesses  28 . Pump  50  is seen below actuating mechanism  60 . 
     FIG. 12  shows a view of the “insides” of dispensing device  20 , including reservoir  70 , pump  50  with nozzle  52  connected to orifice cup  35 , pressure plate  45 , and actuating mechanism  60 .  FIG. 13  shows a front view of device  20  showing orifice cup  35  inserted in opening  26  in sidewall  31  of bottom shell  30 . 
     FIG. 14  shows actuating mechanism  60  connected to pressure plate  45  by its front arms  62 , which, in turn, is connected to pump  50  (including spring  51 ). 
     FIG. 15A  shows an alternative embodiment of the portable dispensing device.  FIG. 15B  shows an “exploded” view of this device. This second embodiment of the device includes a housing  100  with a base  102 , and a lid  104 . Dispensing button  106  is inserted into housing  100  and protrudes through lid  104 . Button  106  has a flange  107  that prevents it from being pulled out of the device through opening  105  in lid  104 . 
   Reservoir  108  fits inside housing  100  and is connected, e.g., by a pressure fit, to pump mount  110 . Pump  50  fits securely in pump mount  110 , and is inserted into reservoir  108 . Reservoir neck  109  is press fit or threaded into opening  111  in pump mount  110 , thereby sealing pump  50  inside reservoir  108 . 
     FIG. 16  shows a top view of this device.  FIG. 17  is a side cross-sectional view of the device along section line A-A in  FIG. 16 . When pump  50  is moved forwards (to the right in  FIG. 17 ), nozzle  52  is pressed into the pump, thereby drawing liquid from reservoir  108  and expelling it through orifice  101  in housing  100 . In this embodiment, there is no need for an orifice cup, but one can be used. 
     FIG. 18A  shows dispensing button  106  and its actuating arms  120  (the second arm is not visible in this figure). The two actuating arms straddle pump mount  110  (which is similar to pressure plate  45 ). As best seen in  FIG. 18B , each actuating arm  120  has an angled face  122  that contacts a wedge  112  on either side of pump mount  110 . 
   When dispensing button  106  is pushed downward, the two angled faces  122  are pressed against the two wedges  112  on either side of pump mount  110 . This pressure, in turn, forces the wedges, and thus the pump mount, pump, and reservoir, to move horizontally (laterally) forwards (right in  FIG. 18B ). This causes nozzle  52  of pump  50  to be pressed into the pump causing it to expel liquid drawn from reservoir  108 . In other respects, this device is similar to the first embodiment described herein. 
   Thus, in all embodiments, a force in a first direction (e.g., downwards) is applied to a surface of the device, or a dispensing button, which contacts an actuator mechanism that translates the force into a second direction (e.g., horizontally or laterally), which is approximately (or exactly) at 90° to the first direction. The force in the second direction moves an internal pump towards a wall of the device, causing a nozzle of the pump to be pushed into the pump to dispense liquid contained in the housing or reservoir in the housing. 
   OTHER EMBODIMENTS 
   It is to be understood that while the invention has been described in conjunction with the detailed description thereof, the foregoing description is intended to illustrate and not limit the scope of the invention, which is defined by the scope of the appended claims. Other aspects, advantages, and modifications are within the scope of the following claims.