Spray dispensing device

Abstract: A spray dispensing device is provided which can be used with a non-pressurized container (1). The device includes passageways for directing streams of air (13, 14) and liquid (4, 6, 9, 12) to a mixing chamber (15) wherein the liquid is broken up into droplets and emitted as a fine spray through an orifice (16). A valve (10) allows manual adjustement of air-liquid ratio of the mixture which emanates from the spray orifice (16). The device includes also a dip tube (3) for the liquid (2) which is provided with a check valve (7, 8) for retaining liquid at a high level in the dip tube after each spray cycle so that spraying is nearly instantaneous upon actuation.

Description: The invention relates to a spray dispensing device for atomizing a liquid. Although squeeze bottle type sprayers have been used for many years, such sprayers were largely replaced for a long period of time by pressurized can dispensing systems. A major advantage to the use of pressurized cans is the nearly instantaneous spraying which occurs upon actuation. However, there has been an increasing concern over the harmful effects on the atmosphere of the propelling gases, such as fluorocarbons, which are used in such pressurized cans. In addition, pressurized can dispensing systems are relatively expensive to manufacture. Accordingly, squeeze bottle type sprayers and manual pump sprayers have become more prevalent in recent years. Products which can be dispensed in the form of a spray can be easily atomizable liquids, such as water based materials, or viscous materials which are more difficult to atomize such as oil based materials. In the case of a pressurized can there is sufficient force available for mechanical means to break up liquid droplets into a fine spray. However, in squeeze bottle type sprayers the force required to break up droplets must be supplied manually, that is by squeezing the bottle. Therefore, it is much more difficult to achieve a high degree of atomization with such bottles. Squeeze bottle type sprayers typically utilize a dip tube for directing liquid to a mixing chamber. Upon squeezing the bottle, air located above the liquid level is forced under pressure through a passage toward the mixing chamber where it impinges on a stream of the liquid in an effort to break up the liquid into droplets. The liquid is dispersed in a spray pattern through an orifice in the mixing chamber. A drawback to spray dispensing devices is that it has not been possible to effectively vary the liquid to air ratio of the dispensed spray. For example, U.S. Patent No. 4,401,270 describes a typical squeeze bottle type sprayer which can dispense liquid in only two possible spray patterns, either a pure liquid stream or an air-liquid mixture having a fixed liquid/air ratio. US-A-2,617,686 discloses a spray dispensing device which does permit the liquid/air ratio to be varied. US-A-4,186,882 discloses a spray dispensing device in which liquid and air are discharged in the same direction into a mixing chamber and that direction points towards the discharge orifice for the resulting spray. According to a first aspect of the present invention, there is provided a spray dispensing device, for use with a non-pressurized container holding a volume of a liquid and air above the liquid wherein said container is actuable by squeezing it to force liquid through a dip tube of said spray dispensing device, said spray dispensing device comprising: a dispenser housing defining a cavity therein, with an air orifice and a liquid orifice being defined through said housing and a spray orifice being defined at a terminal point of a tapered section of said housing, said tapered section defining a mixing chamber therein; a dip tube extending from an underside of said housing and communicating with said liquid orifice; and a valve received in said cavity and terminating at said mixing chamber, said valve defining a liquid passageway therein, said liquid passageway communicating with said mixing chamber and with said liquid orifice, and said valve and said dispenser housing defining an air passageway therebetween which is concentrically disposed around said liquid passageway, said air passageway communicating with said mixing chamber and with said air orifice; wherein a section of said liquid passageway points towards said mixing chamber and said spray orifice in a first direction and communicates with said mixing chamber at a location which is directly opposite to said spray orifice, and wherein said air passageway points towards said mixing chamber in said first direction and communicates with said mixing chamber at a location which is directly opposite to said tapered section of said dispenser housing; the arrangement being such that, upon actuation of said container, a stream of air from said air passageway is deflected by said tapered section to converge and impinge upon a core stream of liquid from said liquid passageway in said mixing chamber to atomize the stream of liquid; characterized in that said valve is selectively movable within said cavity between at least: a first position wherein said air passageway communicates with said air orifice and wherein said liquid passageway communicates with said liquid orifice and said dip tube to define a first extent of communication between said dip tube and said mixing chamber, whereby a first stream of air can pass through said air orifice, through said air passageway and into said mixing chamber at a first air flow rate, and a first stream of liquid can pass through said dip tube, through said liquid orifice, through said liquid passageway and into said mixing chamber at a first liquid flow rate to engage the first stream of air such that a liquid-air mixture, having a first ratio of liquid to air, can emanate from said spray orifice as a spray; and a second position wherein said air passageway communicates with said air orifice and wherein said liquid passageway communicates with said liquid orifice and said dip tube to define a second extent of communication between said dip tube and said mixing chamber which is greater than said first extent of communication, whereby a second stream of air can pass through said air orifice, through said air passageway and into said mixing chamber at a second air flow rate which is equal to said first air flow rate, and a second stream of liquid can pass through said dip tube, through said liquid orifice, through said liquid passageway and into said mixing chamber at a second liquid flow rate, which is greater than said first liquid flow rate, to engage the second stream of air such that a liquid-air mixture, having a second ratio of liquid to air which is greater than said first ratio, can emanate from said spray orifice as a spray. According to a second aspect of the present invention, there is provided a squeeze bottle sprayer which is actuable upon squeezing a bottle to force liquid up a dip tube and emit a liquid air-spray through a spray orifice, comprising: a squeezable bottle containing a volume of liquid and air above the liquid; and a spray dispensing device according to the first aspect of the present invention, wherein said spray dispensing device is mounted on said bottle and has its dip tube extending into said volume of liquid and has its air orifice in communication with said air above said liquid. A non-limiting embodiment of the present invention will now be described with reference to the accompanying drawings, in which:- FIG. 1 is a cross-sectional view of a spray dispensing device in accordance with the invention, mounted on a squeeze type bottle, illustrating the valve in its fully open position; FIG. 2 is the same cross-sectional view which is illustrated in FIG. 1, but with the valve in its fully closed position; FIG. 3 is a perspective view of a squeeze bottle which includes a spray dispensing device in accordance with the invention; and FIG. 4 is a segmented view of a spray dispensing device is accordance with the invention which illustrates the individual components of the device. Referring now more particularly to the drawings, and to those embodiments of the invention here chosen by way of illustration, it will be seen in FIG. 1 of the drawings that the embodiment of the spray dispensing system will be described in connection with a squeezable bottle 1 holding a quantity of a liquid or other fluent material 2. Squeezable bottle 1 can be made from any suitable plastic known in the art. A spray dispensing device housing 17 is adapted to be mountable atop a neck 5 of bottle 1. The device includes a dip tube 3 which is sized so that its bottom open end 4 is disposed near the bottom of bottle 1 when the spray dispensing device is mounted on the bottle. The top end of dip tube 3 receives a restricted conduit 6 of a ballcheck valve 7. Restricted conduit 6 communicates with dip tube so as to allow fluid 2 to pass therethrough. The inner diameter of restricted conduit 6 is smaller than the diameter of ball 8 of ballcheck valve 7 so that ball 8 ordinarily sits atop restricted conduit 6. When ball 8 is in this position, the ballcheck valve 7 is closed so that the top end of dip tube 3 is also closed. The inner diameter of the remainder of ballcheck valve 7 is larger than the diameter of ball 8. In this way ball 8 is free to move upward in response to upward movement of fluid in the dip tube to open ballcheck valve 7. The top of ballcheck valve 7 receives a coaxially disposed feed tube 9 which allows for the passage of fluid from restricted conduit 6 toward valve 10. Feed tube 9 has an inner diameter which is smaller than the diameter of ball 8 so as to limit the movement of ball 8 in an upward direction. Therefore, feed tube 9 is positioned a small distance upward from ball 8 so that ball 8 is free to move upward to open ballcheck valve 7. For simplicity of construction feed tube 9 is an extension of a valve wall 11 of housing 17. Feed tube 9 of valve wall 11 can communicate with a product passageway 12 within valve 10 when valve 10 is in an open position, which will be described. Valve wall 11 is also provided with an air orifice 13 which can communicate with an air passageway 14 within valve 10 when valve 10 is in an open position. Valve 10 is rotatably received in the cavity between valve walls 11 and 18 of spray dispenser housing 17. Tapered portions 19 and 20 of valve walls 11 and 18, respectively, define a cavity therebetween which shall be referred to as mixing chamber 15. Product passageway 12 leads to mixing chamber 15 in a generally horizontal direction. It can be seen from FIGS. 1 and 2 that air passageway 14 is an annular passageway which is concentrically disposed around the horizontal portion of product passageway 12 and also leads to mixing chamber 15 in a horizontal direction. Tapered portions 19 and 20 terminate before meeting to define spray orifice 16 of mixing chamber 15. Housing 17 is connected to the top of bottle neck 5 by a ring 21. Ring 21 may be a screw cap whose inner surface is provided with helical threads 26 defining grooves which are engageable with helical threads 22 on the outer surface of neck 5. An outwardly extending lip 23 around the bottom periphery of housing 17 engages with an inwardly extending lip 24 of ring 21 to lock housing 17 onto bottle neck 5. A foam gasket 25 may be provided between lip 23 and the top of bottle neck 5 for enhanced sealing. The spray dispensing device can be conveniently removed from bottle 1 as a unit by simply unscrewing ring 21 to separate housing 17 from bottle neck 5. This feature has the advantage of allowing the bottle 1 to be refilled with product 2. The spray dispensing system is then easily reconnected to bottle neck 5 by ring 21. Valve 10 is housed within the cavity between valve walls 11 and 18 of housing 17. Valve 10 is rotatable about its longitudinal axis between a completely closed position (FIG. 2) and a completely open position (FIG. 1). In the completely closed position (FIG.2) the product passageway 12 is not aligned with the feed tube 9. As illustrated in FIG. 2, in this position the body of valve 10 completely seals off feed tube 9. The structure of valve 10 is such that as the valve is rotated toward the completely open position, the air passageway 14 first becomes aligned with air orifice 13 before product passageway 12 begins to communicate with feed tube 9. Upon continued rotation of the valve toward the completely open position, the product passageway begins to communicate with feed tube 9, allowing a certain extent of communication between the feed tube and mixing chamber so that a thin stream of liquid can pass to the mixing chamber 15 at a certain flow rate. The flow rate is the volume of liquid which can flow per unit of time through the feed tube, through the product passageway and into the mixing chamber. Upon continued rotation of the valve toward the completely open position, the extent of the communication between feed tube 9 and product passageway 12 increases, thereby increasing the extent of communication between the feed tube and the mixing chamber to allow a thicker stream of liquid to pass to the mixing chamber ( i.e. , an increased flow rate). However, the extent of communication between air orifice 13 and mixing chamber 15 is already at its constant maximum before product passageway 12 even begins to communicate with feed tube 9. Therefore, the ratio of liquid to air which is delivered to the mixing chamber will increase as the valve 10 is rotated toward the completely open position thereby increasing the wetness of the spray. In the completely open position of valve 10, the extent of communication between product passageway 12 and feed tube 9 is at a maximum so that the ratio of liquid to air delivered to the mixing chamber is at a maximum. Thus, it can be seen that the wetness of the spray can be controlled by adjusting valve 10. It should be appreciated by those skilled in the art that variations in the design of valve 10 are possible. For example, instead of being rotatable, the valve may be slidable so that the extent of communication between the product passageway 12 and feed tube 9 varies upon sliding motion of the valve. In the preferred embodiment the valve 10 is rotatable 90° from the completely closed position (FIG. 2) to the completely open position (FIGS. 1 and 3). The operation of the preferred embodiment of the invention as used with a squeeze bottle will now be explained by describing the path of fluid and air. Upon squeezing the bottle 1 the pressure inside the bottle increases urging fluid 2 up dip tube 3. Fluid is forced through restricted conduit 6 and pushes ball 8 upward off of the top of conduit 6 thereby opening ballcheck valve 7. The fluid is then free to flow into feed tube 9 toward product passageway 12. From passageway 12 the fluid stream is injected into mixing chamber 15 in a horizontal direction. Upon squeezing the bottle the increase in pressure also forces air above the fluid level in the bottle through air orifice 13 into air passageway 14. It can be seen that the distance which must be travelled by the air to reach the mixing chamber 15 is less than the distance which must be travelled by the liquid so that liquid does not reach the mixing chamber before the air. In this way, it is made certain that the fluid is mixed with air before emanating from orifice 16. The air stream also enters the mixing chamber 15. Tapered portions 19 and 20 of valve walls 11 and 18 direct the air stream to converge and impinge upon the horizontal core stream of liquid at an acute angle. When liquid flows into the mixing chamber it is swirled around by the angular flow of air. The liquid is subjected to considerable turbulence which breaks it up and intimately mixes it with the air. The result is that a fine spray is propelled out of orifice 16. When pressure is released on the container it returns to its original shape as external air is drawn into the container through orifice 16. The drawing of air through orifice 16 cleans the orifice and the mixing chamber 15 after each squeeze cycle thereby inhibiting clogging of the orifice. This self-cleaning feature is particularly advantageous in the case of a viscous product where clogging is most frequently encountered. The release of pressure also causes liquid to drop down feed tube 9 which helps ball 8 to drop thereby closing the top of restricted conduit 6. It will be appreciated that the closing of conduit 6 by ball 8 will trap liquid in feed tube 3. Thus, during the next squeeze cycle product will already be at a very high level in the dip tube so that less time will transpire before spray is emitted. In this way the spray dispensing device achieves nearly instantaneous spraying without the need for a pressurized container.

Claims: A spray dispensing device, for use with a non-pressurized container (1) holding a volume of a liquid (2) and air above the liquid wherein said container is actuable by squeezing it to force liquid through a dip tube (3) of said spray dispensing device, said spray dispensing device comprising: a dispenser housing (17) defining a cavity therein, with an air orifice (13) and a liquid orifice (9) being defined through said housing and a spray orifice (16) being defined at a terminal point of a tapered section (19, 20) of said housing, said tapered section defining a mixing chamber (15) therein; a dip tube (3) extending from an underside of said housing (17) and communicating with said liquid orifice (9); and a valve (10) received in said cavity and terminating at said mixing chamber (15), said valve defining a liquid passageway (12) therein, said liquid passageway communicating with said mixing chamber and with said liquid orifice (9), and said valve and said dispenser housing (17) defining an air passageway (14) therebetween which is concentrically disposed around said liquid passageway (12), said air passageway communicating with said mixing chamber (15) and with said air orifice (13); wherein a section of said liquid passageway (12) points towards said mixing chamber (15) and said spray orifice (16) in a first direction and communicates with said mixing chamber at a location which is directly opposite to said spray orifice, and wherein said air passageway (14) points towards said mixing chamber (15) in said first direction and communicates with said mixing chamber at a location which is directly opposite to said tapered section (19, 20) of said dispenser housing (17); the arrangement being such that, upon actuation of said container (1), a stream of air from said air passageway (14) is deflected by said tapered section (19, 20) to converge and impinge upon a core stream of liquid from said liquid passageway (12) in said mixing chamber (15) to atomize the stream of liquid; characterized in that said valve (10) is selectively movable within said cavity between at least: a first position wherein said air passageway (14) communicates with said air orifice (13) and wherein said liquid passageway (12) communicates with said liquid orifice (9) and said dip tube (3) to define a first extent of communication between said dip tube and said mixing chamber (15), whereby a first stream of air can pass through said air orifice, through said air passageway and into said mixing chamber at a first air flow rate, and a first stream of liquid can pass through said dip tube, through said liquid orifice, through said liquid passageway and into said mixing chamber at a first liquid flow rate to engage the first stream of air such that a liquid-air mixture, having a first ratio of liquid to air, can emanate from said spray orifice (16) as a spray; and a second position wherein said air passageway (14) communicates with said air orifice (13) and wherein said liquid passageway (12) communicates with said liquid orifice (9) and said dip tube (3) to define a second extent of communication between said dip tube and said mixing chamber (15) which is greater than said first extent of communication, whereby a second stream of air can pass through said air orifice, through said air passageway and into said mixing chamber at a second air flow rate which is equal to said first air flow rate, and a second stream of liquid can pass through said dip tube, through said liquid orifice, through said liquid passageway and into said mixing chamber at a second liquid flow rate, which is greater than said first liquid flow rate, to engage the second stream of air such that a liquid-air mixture, having a second ratio of liquid to air which is greater than said first ratio, can emanate from said spray orifice (16) as a spray. The spray dispensing device according to claim 1, wherein said valve (10) is selectively movable within said cavity between said first position, said second position, and a multiplicity of further positions wherein said air passageway (14) communicates with said air orifice (13) in each further position and wherein said liquid passageway (12) communicates with said liquid orifice (9) and said dip tube (3) to define a corresponding multiplicity of different extents of communication between said dip tube and said mixing chamber (15) corresponding respectively to said further positions, whereby a stream of air can pass through said air orifice, through said air passageway and into said mixing chamber, and a stream of liquid can pass through said dip tube, through said liquid orifice, through said liquid passageway and into said mixing chamber at a corresponding multiplicity of different liquid flow rates corresponding respectively to said further positions. The spray dispensing device according to claim 1 or 2, wherein said valve (10) is selectively movable to a closed position in which said liquid passageway (12) is not in communication with said liquid orifice (9). The spray dispensing device according to claim 3, wherein said air passageway (14) communicates with said mixing chamber (15) and said air orifice (13) in said closed position. The spray dispensing device according to claim 3 or 4, wherein said valve (10) has a longitudinal axis aligned through said spray orifice (16) and said liquid passageway (12) and wherein said valve is selectively movable to said closed position by rotation about said longitudinal axis. A squeeze bottle sprayer which is actuable upon squeezing a bottle (1) to force liquid (2) up a dip tube (3) and emit a liquid air-spray through a spray orifice (16), comprising: a squeezable bottle (1) containing a volume of liquid (2) and air above the liquid; and a spray dispensing device according to any one of claims 1 to 5, wherein said spray dispensing device is mounted on said bottle (1) and has its dip tube (3) extending into said volume of liquid (2) and has its air orifice (13) in communication with said air above said liquid.

Inventors: DELANEY HENRY W JR, DELANEY, HENRY W., JR.
Applicants: EMSON RES, EMSON RESEARCH INCORPORATED
Application year: 1992
Main classification: B05B11
IPC codes: B65D83, B05B11