Trigger sprayer

Abstract: A trigger sprayer (10) has a housing (12) with a first liquid passage (34) containing a spinner assembly (22). An elastomeric pump element (16) is positioned generally horizontally such that pulling the trigger (14) retracts the element (16) and releasing the trigger (14) allows the element (16) to extend. The sprayer (10) includes a spinner assembly (22) and valving to control the flow of liquid within the sprayer (10). In one aspect of the invention, the housing (12) has front and rear sections with the rear section having a saddle portion and being hinged to the front section for pivotal movement from an open position for molding the housing to a closed position for operating the sprayer (10). In another aspect of the invention, the container (28) has a rear portion (202) which extends upwardly past the neck and defining a saddle recess (214), with the housing (12) connected to the neck of the container (28) and positioned forwardly of the upwardly extending container portion. The sprayer (10) may include an elastomeric spring for biasing the pump element in the extended position.

Description: Background of the Invention This invention is directed to the field of trigger dispensers, also known as trigger sprayers. Generally, a trigger dispenser of the type involved here is a relatively low cost pump device which is held in the hand and which has a trigger operable by squeezing or pulling the fingers of the hand to pump liquid from a container and through a nozzle at the front of the dispenser. Such trigger dispensers may have a variety of features that have become common and well-known in the industry. For example, the dispenser may be a dedicated sprayer that produces a defined spray pattern for the liquid as it is dispensed from the nozzle. It is also known to provide adjustable spray patterns such that with a single dispenser the user may select any one of several stream patterns from a stream to a fine mist. Some known trigger dispensers also include a way to seal the dispenser to prevent liquid from leaking from the nozzle orifice during shipment or non-use. A variety of sealing arrangements are known. It is also well-known to provide trigger dispensers with a means to produce foaming of the liquid as it is dispensed from the nozzle orifice. Such trigger dispensers are generally referred to in the industry as "foamers". Various types of foamers are well-known. While trigger sprayers of the type to which the present invention is directed are of relatively low cost, the various aspects of the present invention serve to further reduce costs, while at the same time providing versatility in design and reliable service. To put this into perspective, millions of trigger sprayers are sold each year for use in dispensing a wide variety of products. Because of the large volumes, a savings of only a few cents, or even one cent, is significant. It has been proposed in European patent application 0 471 610 to reduce the costs of manufacturing a trigger sprayer by providing a nozzle which has a combined core and valve member which is located in the discharge passage of the nozzle. The valve part has a flexible circular lip which is dimensioned to provide a seal around the entire circumference of the inside of the discharge passage. The core/valve member is axially slidable in response to pressure changes as the trigger is operated. When the trigger is squeezed, fluid pressure forces the core/valve member up against a diaphragm with a discharge orifice, and then causes the lip to flex and allow fluid to pass through the core member and be ejected through the discharge orifice. A problem with this known design is that the axial movement of the core/valve member in the passage will cause wear of the valve lip and a consequent reduction in sealing effectiveness. If fluid can pass through the core member before the core member is pressed up against the diaphragm, because of a less than perfect seal, the resulting spray will have variable characteristics and leakage may result. International Patent Application WO-A-92/07660 describes a low cost trigger sprayer which has a rigid plug valve that is held against a valve seat by a flexible spring. The spring flexes to cause the valve plug to move away from the valve seat to permit fluid flow through a discharge passage. A problem with this construction is that insertion of the valve assembly into the discharge passage from the nozzle opening can cause the valve plug to engage with a centring guide and not seat properly in the valve seat. It is an objective of the present invention to provide a trigger sprayer with cost-saving features relative to those presently in the marketplace while maintaining acceptable performance criteria. Summary of the Invention According to an aspect of the present invention there is provided a valve assembly for use in a spray dispenser of a type used for dispensing a liquid from a container attached to the spray dispenser as specified in Claim 1 By locking the body portion relative to the cavity, the position of the spinner head relative to the nozzle orifice is fixed so that more precise spray characteristics are maintained. By having a flexible disk-like valve connected to a rigid, elongate body, if the valve assembly is improperly assembled into the discharge passage cavity where the disk-like valve is not properly positioned on the valve seat, the valve assembly will project from the nozzle opening of the discharge passage cavity and the nozzle assembly will not fit properly in the cavity. The spinner assembly comprises an elongated body portion having a swirl chamber at a front end thereof, and a flexible elastomeric valve portion at the rear thereof. The spinner assembly is adapted to be housed within a liquid discharge cavity of a trigger sprayer housing with the valve portion overlying an opening in the cavity and defining a primary valve to the trigger sprayer. The valve portion comprises a flexible disc, and the rear of the elongated body portion may be formed in an axial hub with the disc attached at its centre to the hub. The entire spinner assembly may be of integral moulded construction. The spinner assembly may further comprise a second flexible valve portion formed at the rear of the spinner assembly and adapted to overlie another opening in the housing to define a check valve for the sprayer, the main body portion and valve portions being integrally moulded. A more detailed description of an embodiment and aspects of the invention is set out below. Description of the Drawings Figure 1 is a view in section depicting an embodiment of a trigger sprayer useful for understanding the present invention. Figure 2 is a view in section depicting a modification of the pump element of the trigger sprayer of Figure 1. Figure 3 is a view in section depicting another embodiment of a trigger sprayer useful for understanding the present invention. Figure 4 is a sectional view showing an alternate pump element for the trigger sprayer of Figure 3. Figure 5 is a view in section showing an alternate embodiment of a trigger sprayer useful for understanding the present invention. Figure 6 is a view in section showing another alternate embodiment of a trigger sprayer useful for understanding this invention. Figure 7 is a view in section showing an alternate embodiment of the trigger sprayer of Figure 5. Figure 8 is a view in section showing an alternate embodiment of the trigger sprayer of Figure 6. Figure 9 is a view in section showing an alternate embodiment of the pump element of the trigger sprayer of Figure 8. Figure 10 is a view in section showing another embodiment of a trigger sprayer useful for understanding the present invention. Figure 11 is a view in section showing an embodiment of the trigger sprayer of the present invention. With reference to Figure 1 of the drawing, there is shown a trigger sprayer assembly 10. The assembly includes a housing 12, a trigger 14 mounted to the housing for actuation relative to the housing, a pump element 16, a plunger 18 between the trigger and pump element, a vent assembly 20, a spinner assembly 22, a nozzle assembly 24 at the front of the housing, and a connector 26 for connecting the trigger sprayer assembly to a container 28. The housing 12 has a generally horizontal barrel portion having a generally horizontal cavity 34 therein with a valve seat 36 at the rear end thereof. The nozzle assembly 24 is mounted in the front end of the cavity and has a barrel portion 40 extending within the cavity. The nozzle assembly has a front wall 42 with an orifice 44 through which liquid in the container is dispensed upon operation of the trigger sprayer assembly. The nozzle assembly also has a door 46 hinged at 48 by means of a living hinge. The door has a knob 50 which seats within the orifice 44 when the door is closed (pivoted downwardly) to prevent liquid from leaking from the orifice. The door has suitable latching means 52 for holding the door closed. The door also has a tab 54 which seats within an opening 56 in the top of the housing when the door is pivoted to its stored position (see Figure 3) to in effect hold the door open. This last described feature is optional because the door will stay in the position shown in Figure 1 if it is not latched in the closed position so that during operation of the trigger sprayer assembly the door does not interfere with the dispensing of the liquid. The nozzle assembly further has a tab 60 which engages in the opening 56 to lock the nozzle to the housing in the position shown in Figure 1. The spinner assembly 22 is located within the first liquid passage 34 and includes a spinner head portion 70, a valve portion 72, and a spring portion 74 between the spinner head and valve portion for biasing the valve portion against the valve seat 36. The valve portion 72 and valve seat 36 define a primary valve 75. The spinner head 70 has an annular ring 76 that fits within a complementary annular groove in the wall of the nozzle assembly to lock the spinner head within the tubular portion of the nozzle assembly to prevent relative longitudinal movement therebetween. This assures that the spinner face 80 of the spinner head always remains at a fixed distance relative to the orifice 44 to assure a constant spray pattern. The spinner face is of the conventional type having a spinner recess for generating in combination with the orifice the desired spray characteristics. The trigger 14 is mounted to the housing for actuation relative to the housing by the fingers of the hand. In this embodiment, the trigger is pivotally mounted at its upper end to the forward portion of the housing and has a rounded socket (90) for receiving the forward rounded end of the plunger 18. The rear end of the plunger has a socket 92. The pump element 16 is elastomeric and has a forward projecting portion 94 having an annular ring 96 that seats within a complementary annular recess within the socket 92 for securing the pump element to the plunger. The pump element also has a bulb portion 100 defining a pump chamber 102 therein. The bulb portion is generally circular about its longitudinal axis and has a rear annular flange 104 engaged within a complementary annular groove within the housing for securing the elastomeric pump element to the housing. The housing has a socket portion 110 into which the upper end of a dip tube 112 extends, the dip tube directing liquid from the container 28 into the trigger sprayer assembly upon operation of the assembly. At the upper end of the socket 110 is a cavity portion 114 within the housing. The housing also has a passage 120 extending from the cavity to a check valve 122. The check valve 122 comprises a valve seat at the end of the cavity 120, and a valve member 124 which, in this embodiment of the invention, is an elastomeric flap element formed integrally with the elastomeric pump element 16. When the pump element is contracted or collapsed creating positive pressure within the chamber 102, the valve element 124 seals the passage 120 against the flow of liquid into the chamber, but when the elastomeric pump element extends, creating negative pressure within the chamber 102, the valve element 124 unseals the passage 120 allowing the flow of liquid from the container into the chamber by way of the dip tube. The housing also includes an opening 130 from the chamber to the cavity portion 114. A plug 140 is housed within the socket portion 110 and cavity 114, the plug having a lower tubular portion 142 within the socket 110 with the upper end of the dip tube received within the lower tubular portion 142. The plug also has an intermediate tubular portion 144 and an upper tubular portion 146. At the base of the intermediate tubular portion 144 is a wall 150 just above the passage 120 to block the flow of liquid from the dip tube directly to the primary valve 75. The intermediate portion 144 has an annular shoulder 156 that seats within a complementary annular groove in the wall of the housing to lock the plug within the cavity, the intermediate portion 144 being in sealing engagement with the wall of the cavity to prevent the direct flow of liquid from the dip tube to the primary valve. The upper portion 146 of the plug engages a depending neck portion 160 of the housing to secure the upper end of the plug. The upper end portion 146 is spaced from the wall of the cavity 114 to define with the opening 130 a second liquid passage 162 for the flow of liquid from the chamber 102 to the primary valve 75. The housing also includes a portion extending beneath the pump element and defining a cylindrical chamber 170 with a vent slot 172 extending longitudinally in the wall of the vent chamber at the bottom thereof. A vent piston 174 reciprocates within the cylindrical chamber 170 in sealing engagement therewith. The vent assembly 20 also has a vent arm 176 formed integrally with the plunger and extending from the main portion of the plunger to the vent piston 174 such that reciprocating movement of the plunger also produces reciprocating movement of the piston. With the trigger 14 in the released position shown in Figure 1, the vent piston 174 seals the forward end of the vent cylinder so that liquid from the container cannot escape through the slot 172 and out the forward end of the vent cylinder. With the trigger 14 pulled, the vent piston moves to a rear position (to the right as viewed in Figure 1) to vent the slot 172 to atmosphere so that air is allowed to flow through the forward end of the vent cylinder and the vent slot into the container to prevent collapsing of the container during operation of the trigger sprayer assembly. The housing also includes a connector portion 26 which in this embodiment of the invention is formed integrally with the housing and which connects the housing to the neck 180 of the container 28. The connector 26 of the housing and the neck 180 of the container have complementary bayonet coupling elements 182, 184 for securing the housing to the container so that the trigger sprayer housing may be snapped onto the neck of the container without requiring rotation of the trigger sprayer assembly relative to the container. A suitable gasket 190 is located between the upper end of the neck and the base of the connector to prevent leakage. The trigger sprayer assembly and container combine to provide the means for holding and operating the assembly to dispense the liquid from the container, and further to provide versatility in overall design using a fixed trigger sprayer assembly configuration. Thus, the housing has a rear surface 200. The container 28 has a rear section 202 which extends upwardly past the neck portion and which has a front wall 204 which faces the wall 200. In this embodiment, the walls 200, 204 are generally vertical, are in close proximity, and are congruent. The rear section 202 has an upper wall 206 generally aligned with the top of the housing, a rear wall 208, and lower walls 210, 212 which form between them a saddle recess 214 for ergonomically receiving the web of the hand between the thumb and first finger for operating the trigger sprayer assembly. The rear section of the container may be formed integrally with the neck portion. Therefore, it can be seen that with this embodiment, the trigger sprayer assembly provides the mechanism for pumping the liquid from the container and dispensing it through the orifice 44, while the container, and particularly the rear section 202 of the container, provides the saddle recess for operating the trigger sprayer assembly. Also, the overall design appearance is dictated by the combined design characteristics of the trigger sprayer assembly and the rear section 202 of the container. In this way, the overall design appearance may be changed simply by altering the configuration of the rear section 202 without altering the configuration of the trigger sprayer assembly. Examples of other design configurations are shown in Figures 3, 5, and 7. These are shown only by way of example as a great many overall designs may be achieved. Figure 2 illustrates a modification of the sprayer shown in Figure 1 where the pump element 16 has a bellows portion 230 rather than the bulb portion 100 as shown in Figure 1. The forward end of the bellows portion 230 is secured in an annular groove 232 in the rear end of the plunger 18 which also has a recess 234 with a rearwardly extending sleeve 236. The rear end of the bellows is secured to the housing 12 within a shoulder 240. The housing has a rod 242 which extends forwardly into telescoping engagement with the sleeve 236 to give structural stability to the pump element. A sleeve-like elastomeric valve member 250 surrounds the base of the rod as shown, and has an integrally-formed flap portion 252 which overlies an opening at the end of a passage 254 through which liquid flows from the dip tube 112 into the chamber 256 within the bellows. The flap portion 252 and opening define a check valve similar to the check valve 122 in Figure 1. An opening 260 extends between the chamber 256 and the passage 162. Except for these differences, the structure and operation of the sprayer of Figure 2 is the same as that of Figure 1. Figure 3 shows another example of a trigger sprayer which is similar to that of Figure 1 but with certain modifications. With this embodiment, the shape of the upwardly extending rear section 202 of the bottle is different from that of Figure 1, but its function is the same. Also, the shape of the cavity 270 is different from that of cavity 114 in Figure 1. The cavity 270 is narrower and extends from the top of the dip tube 112 to the primary valve 75. An elastomeric plug 272 is located between a passage 274, which leads from the upper end of the dip tube to the check valve 122, and an opening 276 which leads from the chamber 102 to the cavity 270. The plug 272 blocks the direct flow of liquid through the cavity from the top of the dip tube to the primary valve. The housing 12 has a vertical socket 280 to receive the upper end of the dip tube. Figure 4 illustrates a modification of the sprayer of Figure 3, where the elastomeric pump element 16 is a bellows 290 similar to the bellows 230 of Figure 2. Figure 5 illustrates another trigger sprayer. The pump element 16 has a piston portion 300 formed integrally with the plunger 18. The housing 12 has a forwardly-extending portion 302 which defines a chamber 304. The piston 300 reciprocates within the chamber 304 upon operation of the trigger. The piston 300 is biased to the extended position shown in Figure 5 by a coil spring 306 mounted between a rearwardly extending portion 308 and a forwardly extending portion 310 of the housing. The upper end of the dip tube 112 is received in a vertical socket 312 in the housing. A cavity 316 extends from the top of the dip tube to the top of the housing and defines a valve seat at the upper end of the dip tube. An opening 320 communicates the cavity 316 with the pump element chamber. A plug 322 is located in the cavity and extends from the top of the housing to the bottom of the housing. The upper end of the plug is flared at 324 which cooperates with an annular shoulder 326 of the housing to lock the plug within the cavity. The top of the plug is flush with the top of the housing. At the lower end of the plug is a disc-shaped valve member 330 which is flexibly connected to the main portion of the plug by a web 332. The entire plug, including the web 332 and valve portion 330, is integrally formed. The valve portion 330 and valve seat define a check valve. The wall of the cavity 316 and the upper portion of the plug 322 define a second passage 336 which communicates with the chamber of the pump element through an opening 338. In operation, pulling the trigger causes the piston 300 to move rearwardly to pump liquid from the chamber, through the opening 338 and passage 336, and the primary valve, to the nozzle. The positive pressure in the chamber holds the check valve member 330 closed. Releasing the trigger allows the piston 300 to move forwardly under the spring bias, thereby reducing the pressure in the chamber and causing the check valve 330 to open so that liquid flows from the dip tube into the chamber by way of the passage 320. The middle portion of the plug 332 blocks the direct flow of liquid through the cavity 316 from the check valve to the primary valve. Therefore, in addition to the features previously mentioned, the embodiment of Figure 5 utilizes a relatively low cost check valve arrangement which is inexpensive to make and assemble. Figure 6 shows another embodiment of a trigger sprayer which has the same pump element and check valve arrangement as shown in Figure 5, but which uses a different structure for providing a saddle recess for the hand during operation of the trigger sprayer assembly. In accordance with the embodiment of Figure 6, the trigger sprayer housing 12 has a front section 350 and a rear section 352 which is hinged to the front section by a living hinge 354, which in this embodiment is at the top of the housing. The housing, including the hinge 354 and rear section 352, is integrally formed with the rear section 352 moulded in the position shown in dashed lines, and then assembled for operation with the rear section as shown in solid lines. As shown, the rear section 352 has a sloping wall 360, a rear hump 362, an inwardly-extending wall 364, and a tail wall 366. A saddle recess 368 is formed between the walls 364 and 366 for ergonomically receiving the web of the hand between the thumb and first finger during operation of the sprayer. In this embodiment the sprayer housing is connected to the neck of a bottle by a threaded closure 370. The upper end of the closure has an inwardly-extending shoulder 372 which snaps over an outwardly-extending shoulder 374 of the housing. The closure has an upper notch 376 which receives the lower end of the rear section 352 to lock the rear section 352 in the closed position shown by solid lines. During assembly, the rear section 352 is pivoted about the hinge 354 to the closed position, and then the closure member 370 is snapped onto the housing to lock the rear section in the closed position as shown. Although one cross-section configuration of the rear section is shown, it is to be understood that there are many possible configurations that may be used. The trigger sprayer assembly of Figure 6 is easy to mould and assemble which saves costs, and yet provides the desired ergonomics and aesthetics. Figure 7 shows an embodiment similar to Figure 5 but with an alternate check valve assembly. As shown in Figure 7, a cavity 380 extends from the top of the dip tube to the primary valve 75. The lower end of the cavity has a wide section that receives a check valve assembly 382. The check valve assembly includes a plastic check valve frame 384 having a vertical valve seat 386 and a side opening 388 which communicates with an opening 390 to the pump element chamber. A ball valve 392, which may be of plastic, seats within the valve seat by its own weight. The frame 386 has a integrally-formed plug portion 394 which blocks the direct flow of fluid through the cavity 380 from the check valve to the primary valve. The operation of the sprayer embodiment of Figure 7 is the same as that of Figure 5 except for the difference in configuration of the check valves. Figure 8 shows a trigger sprayer embodiment which is similar to that of Figure 6 except that the pump element 16 is an elastomeric bulb as shown in Figures 1 and 3 with an integrally-formed elastomeric check valve member 122. It also uses a plug 272 as shown in Figure 3. With the embodiment of Figure 8, the rear end of the bulb has an outwardly-extending annular flange 400 which seats against an annular surface 401 of the housing and is held in place by a snap ring 402. It is to be understood that while the embodiment shown in Figure 6 has a threaded closure which holds the rear section 352 in the closed position, the connector portion may also be of the bayonet type integrally formed with the housing as shown in Figure 8. In such case the rear section 352 is locked in the closed position by snapping the lower end 404 of the rear section past the upper end 406 of the connector until it lodges in a notch 408, similar to the notch 376, at the top of the connector. Figure 9 shows an alternate form of the embodiment of Figure 8 where the plunger 18 and pump element 16 are integrally formed. Figure 10 illustrates still another embodiment of a trigger sprayer which in many respects is similar to those previously described but with certain modifications. In this embodiment the plunger 18 has a deep recess 410 which receives a tubular projection 412 of an elastomeric bulb pump element 414. The pump element also has a forwardly-extending sleeve 416 surrounding the tubular projection 412 and which is secured within a shallower recess 418 in the plunger. The sleeve 416 has an annular shoulder 420 which seats within a complementary annular groove in the plunger to secure the pump element to the plunger. The housing has a forwardly-extending rod 422 which slides within the tubular portion 412 of the elastomeric bulb in telescoping relation. The rod gives structural stability to the pump element as it extends and retracts during operation of the sprayer. The rod 422 is structurally supported with reinforcing ribs 424. The elastomeric bulb 414 has an elastomeric valve element 426, somewhat similar to the valve element 124 (Figure 1), which seals an opening 428 from a cavity 430 at the top of the dip tube. The valve element 426 defines a check valve. Another opening 432 communicates the pump element chamber with the cavity 430 to provide a second liquid passage for the flow of liquid from the chamber to the primary valve. An elastomeric plug 434 blocks the direct flow of liquid in the cavity 430 from the dip tube to the primary valve. This embodiment also has a rear section 450 of the housing which is pivotally connected to the front section 451 by a living hinge 452. However, in this embodiment the rear section is hinged at the bottom of the housing, rather than at the top as with the embodiments of Figures 6 and 8. In Figure 10 the connector portion for connecting the housing to the neck of the bottle is integrally formed with the housing and is of the bayonet type, the rear section 450 of the housing being hinged at the lower end of the connector portion. The housing is moulded with the rear section 450 in the position shown by dashed lines, and then during assembly the rear section is pivoted to the solid line closed position. The configuration of the rear section 450 is an example of the many configurations that may be used. It has a top wall 454, back wall 456, bottom wall 458, and tail wall 460. A saddle recess 462 is formed between the walls 458 and 460 for ergonomically receiving the web of the hand between the thumb and first finger for operation of the sprayer. The top wall 454 has a portion 464 that extends past the edges of the rear section side walls to overlie the top of the housing front section 451 as shown at 468. Figure 11 illustrates an embodiment of the present invention. The housing 480 has a front section 482 and a rear section 484. The housing has an integrally-formed bayonet connector 486 for connecting the housing to a container. The rear section 484 is pivotally attached at the bottom to the bayonet connector 486 by a living hinge 488 similar to the embodiment of Figure 10. The upper end of the rear section 484 has a plug portion 490 formed integrally therewith and which has outwardly-extending shoulders 492. The housing 480 has a vertical cavity 494 which receives the upper end of the dip tube. A fluid passage 496 extends from the upper end of the dip tube to a check valve 498. The check valve comprises a valve seat 500 formed in the housing at the upper end of the passage 496, and a ball valve 502 which is inserted through an opening 504 in the housing above the check valve 498. The rear section 484 of the housing is secured in the closed position as shown in Figure 11 by snapping the plug portion 490 into the top of the opening 504, the opening having complementary recesses to receive the shoulders 492 in snap engagement. Hence, during assembly, the housing is moulded with the rear section in a horizontal position like the housing of Figure 10. After the ball valve 502 is inserted through the top opening of the housing, the rear section is pivoted to the closed position and the plug portion 490 snapped into the opening to enclose the ball valve. In this embodiment the pump element comprises a piston 510 which reciprocates within a cylinder portion 512 formed by the housing. Rather than a metal coil spring as shown in Figures 5, 6, and 7, in this embodiment an elastomeric spring 514 biases the piston in the extended position shown in Figure 11. The elastomeric spring 514 is of integral construction and has a base 516 which forms an annular sleeve 518. The sleeve fits within an annular groove 520 in the housing. The annular groove defines a central cylindrical portion 522 of the housing which fits within the sleeve. The elastomeric spring has a radial portion 524 seated within a complementary groove in the housing, and a curved forwardly projecting portion 526 extending therefrom with the forward end lodged within a groove 528 formed in the rear face of the piston. The resilient elastomeric arm portion 526 of the spring element biases the piston in the extended position. The elastomeric spring element represents a cost savings in a trigger sprayer utilizing a reciprocating piston pump element. A liquid passage 530 extends from the pump chamber to passages 532 formed in the housing at the rear of the cavity 34 which houses a spinner assembly 534. The spinner assembly is of integral moulded construction with the main portion 536 of the assembly extending nearly the full length of the cavity and being relatively rigid. The front face 538 of the spinner assembly is formed in a conventional manner with tangential grooves and a spinner recess or swirl chamber for imparting a spinning motion to the liquid before exiting through the nozzle orifice to produce a spray pattern. The main portion has suitable slots 540, 542 to allow the flow of liquid through the cavity toward the orifice. At the rear of the spinner portion 536 there are radial fins 544 which fit in close proximity to the wall of the cavity to centre the rear of the spinner portion 536. An axial hub 546 extends to the rear and has a flexible diaphragm disc 548 moulded integrally with the hub. With the spinner assembly mounted in the cavity 34, the diaphragm disc overlies the openings 532. The length of the spinner assembly 534 relative to the cavity 34 is such that a preload is applied to the diaphragm disc to give it a dish-shaped configuration as shown in Figure 11 after the spinner assembly is mounted in the cavity. The spinner assembly either may be moulded with the diaphragm disc flat, or in a dish-shaped configuration. To assemble the spinner assembly, the spinner assembly 534 is inserted into the cavity 34 from the front of the housing, and then the nozzle assembly 24 is attached to the housing to capture the spinner assembly within the cavity. In operation, when the trigger is pulled the liquid pressure causes the diaphragm disc 548 to flex so that liquid may flow from the chamber, through the passage 530, openings 532, and past the diaphragm disc and into the cavity 34. Upon releasing the trigger there is a reduction of pressure in the passage 530 and openings 532 such that the diaphragm disc seals the openings 532 to prevent the passage of liquid therethrough. Instead, liquid is drawn from the container, through the dip tube and check valve 498, passage 530, and into the pump chamber. The entire housing is integrally moulded of a suitable plastic material such as polypropylene. Other components of the sprayer assembly, particularly those that perform a sealing function, are moulded of a suitable plastic material such as polyethylene. One such material is HYTREL which is a product of Dupont Co. While the present invention has been described by reference to a specific embodiment, it should be understood that modifications and variations of the invention may be constructed without departing from the scope of the invention defined in the following claims.

Claims: A valve assembly for use in a spray dispenser of a type used for dispensing a liquid substance from a container attached to the spray dispenser, the dispenser having a housing (480) with an orifice (44) through which the liquid substance is dispensed and a pump (510) for drawing the liquid substance from the container and expelling the substance through the orifice, the dispenser including an inlet passage (496) for communication of the liquid substance between the container and the pump (510) and a discharge passage cavity (34) for communication of the liquid substance between the pump (510) and the orifice (44), the valve assembly comprising: a rigid, elongate body (536) having a first and a second end, the first end being configured to be positioned adjacent the housing orifice (44) when the body (536) is assembled in the spray dispenser discharge passage (34); and an elastomeric valve element (548) attached to the second end of the valve assembly body (536); characterised in that the rigid, elongate body is adapted to be locked within the discharge passage cavity (34) to prevent axial movement of the body (536) in the discharge passage cavity (34) and in that the elastomeric valve element is a flexible disk-shaped valve (548) positioned in the discharge passage cavity (34), the disk shaped valve (548) preventing a flow of liquid through the discharge passage (34) from the orifice (44) to the pump (510) and the disk-shaped valve (548) being constructed to flex when subjected to liquid under pressure in the pump (510) to permit a flow of liquid through the discharge passage cavity (34) from the pump (510) to the orifice (44), the disk-shaped valve (548) has opposite convex and concave surfaces, and the convex surface is positioned in the discharge passage cavity (34) facing in an upstream direction toward the pump (510). A valve assembly as claimed in Claim 1 wherein the discharge passage includes a valve seat (532) and the elastomeric valve element (548) is configured to seat against the valve seat (532) to inhibit the liquid substance from flowing through the discharge passage cavity (34) in a direction from the first end to the second end but to permit the liquid substance to flow through the discharge passage cavity (34) in an opposite direction from the second end to the first end. The valve assembly of Claim 1, wherein: the disk-shaped valve (548) is constructed so that a portion of the disk-shaped valve flexes in response to being subjected to liquid under pressure in the pump (510) while another portion of the disk-shaped valve (548) remains stationary in the discharge passage cavity (34). The valve assembly of Claim 1, wherein: a valve seat (532) is positioned in the discharge passage cavity (34) and the disk-shaped valve (548) engages with the valve seat (532) in an at rest position of the disk-shaped valve (548) relative the valve seat (532), and the disk-shaped valve (548) is constructed so that a portion of the disk-shaped valve (548) will be caused to flex relative to the discharge passage cavity (34) and away from the valve seat (532) when the disk-shaped valve (548) is subjected to liquid under pressure in the pump (510). The valve assembly of Claim 4 wherein: the disk-shaped valve (548) is constructed so that another portion of the disk-shaped valve (548) will remain stationary relative to the discharge passage cavity (34) when the portion of the disk-shaped valve (548) is caused to flex relative to the discharge passage cavity (34) and away from the valve seat (532). The valve assembly of Claim 1 wherein: the discharge passage cavity (34) has an inlet opening (532); the disk-shaped valve (548) has a peripheral edge portion that surrounds a center portion of the disk-shaped valve (548), the center portion remains stationary relative to the inlet opening (532) while the peripheral edge moves away from the inlet opening (532) to permit a flow of liquid into the discharge passage cavity (34), and while the peripheral edge moves toward and overlies the inlet opening (532) to block a flow of liquid through the inlet opening (532). The valve assembly of Claim 1 wherein: the discharge passage cavity (34) has a center axis and an inlet opening (532) at an upstream end of the discharge passage cavity (34) and the orifice (44) positioned at a downstream end of the discharge passage cavity (34); and the disk-shaped valve (548) and the first end of the rigid, elongate body (536) are joined to one another at the center axis of the discharge passage cavity (34). The valve assembly of Claim 7 wherein: the body (536) extends from the inlet opening (532) to the orifice (44). The valve assembly of Claim 8 wherein; the body (536) is longer than the discharge passage cavity (34) to hold the disk-shaped valve (548) against the inlet opening (532). The valve assembly of Claim 8 wherein: the body (536) exerts an axial force on the disk-shaped valve (548) to bias the disk-shaped valve (548) against the inlet opening. The valve assembly of Claim 7 wherein: the body (536) includes a plurality of radially extending fins (544) configured to engage an interior surface of the discharge passage and center the disk-shaped valve (548) at the inlet opening (532).

Inventors: FOSTER DONALD D, NELSON PHILIP L, FOSTER, DONALD D., NELSON, PHILIP L.
Applicants: CONTICO INT INC, CONTICO INTERNATIONAL, INCORPORATED
Application year: 1993
Main classification: B05B11
IPC codes: B05B1, B05B11