HIGH PRESSURE MANUALLY-ACTUATED SPRAY PUMP WITH REDUCED ACTUATION FORCE

Abstract: A high pressure manually-actuated spray pump (300) for dispensing a fluid. The spray pump (300) comprises a nozzle (110) through which the fluid is dispensed and a pumping engine (120). The pumping engine (120) comprises a reservoir (195), a closure (150), and a plunger (130). The reservoir (195) has an open top (152) and a closed bottom and an interior surface (193). The plunger (130) has an outer surface (135) and a longitudinal passageway (132) extending therethrough. The plunger (130) further having an outlet valve (240) mounted therein and an upper end (126) and a lower end (128). The lower end (128) being slidably disposed within the open top (152) of the reservoir (195) forming an interior chamber (178) within the reservoir (195). The interior chamber (178) has an annular chamber (133) and a main chamber (179). The annular chamber (133) being in fluid communication with the main chamber (179). The annular chamber (133) is formed by the outer surface (135) of the plunger (130) being spaced away from the interior surface (193) of the reservoir (195) such that there is no frictional contact between the outer surface (135) and the interior surface (193). The closure (150) being attached to the open top (152) of the reservoir (195) allowing the plunger (130) to slidably extend through the closure (150) such that the interior chamber (178) is sealingly closed. The nozzle (110) is mounted on the upper end (126) of the plunger (130) such that the longitudinal passageway (132) is in fluid communication with the nozzle (110). The interior chamber (178) is separated from the longitudinal passageway (132) by the outlet valve (240).

Description: HIGH PRESSURE MANUALLY-ACTUATED SPRAY PUMP WITH REDUCED ACTUATION FORCE FIELD OF THE INVENTION The present invention relates to an improved non-aerosol spray pump for producing an aerosol-like spray, and more particularly, to an improved non-aerosol spray pump that is capable of generating the high hydraulic pressure required for an ultra fine spray. BACKGROUND OF THE INVENTION Today, hand held spray dispensers for hair sprays are typically either of the manually-actuated spray pump type or the aerosol spray type. Aerosol spray dispensers utilize a liquefied propellant that "flashes off', to create an ultra fine spray. These ultra fine sprays have mean droplet diameters or mean particle sizes on the order of about 40 microns. When the propellant "flashes off', the phase change causes the liquid to disintegrate into ligaments and droplets. Although the small mean droplet diameter of ultra fine sprays produced by aerosols tends to leave a desirable dry feel on the hair, aerosols continue to be the subject of environmental debates. Therefore, many consumers prefer to use manually- actuated spray pump dispensers. Manually-actuated spray pump dispensers or finger pumps rely on the consumer to generate a hydraulic pressure in the pumping engine in order to dispense the fluid. Most pumping engines typically use a standard piston and cylinder arrangement in order to generate this hydraulic pressure. Thus, when the consumer applies an actuation force by pushing downward on the piston, the hydraulic pressure of the fluid in the cylinder is increased. For example, in a pressure swirl nozzle type spray pump dispenser, the hydraulic pressure created in the pumping engine forces fluid into a pressure swirl nozzle that imparts a rotational motion to the fluid. The fluid spins inside of the nozzle and forms a thin conical sheet which exits into the atmosphere and breaks up into ligaments and droplets. One fluid of current interest that requires the generation of a high hydraulic pressure in order to be properly dispensed by a manually-actuated spray pump dispenser is hair spray. Most manually-actuated spray pump dispensers have been unable to produce sprays having a mean droplet diameter of less than about 55 microns for many of the hair spray fluids currently on the market. These larger mean particle sizes, i.e. greater than about 55 microns, produced by conventional manual spray pumps result in sprays that consumers refer to as "wet". The wet and sticky feel of such sprays is due to the longer drying time required to dry the larger-sized particles. Several methods have been proposed for reducing the mean particle size produced by conventional manual spray pumps, for example, one of which is to increase the amount of hydraulic pressure created within the spray pump. Typically, most conventional spray pumps operate at a hydraulic pressure of about 90 psig. Research has indicated that when the hydraulic pressure in these conventional spray pumps is increased upward to levels near about 200 psig, mean droplet diameters of about 40 microns or less are achievable when used with a swirl type nozzle. A method of developing a high hydraulic pressure of about 200 psig involves the use of a preloaded or precompression type outlet valve that will not open until the desired high hydraulic pressure (that is 200 psig) is reached. In order to reach these high hydraulic pressures, typically the stiffiiess of a precompression spring is increased. A stiffer precompression spring will prevent opening ofthe outlet valve until the desired high hydrauhc pressure criteria is met. However, with this type of an outlet valve arrangement, the actuation force to be applied on the plunger that is required to dispense fluid from such a conventional spray pump can range from about 10 Ibf to about 20 Ibf. An actuation forces in this range is far too excessive for most ordinary consumers. Such an actuation force at this level can quickly fatigue me finger and hand of even the most physically adept person, let alone the typical users of most finger pumps. Thus, a need exists for a manually-actuated spray pump that is capable of delivering substantially higher hydraulic pressures than conventional spray pumps without a corresponding increase in the actuation force which can be used to provide an ultra fine spray from a non-aerosol dispenser. SUMMARY OF THE INVENTION In one aspect ofthe invention, a manually-actuated spray pump for dispensing a fluid is provided. The spray pump comprises a nozzle through which the fluid is dispensed and a pumping engine. The pumping engine comprises a reservoir, a closure, and a plunger. The reservoir has an open top, a closed bottom, and an interior surface. The plunger has an outer surface and a longitudinal passageway extending therethrough. The plunger further has an outlet valve mounted therein and has an upper end and a lower end. The lower end of the plunger is slidably disposed within the open top of the reservoir forrning an interior chamber within the reservoir. The interior chamber has an annular chamber and a main chamber. The annular chamber is in fluid communication with the main chamber. T e annular chamber is formed by the outer surface ofthe plunger being spaced away from the interior surface ofthe reservoir such that there is no frictional contact between the outer surface of the plunger and the interior surface. The closure is attached to the open top of the reservoir and has an aperture therein allowing the plunger to slidably extend through the closure such that the interior chamber is sealingly closed. The main chamber is formed from a remainder of the interior chamber. Thus, the annular chamber and the main chamber are portions of the interior chamber with volumes that vary inversely during movement ofthe plunger within the reservoir. The annular chamber increases in volume and the main chamber decreases in volume during application of an actuation force. The nozzle is mounted on the upper end of the plunger such that the longitudinal passageway is in fluid communication with the nozzle. The interior chamber is separated from the longitudinal passageway by the outlet valve. This spray pump is operable in response to the application of an actuation force upon the nozzle causing the plunger to move within the reservoir and pressurize the fluid within the interior chamber such that a high hydraulic pressure is generated within the interior chamber in response to the movement of the plunger. The outlet valve opens in response to tiie high hydraulic pressure thereby allowing a portion of the fluid to flow from the interior chamber through the longitudinal passageway and through the nozzle wherein the actuation force used to generate such high hydraulic pressure is lower compared to conventional spray pumps that generate the same high hydraulic pressure. In a second aspect of the present invention, a peripheral ring is affixed to the outer surface of he plunger and is in slidable contact with d e interior surface ofthe reservoir. The peripheral ring separates or defines a boundary between the annular chamber and the main chamber. T e peripheral ring also has a flow path extending therethrough allowing the annular chamber to be in fluid communication with the main chamber. In another aspect of the present invention, the peripheral ring has an upper sealing surface extending to the interior surface ofthe reservoir and a lower sealing surface extending to d e interior surface of the reservoir. The upper sealing surface and the lower sealing surface are in slidable sealing contact with the interior surface ofthe reservoir. BRIEF DESCRIPTION OF THE DRAWINGS While the specification concludes with claims which particularly point out and distinctly claim the invention, it is believed that the present invention will be better understood from the following description taken in conjunction with the appended claims and the accompanying drawings, in which like reference numerals identify identical elements and wherein; Fig. 1 is a vertical, cross-sectional view of a conventional spray pump; Fig. 2a is a simplified partial cross-sectional view of a pumping engine illustrating the force balance in a conventional spray pump; Fig. 2b is a simplified partial cross-sectional view of a pumping engine illustrating the force balance in a spray pump incoφorating the present invention; Fig. 3 is a vertical, cross-sectional view of a spray pump incoφorating the present invention, shown in a fully upright position; Fig. 3a is a full annular cross-section ofthe spray pump of Fig. 3 taken along line 3a- Fig. 4 is a vertical, cross-sectional view of the spray pump of Fig. 3 shown in a retracted, end-of-stroke position; Fig. 5 is a vertical, cross-sectional view of a first alternative embodiment of a spray pump incoφorating the present invention; and Fig. 6 is a vertical, cross-sectional view of a second alternative embodiment of a spray pump incoφorating the present invention. DETAILED DESCRIPTION OF THE INVENTION Referring now to the drawings, Fig. 1 depicts a conventional spray pump, designated generally as 100, of which the present invention is an improvement. As shown in Fig. 1, the conventional spray pump 100 consists of a nozzle, designated generally as 10, and a pumping engine, designated generally as 20, which are adapted for connection to a container (not shown) in which the fluid to be dispensed can be stored. The nozzle 10 includes an actuator head 12, a channel 34, and a nozzle insert 14 having an exit orifice 18. The nozzle insert 14 can be press fit into the actuator head 12 such that it is in fluid communication with the channel 34. Formed within the nozzle insert 14 is a swirl chamber 16 for transforming a pressurized fluid into an atomized spray. The pumping engine 20 shown in Fig. 1 comprises a stem or plunger 30, a reservoir 95, a closure 50, a precompression spring 90, a return spring 70, a poppet 40, a retainer cup 60, and a closed bottom 82. The plunger 30, having an outer surface 35, extends downwardly from the channel 34 in the nozzle 10 and the plunger 30 also includes a longitudinal passageway 32 for conveying fluid to the nozzle 10. The plunger 30 has a piston or peripheral ring 44 formed at a lower end 28 thereof, opposite the nozzle 10 which is attached at an upper end 26 thereof. The peripheral ring 44 extends radially outwardly from the plunger 30. The peripheral ring 44 includes an upper sealing surface 36 extending upward from the peripheral ring 44 and a lower sealing surface 39 extending downward from the peripheral ring 44. The upper and lower sealing surfaces 36 and 39 are annular in shape and create a leak tight seal between the peripheral ring 44 and an interior surface 93 of the reservoir 95. The reservoir 95, in the shape of a cylinder, is connected at an open top 52 thereof to the closure 50 adjacent to the plunger 30. The reservoir 95 extends downwardly and can be disposed within a container (not shown). An annular gap 91 is formed between the interior surface 93 of the reservoir 95 and the upper and lower sealing surfaces 36 and 39 of the peripheral ring 44. The reservoir 95 includes a vent hole 96 extending from the interior surface 93 through to the outside of the reservoir 95 such that the vent hole 96 forms a vent from the annular gap 91. The reservoir 95 also includes a priming blip 97 protruding from the interior surface 93 inwardly. This priming blip 97 does not extend continuously around the periphery of the interior surface 93 and the priming blip 97 can be located at one point along the circumference of the interior surface 93. In addition, a valve seat 98 is located at the closed bottom 82 of he reservoir 95. The closed bottom 82 is formed by the valve seat 98 which acts in conjunction widi a ball 80, such mat the ball 80 rests in die valve seat 98. When constructed in this manner the closed bottom 82 is in the form of an inlet valve 82 which controls die transfer of fluid from the container (not shown) into an interior chamber 78. A boss 99 is located on the reservoir 95 below the valve seat 98. The boss 99 is adapted to receive a dip tube (not shown). The dip tube (not shown) is used for conveying fluid from the container (not shown) to die inlet valve 82. As shown in Fig. 1, the interior chamber 78 of the reservoir 95 is positioned below d e peripheral ring 44 on the plunger 30. Thus, the interior chamber 78 is situated wholly below the peripheral ring 44. A more detailed description of die features and components of such a conventional spray pump 100 can be found in, for example, U.S. Patent No. 5,064,105 issued November 12, 1991 to Montaner and U.S. Patent No. 5,025,958, issued June 25, 1991 to Montaner et al., which are hereby incoφorated herein by reference. Conventional spray pumps 100 of this general type are, for example, commercially available versions sold by Calmar Dispensing Systems Inc. under the trade name "Mark IV Fine Mist Sprayer". In accordance with the present invention, it has been determined that the actuation force required by the conventional spray pump 100, shown in Fig. 1, can be reduced by reducing the area of the peripheral ring 44. This can be achieved by reducing d e effective area on which d e hydraulic pressure acts. For example, if a solid circular surface has a given diameter, and dius a certain measurable area, and this diameter is reduced, it is diis reduction in diameter or size that reduces the measurable area of the solid circular surface. Since, the force equation is pressure multiplied by area (F = P * A), where F = force, P = pressure, and A = area, for a given value of P which acts normal to all the surfaces, if A is reduced dien F is also reduced proportionally. The effective area (A) is defined as the cross- sectional area of die plunger 30 that when multiplied by die distance the plunger 30 has moved widiin the reservoir 95 it equates to die volume of fluid displaced. In die present invention, the effective area (A) of die peripheral ring 44 is reduced and dius, the actuation force (F) required to create the hydraulic pressure (P) in die interior chamber 78, is reduced. Preferably, this actuation force is less than about 10 Ibf (44.5 N), and more preferably, die actuation force is less than about 7 Ibf (31.1 N). Fig. 2a illustrates a simplified partial cross-sectional drawing of the pumping engine 20 of a conventional spray pump 100 and Fig. 2b illustrates a simplified partial cross- sectional drawing of die pumping engine 120 of a high pressure manually-actuated spray pump 300 according to the present invention. The pumping engine 120 of the present invention as shown in Fig. 2b, provides a novel way of reducing die effective area (A) of die peripheral ring 144, and thus die required actuation force. The effective area of the peripheral ring 144 is reduced by providing at least one flow path 131 that extends through the peripheral ring 144 between a main chamber 179 and an annular chamber 133. This flow path 131 allows fluid from the main chamber 179 to flow through, to communicate widi, and pressurize the annular chamber 133. In Fig. 2a, the plunger 30 and the peripheral ring 44 of the pumping engine 20 are shown having an actuation force of Fι=Pι*Aι . In contrast, the peripheral ring 144 and die plunger 130 ofthe pumping engine 120, incoφorating the present invention as shown in Fig 2b, have an actuation force of Since Pj, which acts normal to all die surfaces, Ai and ki are always positive numbers, and since A2 is less dian Ai, the actuation force F2 will be less dian Fi . Restated, the present invention alters d e force equation by reducing the effective area of die peripheral ring 144, diereby reducing die actuation force required to dispense die fluid. This reduction in area however, results in less fluid being displaced from the pumping engine 120 for an equivalent length of stroke. Fig. 3 and 4 illustrate the high pressure manually-actuated spray pump 300 of die present invention in greater detail. Fig. 3 illustrates the high pressure manually-actuated spray pump 300 in die fully upright position, while Fig. 4 illustrates d e high pressure manually-actuated spray pump 300 in a retracted, end of stroke position. As shown in Fig. 3, die present invention has many ofthe same components and operational characteristics and is an improvement of the conventional spray pump 100, shown in Fig. 1. However, the spray pump 300, shown in Fig. 3, incoφorates a flow padi 131 into die peripheral ring 144. The flow padi 131 allows fluid to travel from the main chamber 179, past die lower sealing surface 139 and past die upper sealing surface 136, and into the annular chamber 133 which is, preferably, provided above die peripheral ring 144. The interior chamber 178 is made up of and includes die main chamber 179, the annular chamber 133, and die flow path 131. The interior chamber 178, thus, comprises all d e open space widiin die reservoir 195 that is in fluid communication wid the annular chamber 133 when die inlet valve 182 and ie outlet valve 142 are closed. In d is embodiment, d e annular chamber 133 is formed between the upper sealing surface 136 and the outer surface 135 of die plunger 130 and also between die interior surface 193 of die reservoir 195 and die outer surface 135. The annular chamber 133 can be formed in various odier manners and between various other components. For example, and not by way of limitation, die annular chamber 133 can be formed as a cavity located wholly widiin the plunger 130; the annular chamber 133 can be formed as a cavity located partially within d e inner lip 156 of the closure 150, or any combination of these and various od er components. Preferably, die annular chamber 133 is of a smaller volume dian d e main chamber 179 prior to initiation of a dispensing cycle and preferably, die annular chamber 133 is located above die main chamber 179. Thus, the annular chamber 133 and die main chamber 179 are portions of die interior chamber 178 widi volumes d at vary inversely during movement of die plunger 130 widiin d e reservoir 195. Additionally, die annular chamber 133 is preferably annular in shape but can be of any number of various volumetric shapes or geometric configurations. The main chamber 179 is formed of a remainder of the interior chamber 178 extending to the closed bottom 182, not including the annular chamber 133 or the flow path 131. Preferably, die closed bottom 182 is in die form of an inlet valve 182. More preferably, d e closed bottom 182 has a valve seat 198 and a ball 180 forming d e inlet valve 1 2 dierein which allows the fluid to enter the interior chamber 178. The plunger 130, as shown in Fig. 3, has a longitudinal passageway 132 extending axially theredirough and an upper end 126 and a lower end 128. The nozzle 110 is fixedly mounted on die upper end 126 of die plunger 130 such diat die longitudinal passageway 132 is in fluid communication wid the nozzle 110. Opposite d e nozzle 110 which is affixed to d e plunger 130 at the upper end 126, the peripheral ring 144 located or formed at die lower end 128 of die plunger 130. Preferably, the peripheral ring 144 extends radially outward from die plunger 130. More preferably, the peripheral ring 144 is made integral to die plunger 130. Alternatively, the peripheral ring 144 can be made as a separate piece that is attached onto d e outer surface 135 of the plunger 130. In this embodiment, die peripheral ring 144 has an upper sealing surface 136 extending to d e interior surface 193 of die reservoir 195 and a lower sealing surface 139 extending to the interior surface 193 of the reservoir 195. Preferably, the upper sealing surface 136 extends substantially upward and radially outward from die peripheral ring 144 and die lower sealing surface 139 extends substantially downward and radially outward from die peripheral ring 144. More preferably, the upper and lower sealing surfaces 136 and 139 are annular in shape. The upper sealing surface 136 and the lower sealing surface 139 are in slidable sealing contact wid d e interior surface 193 of the reservoir 195. Thus, the spray pump 300 has a reservoir 195 with an interior surface 193 d at is in sliding contact widi die upper and lower sealing surfaces 136 and 139 which create a leak tight seal between die peripheral ring 144 and d e interior surface 193 of die reservoir 195. Preferably, die peripheral ring 144 is spaced away from die interior surface 193 by die upper and lower sealing surfaces 136 and 139. More preferably, the peripheral ring 144 has at least one axial flow path 131 extending therethrough allowing fluid to be in communication diroughout the interior chamber 178 and allowing fluid to flow from d e main chamber 179 into d e annular chamber 133. The equation for approximating die pressure drop of die fluid through the flow padi 131 is given by: ΔP = [ 128 * Q • μ * L 1 / [ π * L * ] where ΔP is die pressure drop across the flow padi 131, μ is die viscosity of die fluid, Q is the flow rate through the flow padi 131, D n is the hydraulic diameter of the flow path 131, and L is the length ofthe flow path 131. The hydraulic diameter is equivalent to an effective diameter of the cumulative flow padi 1 1 areas. For a given flow rate (Q) of fluid moving into die annular chamber 133, die pressure drop (ΔP) across die flow padi 131 increases as die hydraulic diameter (D n ) decreases. As the hydraulic diameter (Dj,) becomes sufficiently small, the pressure drop (ΔP) becomes large enough diat the pressures inside the annular chamber 133 and main chamber 179 are no longer equivalent. When this condition occurs, die actuation force (F) required to be applied upon die actuator head 112 by a consumer to dispense product will increase due to increase in hydraulic pressure (P) in die main chamber 179. Referring now to Fig. 3a, which is a full annular cross-section ofthe spray pump 300 taken along line 3a-3a, die flow padis 131 are shown in more detail. The reservoir 195, annular gap 191, peripheral ring 144, interior chamber 178, and poppet 240 are all shown in this cross-section. The peripheral ring 144 is shown having multiple flow paths 131 extending dierethrough. Although die flow padis 131 are depicted as being generally rectangular in shape, numerous odier shapes and configurations could be utilized. For example and not by way of limitation, die flow padis 131, shown in Fig. 3a, could be circular, oval, square, octagonal, irregular, serrated, sinusoidal, oblong, and die like. Additionally, as shown in Fig. 3, diese flow padis 131 are tapered in the axial direction. However, die flow padis 131 can also be arranged in many odier configurations, for example and not by way of limitation, conical, curved, converging, diverging, parallel, irregular, and die like. These flow paths 131 can be of many different shapes and configurations so long as fluid is allowed to pass through the flow padi 131. The closure 150, as shown in Fig. 3, extends circumferentially about the plunger 130 and die reservoir 195. The closure 150 is attached to die open top 152 of die reservoir 195 and has an aperture therein allowing d e plunger 130 to slidably extend through d e closure 150 such diat the interior chamber 178 is sealingly closed. In addition, die closure 150, preferably, includes internal threads 154 for attaching the closure 150 onto a container (not shown) in a leak tight manner. Various alternative methods of attaching die closure 150 onto die container can be utilized. Preferably, d e closure 150 further has an inner lip 156 wherein the inner lip 156 engages the open top 152 of die reservoir 195 thereby attaching the closure 150 to the reservoir 195. The inner lip 156 sealingly engages the open top 152 providing sealing of die interior chamber 178 adjacent to die annular chamber 133. The inner lip 156 also defines die periphery of die aperture in the closure 150 and die inner lip 152 is in slidable sealing contact widi the outer surface 135 ofthe plunger 130 at a location between die upper end 126 and the lower end 128. In the present embodiment, shown in Fig. 3, sealing of die interior chamber 178 is provided by sizing die mating components to allow a frictional or sliding seal in order to prevent leakage from the annular chamber 133 and seal off die interior chamber 178. Alternatively, as shown in Fig. 5, a stem seal 164 of die wiper seal variety can be provided which is, preferably, integral to die inner lip 256. Many additional sealing arrangements can also be utilized, for example, as shown in Fig. 6, an outer closure seal 362 and a stem seal 364 can be provided in order to prevent leakage of fluid from the annular chamber 333. The outer closure seal 362 is preferably, positioned between die closure 350 and d e reservoir 395 adjacent to die open top 352 ofthe reservoir 395. The stem seal 362 is preferably, positioned between the plunger 330 and die closure 350 in order to assure that no fluid leaks from d e annular chamber 333 into d e nozzle 310 around d e plunger 330. Preferably, the outer closure seal 362 and a stem seal 364 are constructed of a resilient material. As further shown in Fig. 3, the pumping engine 120 further comprises a retainer cup 160 attached to die plunger 130 at the lower end 128 which extends widiin die main chamber 179 and d e pumping engine 120 further comprises a poppet 240 slidably or movably disposed widiin d e retainer cup 160 adjacent to die longitudinal passageway 132. An outlet valve 142 is shown formed by die poppet 240 being biased against die longitudinal passageway 132 by a precompression spring 190. The poppet 240 is disposed in die lower end 128 of d e plunger 130 so as to be slidable or moveable away from die longitudinal passageway 132. Preferably, diis movement of die poppet 240 is a translational type movement in which the poppet 240 translates from a first position, blocking die longitudinal passageway 132, to a second position, spaced away from die longitudinal passageway 132 and vice versa. The precompression spring 190, preferably, is disposed about d e outer circumference of the poppet 240. The poppet 240 and die precompression spring 190 are both located widiin a retainer cup 160 which is connected to the lower end 128 of die plunger 130 by a knob 168 and recess 169 diat create a snap fit engagement between die retainer cup 160 and the plunger 130. The knob 168 and recess 169 are, preferably, in the form of multiple prongs which allow fluid to pass between open spaces diereof and surround die poppet 240 adjacent to die lower end 128. The precompression spring 190 acts in conjunction widi a retainer cup 160 to urge die poppet 240 upward and dius die poppet 240 is biased against the longitudinal passageway 132 in order to form the outlet valve 142. Preferably, the outlet valve 142 opens when a predetermined hydraulic pressure is reached widiin die interior chamber 178. The return spring 170 is positioned widiin die interior chamber 178 between die reservoir 195 and the retainer cup 160 and is preferably, disposed about the retainer cup 160. The return spring 170 engages and pushes against a rim 166 located on die retainer cup 160. The return spring 170 urges the retainer cup 160, plunger 130 and nozzle 110 upward and maintains diem in an upright, rest position prior to initiation of a dispensing cycle. Additionally, in order to compensate for a high hydraulic pressure, die stiffness of die precompression spring 190 can be increased. A stiffer precompression spring 190 could utilize wire coils having, for example, larger diameters or stiffer materials. A stiffer precompression spring 190 increases the hydraulic pressure required to move d e poppet 240 away from the longitudinal passageway 132 diereby preventing opening of die outlet valve 142 until d e desired high hydraulic pressure criteria is met. A poppet 240 of greater strength, for example, a solid configuration rather than a hollow configuration, can be utilized in order to provide greater durability when using die stiffer precompression spring 190. Also, a flattened poppet surface 141 can be provided on die poppet 240 at die outlet valve 142 in order to reduce wear on the poppet 240. While die high pressure manually-actuated spray pump 300 of die present invention can be primed in die same manner as the conventional spray pump 100, shown in Fig. 1, the venting scheme for the container is modified. To permit venting ofthe container (not shown), a closure venting hole 138 is provided on die closure 150 and a flute 137 is provided on die nozzle 110. The flute 137 is, preferably, in the form of a recessed area on die nozzle surface 113. The actuator head 112 of die nozzle 110 is sealed along its circumference by maintaining contact widi an upper skirt 15 of d e closure 150 around die periphery of die nozzle surface 113 when the spray pump 300 is in the fully upright position. Referring now to Fig. 4, during operation die actuator head 112 moves downward upon die application of an actuation force. When die actuator head 112 moves downward die flute 137 becomes aligned just inboard of die upper skirt 15 and, in die retracted position, the upper skirt 15 is spaced away from die nozzle surface 113 thereby providing an air gap for venting of die container. Air is thus allowed to communicate between the container and atmosphere through the closure venting hole 138. Alternatively, as shown in Fig. 6, venting of die container can be provided by having die nozzle surface 313 and a skirt surface 319 tapered or in sloped relation such that when die spray pump 500 is in die fully upright position d ere is circumferential contact between die skirt surface 319 and die nozzle surface 313. However, when d e actuator head 312 moves downward an air gap is formed between die skirt surface 319 and die nozzle surface 313, thereby venting the container. A container venting scheme which can increase die actuation force, for example, a protrusion on die nozzle 110 or closure 150 which is used to deflect anodier component in order to form an air gap, may not be preferred, however, such venting schemes, as well as various odier venting schemes, are well known to those skiUed in die art and can be provided widiout departing from die invention disclosed herein. As shown in Fig. 4, since the interior chamber 178 may be initially filled widi air, pruning of the pumping engine 120 is accomplished by moving die plunger 130 downward to pressurize die air widiin the interior chamber 178. As the plunger 130 moves downward, die lower sealing surface 139 on die peripheral ring 144 contacts the priming blip 197, thereby lifting part ofthe lower sealing surface 139 off of die interior surface 193 and allowing air to pass into die annular gap 191 and dien out d rough the vent hole 196. This release of air from the interior chamber 178 produces a vacuum widiin die interior chamber 178 during a return stroke of the plunger 130 as the return spring 170 urges die plunger 130 and nozzle 110 back to their upright positions. This vacuum pulls or sucks fluid dirough the inlet valve 182 and into die interior chamber 178, thereby filling die main chamber 179 of the interior chamber 178 with fluid. In order to initiate a dispensing cycle a user applies an actuation force by pressing downward widi die user's hand or fingers on die actuator head 112. Preferably, this actuation force is less than about 10 Ibf (44.5 N), and more preferably, die actuation force is less dian about 7 Ibf (31.1 N). This actuation force urges the nozzle 110, die plunger 130 and the peripheral ring 144 to move downward widiin d e reservoir 195, diereby pressurizing die fluid in d e interior chamber 178. In the present invention, as d e hydraulic pressure builds diroughout the entire interior chamber 178 and as die plunger 130 is moved downward, die annular chamber 133 increases in volume and die main chamber 179 decreases in volume. A portion of the fluid contained widiin d e main chamber 179 will flow dirough the flow pad 131 into die annular chamber 133. Since the main chamber 179 and die annular chamber 133 are in fluid communication through die flow padi 131, die hydraulic pressure within each chamber is essentially equivalent throughout die interior chamber 178. As the plunger 130 and die peripheral ring 144 move downward widiin d e reservoir 195 in response to die actuation force applied on d e actuator head 112 of d e nozzle 110, die fluid in die entire interior chamber 178 becomes increasingly pressurized. The precompression spring 190 is selected such that its spring force is overcome at a predetermined high hydraulic pressure. When die pressure widiin the interior chamber 178 reaches die predetermined high hydraulic pressure, d e spring force of d e precompression spring 190 is overcome and die poppet 240 is pushed away from die longitudinal passageway 132 by die high hydraulic pressure, diereby opening d e outlet valve 142. As used herein a high hydraulic pressure is the maximum value diat die hydraulic pressure reaches within the interior chamber 178. Preferably, the hydraulic pressure within d e interior chamber 178 reaches a maximum value of at least between about 120 psig (827 kPa) to about 200 psig (1379 kPa), and more preferably, a maximum value of about 200 psig (1379 kPa). When die outlet valve 142 is opened, pressurized fluid travels up die longitudinal passageway 132, dirough die nozzle 110 via d e channel 134 and is dispensed out of the exit orifice 118. Preferably, the fluid is dispensed from the spray pump 300 in an ultra fine spray. Ultra fine sprays as used herein have a mean particle size of about 40 microns or less. At the end of the downward actuation stroke, the hydraulic pressure in the interior chamber 178 decreases below die predetermined high hydraulic pressure due to the release of fluid through the nozzle 110, permitting the precompression spring 190 to again urge or bias the poppet 240 against the longitudinal passageway 132 to close the outlet valve 142, diereby ceasing die flow of fluid. When die user releases the actuator head 112 by removing the actuation force, die return spring 170 pushes against die rim 166 of the retainer cup 160 to urge die retainer cup 160, the plunger 130 and die nozzle 1 10 to return to dieir original upright, positions. As the retainer cup 160 and die plunger 130 move upward, a vacuum is generated in die interior chamber 178 causing the ball 180 to lift off the valve seat 198, allowing fluid to be drawn upward and flow past die inlet valve 182 and to replenish die fluid in die interior chamber 178 for die next dispensing cycle. The actuation force is dependent on die mediod or manner in which fluid is dispensed from die spray pump 300 and die rate at which die plunger 130 travels downward. The actuation force for diis spray pump 300 is measured using, for example, an Instron model 8501 universal testing machine in order to generate d e dispensing cycle and a Nicolet model 410 digital oscilloscope in order to record die measurements and collect die data. The actuator head 112 of die nozzle 110 is downwardly depressed at a rate of about 3 inches per second by die Instron model 8501 in order to simulate a typical consumer moving die plunger 130 downward. A distance of about 0.22 inches is die total distance diat d e plunger 130 travels which equates to the overall pump stroke. The overall pump stroke is limited by die length of d e reservoir 195 and die configuration of die interior chamber 278. Data plots representing d e time, distance, and actuation force are generated. Testing is performed at room temperature conditions of about 72° F. As can be seen in Fig. 4, die annular chamber 133 has expanded in size as die plunger 130 and d e peripheral ring 144 have moved down widiin die reservoir 195. Some portion of the fluid from the main chamber 179 has been transferred dirough the flow path 131 into die annular chamber 133 above the peripheral ring 144 and some portion ofthe fluid from the main chamber 179 has been dispensed out of die nozzle 110 dirough the longitudinal passageway 132. Thus, the present invention enables die effective area of die peripheral ring 144 to be reduced, diereby reducing die actuation force required to dispense fluid from d e pumping engine 120. Since some portion of the fluid is transferred from die main chamber 179 to the annular chamber 133 above the peripheral ring 144 during the dispensing cycle, less fluid is available to be dispensed through the nozzle 110 per equivalent length of stroke of die plunger 130. The volume of fluid dispensed during a single dispensing cycle is referred to as die pump dose which is equivalent to the overall pump stroke in distance multiplied by die effective area of the plunger 130. In order to compensate for any variations in pump dose, the pump stroke can be lengthened or shortened to provide approximately an equivalent pump dose as supplied in a conventional spray pump. It can be seen diat die pump dose can be increased or decreased in d is manner. The pump stroke, in this preferred embodiment, is increased by increasing die lengd of die reservoir 195, plunger 130, and return spring 170 along widi various odier component parts widiin die pumping engine 120. Thus, an equivalent or most any odier desired pump dose can be obtained. In a first alternative embodiment of die high pressure manually-actuated spray pump 400, as shown in Fig. 5, die peripheral ring 144 of Fig. 3 has been removed or reduced in diameter and die annular chamber 233 is in direct fluid communication with die main chamber 279 d us, forming die interior chamber 278. This reduction in diameter can be such diat die diameter of die peripheral ring 144 of Fig. 3 is now substantially the same as die diameter of the plunger 230 or some intermediate stage of greater or lesser diameter wherein the flow path 131 of Fig. 3 has simply become an annular ring about the periphery of the plunger 230 and is dius incoφorated into the annular chamber 233. As shown in Fig. 5, the annular chamber 233 is formed between d e outer surface 235 ofthe plunger 230, the interior surface 293 of die reservoir 295 and d e closure 250. Thus, in this embodiment, fluid widiin die interior chamber 278 can freely flow between the annular chamber 233 and die main chamber 279. As shown in Fig. 5, the effective area ofthe peripheral ring 144 of Fig. 3 is reduced and in essence becomes equivalent to die effective area of the plunger 230. In operation, as the plunger 230 and die poppet 240 move downwardly widiin the reservoir 295 in response to an actuation force on the nozzle 210, fluid is displaced widiin die interior chamber 278 and die fluid becomes increasingly pressurized. When die hydraulic pressure in the interior chamber 278 reaches a predetermined high hydraulic pressure, die poppet 240 will be pushed away from die longitudinal passageway 232 to release fluid through d e longitudinal passageway 232, and dirough the nozzle 210 via die channel 234 in order to be dispensed. Additionally, venting of die interior chamber 278 is accomplished when die bulb 265, located above d e stem seal 164 on die outer surface 235 of die plunger 230 and extending partially around die circumference of the plunger 230, moves downward and contacts die stem seal 164 allowing air to escape out ofthe interior chamber 278. While the present invention has been described with respect to spray pumps d at have a precompression spring 190 and a return spring 170, as shown in Fig. 3, it is to be understood that diis invention can also be applied to odier types of dual spring pumps, as well as to many single spring type spray pumps. In a second alternative embodiment, as shown in Fig. 6, a high pressure manually-actuated spray pump 500 is shown, in which the precompression spring 190 of Fig. 3 and die return spring 170 of Fig. 3, have been replaced widi a single spring 390. In addition, die retainer cup 160 of Fig. 3, has also been eliminated in dus embodiment. The poppet 340 is configured, as shown in Fig. 6, to move away from and into contact widi die longitudinal passageway 332 as die hydraulic pressure increases and decreases respectively, thereby opening and closing the oudet valve 342. The single spring 390 f nctions similarly to the previous embodiments, wid die exception diat die single spring 390 acts in conjunction widi die poppet 340 in order to return the plunger 330 and die nozzle 310 to dieir upright positions. Similar to the embodiment shown in Fig. 3, diis second alternative embodiment incoφorates an annular chamber 333 above die peripheral ring 344 which is in fluid communication widi die main chamber 379 through at least one flow path 331 in the peripheral ring 344. When an actuation force is applied to the actuation head 312 of d e nozzle 310 fluid becomes pressurized widiin the interior chamber 378. The interior chamber 378 is comprised of die annular chamber 333, die flow pad 331 and die main chamber 379. When a predetermined high hydraulic pressure is reached, a portion of die fluid widiin die interior chamber 378 is displaced dirough the oudet valve 342 into die longitudinal passageway 332 and is dispensed from die nozzle 310. Thus, die flow padi 331, as in die previous embodiments, provides a means for reducing die effective area of the peripheral ring 344, so diat a high hydraulic pressure can be generated in die high pressure manually-actuated spray pump 500 without significantly increasing d e actuation force required to initiate a dispensing cycle. The present invention has been described widi respect to a high pressure manually- actuated spray pump 500 for dispensing a fluid. Preferably, the fluid comprises a hair spray. However, it is to be understood diat die present invention can be used for dispensing any number of various types of fluids, for example, hair sprays, cosmetics, perfumes, deodorants, antiperspirants, hard surface cleaners, caφet cleaners, oil based products, stain removers, laundry products, and die like. Although many materials can be used in die construction of d is spray pump, preferably, the precompression spring 190, return spring 170 and single spring 390 are of a helical, metallic material such as stainless steel, and d e ball 80 is preferably constructed of a metal or metallic material such as stainless steel, with all of die remaining components of d is spray pump, preferably, being made of a plastic material such as polyediylene, polypropylene, or the like. The presently preferred plastics manufacturing process is injection molding. Aldiough particular versions and embodiments of die present invention have been shown and described, various modifications can be made to dus high pressure manually- actuated spray pump widiout departing from die teachings of die present invention. The terms used in describing the invention are used in their descriptive sense and not as terms of limitation, it being intended tiiat all equivalents tiiereof be included widiin die scope of die appended claims. The following Example illustrates a fluid and spray pump combination which has been successfully prepared and which illustrates die relationship between d e various parameters discussed in detail above. EXAMPLE A fluid suitable for use in a spray pump according to die present invention is a hair spray product prepared from the following components (% by weight): SD Alcohol 40 78.7600 Water 15.5243 Octylacrylamide/Acrylates/Butylarruneothyl 4.0000 Mediacrylate Copolymer Aminomediyl Propanol 0.7135 Dimethicone Copolyol 0.5000 Cyclometiiicone 0.2400 Ammonium C9-10 Perfluoroalkyl Sulfonate 0.1400 Fragrance 0.1000 Pandienol 0.0100 Octyl Salicylate 0.0100 Myristoyl Hydrolyzed Collagen 0.0020 Keratin Amino Acids 0.0002 100.0000 % An exemplary spray pump according to die embodiment of die present invention depicted in Figure 3, for use widi the product described above, was constructed having die following details: Pumping Engine M300 Finger Pump, Monturas, S. A. Precompression Spring K = 26.2 lb./in. Flow Path Diameter 0.018 inches Quantity of Flow Paths 30 When diis fluid and spray pump combination was tested using die test mediod described above, an actuation force of 7.66 Ibf was obtained at the time die outlet valve began to open.

Claims: What is claimed is: 1. A manually-actuated spray pump for dispensing a fluid, the spray pump comprising a nozzle through which the fluid is dispensed and a pumping engine including a reservoir, a closure, and a plunger, the reservoir having an open top and a closed bottom and an interior surface, the plunger having an outer surface and a longitudinal passageway extending therethrough, the plunger further having an outlet valve mounted therein and an upper end and a lower end, the lower end being slidably disposed within the open top ofthe reservoir forming an interior chamber: characterized in that the interior chamber includes an annular chamber and a main chamber, the plunger further having a peripheral ring which is affixed to the outer surface and is in slidable contact with the interior surface, the peripheral ring separates the annular chamber from the main chamber, the peripheral ring having a flow path therethrough allowing the annular chamber to be in fluid communication with the main chamber, the closure being attached to the open top of the reservoir allowing the plunger to slidably extend through the closure such that the interior chamber is sealingly closed, the nozzle being mounted on the upper end of the plunger such that the longitudinal passageway is in fluid communication with the nozzle, the interior chamber being separated from the longitudinal passageway by the outlet valve, and the spray pump being operable in response to the application of an actuation force upon the nozzle causing the plunger to move within the reservoir and pressurize the fluid within the interior chamber such that a high hydraulic pressure is generated within the interior chamber in response to the movement of the plunger, the outlet valve opening in response to the high hydraulic pressure thereby allowing a portion of the fluid to flow from the interior chamber through the longitudinal passageway to the nozzle, wherein the actuation force used to generate the high hydraulic pressure is lower compared to conventional spray pumps. 2. The manually-actuated spray pump for dispensing a fluid according to Claim 1 wherein the closed bottom is characterized by an inlet valve. 3. The manually-actuated spray pump for dispensing a fluid according to Claim 1 or 2 wherein the outlet valve opens at a predetermined hydraulic pressure. 4. The manually-actuated spray pump for dispensing a fluid according to any one ofthe preceding Claims wherein the outlet valve is characterized by a poppet biased against the longitudinal passageway by a precompression spring. 5. The manually-actuated spray pump for dispensing a fluid according to any one of the preceding Claims wherein the high hydraulic pressure within the interior chamber reaches a value between about 120 psig to about 200 psig. 6. The manually-actuated spray pump for dispensing a fluid according to any one ofthe preceding Claims wherein the actuation force is less than about 10 lb. 7. The manually-actuated spray pump for dispensing a fluid according to any one of the preceding Claims wherein the closure is further characterized by an inner lip, the inner lip is attached to the open top of the reservoir and is in slidable sealing contact with the outer surface of the plunger at a location between the upper end and the lower end. 8. The manually-actuated spray pump for dispensing a fluid according to any one ofthe preceding Claims wherein the fluid is characterized by a hair spray. 9. The manually-actuated spray pump for dispensing a fluid according to any one ofthe preceding Claims wherein the pumping engine further characterized by a retainer cup attached to the plunger at the lower end and extends within the main chamber. 10. The manually-actuated spray pump for dispensing a fluid according to any one ofthe preceding Claims wherein the pumping engine further characterized by a poppet movably disposed within a retainer cup adjacent to the longitudinal passageway, the poppet being moveable between a first position, blocking the longitudinal passageway, and a second position, spaced away from the longitudinal passageway.

Inventors: ARNOLD CHRISTOPHER BERNARD, HERSHEY DONALD EMERSON, LUND MARK THOMAS, ARNOLD, CHRISTOPHER, BERNARD, HERSHEY, DONALD, EMERSON, LUND, MARK, THOMAS
Applicants: PROCTER & GAMBLE, THE PROCTER & GAMBLE COMPANY
Application year: 1996
Main classification: B05B11
IPC codes: B05B11, B65D47