Abstract:
A liquid dispensing device includes a storage container having an opening and dome pump assembly attached thereto substantially over the opening for metered dispensing. The dome pump assembly is integrally formed with a dome button, top portion extension and valve to facilitate manufacture and reduce costs of the pump while improving performance thereof. The valve is employed to pull liquid from the storage container into the dome for metering. An exit passageway formed from the extension and container wall serves as an output valve. The user squeezes the dome and the opposite side of the container pouch concurrently to seal the flapper valve to urge liquid out through the exit passageway for actual dispensing.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 12/832,798, filed Jul. 8, 2010, now abandoned which claims the benefit under 35 U.S.C. §119 (e) of the U.S. Provisional Patent Application Ser. No. 61/223,883, filed on Jul. 8, 2009. The application Ser. No. 12/832,798 is also a continuation-in-part of U.S. patent application Ser. No. 12/052,338, filed Mar. 20, 2008, now U.S. Pat. No. 8,061,566 which in turn is a continuation-in-part of U.S. patent application Ser. No. 11/951,351, filed Dec. 6, 2007, now U.S. Pat. No. 7,997,454 which application claims the benefit under 35 U.S.C. §119 (e) of the U.S. Provisional Patent Application Ser. No. 60/914,243, filed Apr. 26, 2007. The application Ser. No. 12/832,798 is also a continuation-in-part of U.S. patent application Ser. No. 11/074,817, filed Mar. 8, 2005, now U.S. Pat. No. 7,419,322, issued Sep. 2, 2008, which in turn claims the benefit under 35 U.S.C. §119 (e) of the U.S. Provisional Patent Application Ser. No. 60/551,993, filed Mar. 10, 2004. 
    
    
     FIELD OF THE INVENTION 
     This invention relates generally to dispensing devices and packages. More specifically, the present invention relates to metering devices that can controllably dispense fluid media from a source of fluid media. 
     BACKGROUND OF THE INVENTION 
     Various types of fluid material and media are employed for different purposes throughout commerce and industry. For example, there are various products in the personal care, home care, air care, transportation care, and food industries that require some type of dispensing of a fluid material from a source of such material. When this material is sold in commerce, it must be contained and stored in some type of container. When that product is used, it must be dispensed from its storage container to a location for use. 
     In the prior art, there are many different types of dispensers that are employed for the delivery of a stored fluid material to its desired location for use. For example, a storage container having a flexible body with a nozzle tip extending therefrom is commonly provided for such a purpose. An example of such use can be seen in the context of a ketchup dispenser, where a user squeezes the container body to urge the fluid material (i.e., ketchup) out from the container body and through the nozzle tip to accurately deposit the fluid material at the desired location. In such an application, the amount of fluid that is ultimately delivered is determined by how much the user actually squeezed the container body. While this method has provided marginally acceptable results, this method also typically yields an erratic fluid volume since more or less fluid material may be delivered on each successive squeeze of the container body. Also, the container must be held upright to avoid leakage because no valves are employed in the fluid nozzle tip. 
     In another example of a prior art dispensing device, a flexible container is provided that holds a volume of fluid material to be delivered. In an attempt to overcome the leakage issue noted above, a single one-way check valve is provided at the exit port of the flexible container. When the flexible body is squeezed, the material is urged out under pressure through the valve. The difficulty here is that the valve over time becomes partially clogged thereby requiring that the user apply additional pressure to cause the valve to open. As a result, once the valve opens, the additional pressure causes more fluid material to be deposited than the user typically would have desired. 
     U.S. Pat. No. 7,419,322 represents a significant advancement over the above-described systems by providing a fluid dispensing device that includes a container with an interior fluid storage region therein. A flexible metering housing is disposed in fluid communication with the fluid storage region with a first one-way valve disposed between the container and the flexible metering housing. One way flow from the interior fluid storage region of the container fills the predetermined volume of the metering chamber with fluid by vacuum action when a button is depressed and then released. A second valve is in fluid communication with the metering housing and permits one-way fluid flow from the metering chamber to the exterior outer region of the container when the metering housing is depressed again. Each time the metering housing is depressed a substantially equal volume of fluid is dispensed from the container. 
     While the configuration and operation of this metering pump assembly provides excellent results, it should be recognized that it includes at least three separate elements, specifically a flexible button, an intake valve and an output valve. In some situations, it may be desirable to simplify this configuration by integrating various functions and/or reducing the number of parts. 
     U.S. Patent Application Publication No. 2008/0264973 discloses various embodiments that possess such a simplified design, wherein the valving and dispensing functions are incorporated into a design that is relatively simplified and cost-effective to produce, yet that also provides excellent results. However, even in the embodiment incorporating the fewest number of elements (shown in FIG. 17 of US 2008/0264973), the metering pump assembly includes two separate parts, i.e., one element incorporating dome button (608 of FIG. 17) and top portion (610 of FIG. 17) and another element incorporating base plate (602 of FIG. 17) and bottom portion (604 of FIG. 17). 
     In some cases, an even further simplified design may be desirable 
     SUMMARY OF THE INVENTION 
     In this regard, the present invention preserves many of the advantages of the devices disclosed in U.S. Pat. No. 7,419,322 and U.S. Patent Application Publication No. 2008/0264973, while employing a metering pump assembly that is even simpler in design, specifically comprising only a single integrated piece. 
     In accordance with one embodiment of the present invention, a fluid dispensing device includes a flexible pouch having a wall defining an interior compartment, the wall of the pouch having an opening passing therethrough from the interior compartment to an exterior of the pouch. A dome button with a top portion extension extending thereof is sealed to the exterior of the pouch in the vicinity of the opening around most of the periphery thereof to define a metering chamber. However, the end of the top portion extension is left unsealed such that the top portion extension and the exterior surface of the pouch define an exit pathway for the fluid when the dome button is depressed, with the top portion extension and the exterior of the pouch also forming a one-way exit valve. 
     A valve is also incorporated into the integrated construction of the dome button and top portion extension. The integrally formed valve includes an arm that extends from the dome button to provide a protrusion on the free end thereof to sealingly engage with the opening through the pouch to thereby form the one-way intake valve. 
     The valve may be spring-biased in such a fashion to be slightly open when at rest so that liquid may return to the pouch and not exit through the exit pathway, in the form of leakage, when pressure is accidentally placed on the dome button. Stand-off legs inside the dome may be used to retain the valve closed during desired dispensing. It is also possible that the valve may be spring-biased downwardly so that the intake valve member is normally closed so that on a down stroke of the dome button, the intake valve remains closed and metered liquid residing in the dome is urged out through the exit pathway as defined between the top portion extension and the exterior surface of the pouch. On an upstroke of the dome button, the intake valve lifts off the opening through the pouch to permit loading of liquid from the pouch into the metering chamber of the dome button. 
     As shown in the appended Figures, an upstanding circumferential wall is positioned about the dome button to prevent unwanted actuation thereof. The wall is preferably integrally molded with the dome button and the top portion extension. The wall is preferably relatively rigid and is not easily compressed when pressure is placed generally across it. Thus, to actuate the dome button for pumping, the flexible dome button itself must be specifically depressed, such as by a user&#39;s finger. As a result, actuation of the pump assembly is more likely to be carried out only when specifically desired. The integrated formation of parts makes the manufacture easier and less costly while retaining if not improving performance because there are less welds in the finished assembly. 
     Even though the pump includes a one piece construction, it can still carry out automatic shut-off of the exit passageway when pressure is exerted on the exterior of the pouch to help prevent leakage, because pressure on the pouch will force the exterior of the pouch in the area defining the exit passageway toward the top portion extension thereby tending to collapse, flatten and squeeze closed the exit passageway. Any material residing in the exit passageway is thus urged back into the chamber of the flexible dome button. As a result, unwanted leakage is further avoided when accidental or unintentional pressure is placed on the pouch. 
     Although not shown in the appended Figures, to further help prevent unwanted dispensing and leakage from the pump assembly of the present invention, a single use or re-sealable closure may be used. 
     The integrated dome button, top portion extension and valve can be made of any suitable material, such as a plastic or elastomeric material, and combinations thereof. The integrated components can be more rigid or more flexible depending on the application at hand. The pouch can also be made of any of a number of suitable materials or combination of materials, with a plastic or elastomeric flexible sheet material being preferred in some embodiments. In some applications, it may also be desirable for different portions of the pouch to be formed from different materials. For example, in some embodiments, the upper wall of the pouch (i.e., the wall to which the pump assembly is sealed) may be formed from a flexible sheet material, while the lower wall of the pouch may be formed from a rigid or semi-rigid material. Use of other materials and/or combinations of materials is also contemplated. 
     In view of the foregoing, the present invention is well suited for providing controlled metered delivery of liquid in any type of pouch configuration, such as stand-up pouches (SUP) gusseted pouches, printed pouches, reclosable zipper pouches as well as pouches and other vessels that include some type of tear away or punch hole exit port. For example, a hand cleaner dispenser with a tear away exit port would be particularly well-suited for a pump assembly configuration according to the present invention. 
     In general, the present invention can include valve geometry that can easily be modified to handle a large range of viscosities by, for example: 1) modifying the exit pathway width; 2) creating backflow pressure through weld footprints; 3) modifying the shape of the exit pathway; 4) modifying the size and shape of the opening through the pouch; 5) modifying the size, length and configuration of the stand-off legs on the dome button (if provided); 6) modifying the size, shape, flex and configuration of the one-way valve; and (7) incorporating a nozzle in the exit pathway. Also, the exit valve configuration can easily be modified to adjust the automatic shut-off pressure. 
     The pump assembly of the present invention has a wide array of applications of use to take advantage of the unique metered dosage capability of the present invention. Virtually any dispenser with any type of applicator material or combinations of applicator materials in different configurations can employ the present invention. 
     For example, the cleaning products and personal care industry has particular application in the controlled and metered dispensing of bath and shower gels. Also, medicines, cosmetics, hair care products, such as shampoos, skin care products, such as lotions, insect repellants and sunscreen products can employ the present invention. Also, various home products can be delivered in a device according to the present invention. These include products for furniture cleaning and polishing, tub and shower cleaning, floor cleaning and polishing, window cleaning, odor elimination, oven cleaning, laundry cleaning and apparel treatment. Also, air treatment devices can employ the present invention. Cleaning products can be dispensed in a controlled fashion, such as those for cleaning cars, bikes, planes and trucks. The dispensing device is particularly adapted for the personal transport and metered dispensing of sanitizers in liquid or gel form. The food industry has numerous potential applications, particularly for the dispensing of condiments, sauces, vitamins, beverages, beverage concentrates and beverage additives. 
     It is therefore an object of the present invention to provide a fluid dispensing device that can deliver a substantially equal volume of fluid material from each dispensing operation. 
     Another object of the present invention is to provide a fluid dispensing device that prevents inadvertent or accidental dispensing of liquid from the storage container when pressure is inadvertently or accidentally applied to the dome pumping mechanism or storage container of the dispenser. 
     It is a further object of the present invention to provide a fluid dispensing device that is insensitive to gravity. 
     Another object of the present invention to provide an exterior metering dispensing system that has a number of components integrally formed to better incorporate the pump assembly into a given application and simplify manufacturing and assembly of the container onto which it is installed. 
     It is yet a further object of the invention to provide a method of dispensing fluid by sealing an integrally formed pump assembly to a container. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The novel features which are characteristic of the present invention are set forth in the appended claims. However, the invention&#39;s preferred embodiments, together with further objects and attendant advantages, will be best understood by reference to the following detailed description taken in connection with the accompanying drawings in which: 
         FIG. 1  is a perspective view of an embodiment of a metering dispensing system with one-piece pump assembly of the present invention that includes valving to prevent inadvertent or accidental dispensing of liquid therefrom; 
         FIG. 2  is a front exploded perspective view of the metering dispensing system shown in  FIG. 1 ; 
         FIG. 3  is a cross-sectional view, through line  12 - 12  of  FIG. 1 , of a metering dispensing system of the present invention; 
         FIG. 4  is a perspective cross-sectional view, through line  12 - 12  of  FIG. 1 , of a metering dispensing system of the present invention; 
         FIG. 5  is a bottom perspective view of a metering dispensing system with one-piece pump assembly of the present invention; 
         FIG. 6  is a cross sectional view through line  12 - 12  of  FIG. 1  illustrating actual dispensing of the fluid. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Turning now to  FIGS. 1-4 , details are shown of a device  300  that includes the improved dispensing device of the present invention that prevents inadvertent or accidental dispensing of liquid  302  even when pressure is placed on the dome button  404  or storage container  320 . An efficient method of manufacturing a quality dispensing device  300  is to employ heat welding to construct the container  320 . For example, a top sheet  304  is typically heat welded to a bottom sheet  306  about their periphery to form a container  320  with an interior fluid storage region  322  therein. Other types of bonding, e.g. adhesive, are also contemplated. 
     The term weld, as used herein, is meant to include seal, adhere, bond, etc. Welding may be accomplished by heat, vibration, chemical, adhesive, ultrasonic or any other means of joining polymers known to those of ordinary skill in the art. 
     The term seal, as used herein, may be accomplished by pressure, heat, vibration, chemical, adhesive, ultrasonic or any other means of joining polymers known to those of ordinary skill in the art. 
       FIG. 1  illustrates a perspective view of a metering dispenser  300  that employs the improved one-piece pump assembly in accordance with the present invention. An outer storage container  320  is provided that may be formed of two sheets of material  304 ,  306  secured together, such as by welding, a tube of material, sealing, adhesives, etc. A metering pump, comprised of an upper member  326 , pulls liquid  302  from the storage container  320 , meters it, and then dispenses it through top portion extension  318  that forms a pathway to an exit port  308 . 
       FIG. 2  shows an exploded view of the top sheet  304  of material that forms a top portion of the storage container  320  and the metering pump  326  that is shown in  FIG. 1 . The metering pump or upper member  326  is installed onto a sheet of material  304 , which serves as the top wall of the storage container  320 . The sheet of material  304  includes an opening  316  passing from the interior compartment of storage container  320  to the exterior of the container. The dome button  404  of the upper member  326 , in the form of a flexible housing, is positioned above the opening  316 . The top portion extension  318  is positioned on the upper surface of the top sheet of material  304  that forms the storage container  320  for the dispensing device  300 . The upper member  326 , which includes the top portion extension  318  and a flapper valve  408 , is welded at its periphery to the sheet  304  to form the pump construction. Since the top portion extension  318  and the top sheet of material  304  lie adjacent to one another, this structure also serves as an exit valve to prevent further unwanted flow of liquid  302  from the device. 
     Turning now to  FIGS. 3 ,  4  and  6 , further details of the operation of the metering dispensing system are shown.  FIG. 3  illustrates a cross-sectional view, through the line  12 - 12  of  FIG. 1 , of the one-piece pump assembly of a metering dispensing system of the present invention. Valving in the assembly prevents any inadvertent or accidental dispensing of liquid  302  from the storage container  320  when pressure is accidentally or inadvertently applied to the dome button  404 . Stand-off legs  422 ,  424  are provided on the underside of the top of the flexible dome button  404  or the underside of wall  414 . 
     More specifically, the dispensing operation actually requires application of force to the flexible dome button  404  of the upper member  326 , as well as the exterior sheet  306  of the container or pouch. Since it is unlikely that the force would be inadvertently or accidentally applied to these two areas simultaneously, the likelihood of accidental or inadvertent dispensing of liquid is substantially eliminated. 
     Resting above the opening  316  and within the cavity  405  of the dome  404  of the upper member  326  of the present invention is a flapper valve  408 . Although a flapper valve is depicted and further described herein, it is not meant to be limiting. Many types of valves are contemplated by the invention. For instance, a valve having a thin stalk-like piece with a bead on the end could hang down from the inside top of the dome. It is possible that this flapper valve  408  be configured in a normally open condition but may also be configured to lie flat when at rest. As long as the exterior sheet  306  substantially below the dome  404  of the upper member  326  is not forcefully depressed, the flapper valve  408  does not seal against the opening  316  such that any inadvertent contact with the flexible dome pump housing  404  does not result in the dispensing of the product. Instead, since the flapper valve  408  is open, liquid product residing inside the cavity  405  of the upper member  326  will tend to simply flow back through the opening  316  to the reservoir within the storage container  320  itself rather than flow undesirably out through the exit valve to outside of the dispenser. In use, if a person has the dispenser in their pocket or purse and pressure is accidentally or unintentionally placed on the flexible dome button  404  of the upper member  326 , liquid will not flow outside the dispenser thereby preventing a mess from being made due to unintentionally dispensed product. 
       FIGS. 3 and 4 , show a circumferential upstanding wall  414  that encircles dome button  404  that is depressed for metered dispensing. The upstanding wall  414  helps prevent unwanted depression of the dome button  404 . The wall  414  is integrally molded with the dome button  404 , the flapper valve  408  and the top portion extension  318 . The wall  414  is preferably rigid and is not easily compressed when pressure is placed generally across it. Thus, to actuate the dome button  404  for pumping, the flexible dome button  404  itself must be specifically depressed, such as by a user&#39;s finger. As a result, actuation of the pump assembly  326  is more likely to be carried out only when specifically desired. The integrated formation of parts makes the manufacture easier and less costly while retaining if not improving performance because there are less welds or seams in the finished assembly. 
       FIG. 6  illustrates intentional dispensing of liquid  302 . When it is desired to actually dispense the liquid product  302 , the user&#39;s thumb  430  can depress the flexible dome  404  and the user&#39;s index finger  432  can concurrently apply activating force to the portion of the exterior sheet  306  of the container that is substantially below dome button  404  of the upper member  326  such that flexible dome  404 , with the assistance of the stand-off legs  422  under the flexible dome, securely seals and provides a positive lock of the flapper valve  408  over and about the opening  316  thereby closing the liquid flow passage back into the reservoir  434  of the storage container  320 . Thus, the only path for the liquid  302  contained within the cavity  405  of dome  404  is to exit through the exit passageway  436 , formed by the top portion extension  318  and the sheet of material  304 , for intended dispensing of the product, as indicated by the arrows in  FIG. 6 . 
     It should be understood that the stand-off legs  422  on the bottom of the flexible dome button  404  can be modified in size, length and configuration to adjust the amount of squeezing necessary by the user&#39;s fingers  430 ,  432  to effectuate sealing of the flapper valve  408 . For example, preferably four stand-off legs  422  are provided on the bottom of the flexible dome housing  404  in a 2×2 array and can be 1/32 of an inch in length. It is also possible that these stand-off legs  422  can be a single downwardly depending wall, such as in the shape of a circle or square. Such an array is configured to downwardly press against the one-way flapper valve  408  outside of the diameter of the opening  316  to provide a good seal of the flapper valve  408  to top sheet of material  304 . 
     Turning again to  FIG. 4 , the present invention provides further structure to prevent unwanted dispensing of liquid. In addition to the improved one-piece pump assembly, as above, automatic shut-off of the exit port passageway  436 , when pressure is exerted on the exterior of the storage container  320 , serves to prevent leakage. In  FIG. 4 , when pressure is applied to the outside of the storage container or pouch  320 , as indicated by arrows referenced A, the exit port passageway  436  tends to collapse, flatten and squeeze closed. As a result, any material residing in the passageway is urged back into the cavity  405  of the upper member  326 , as indicated by arrow referenced B. As a result, unwanted leakage is prevented when accidental or unintentional pressure is placed on the storage container  320 . 
     Referring back to  FIG. 6 , the operation of a dispensing device of the present invention is further explained. The dome button  404  of the upper member  326  is depressed to initiate a vacuum operation. More specifically, when the button  404  is further released, fluid  302  is pulled from the fluid storage region  434  of the container body  320  into the metering cavity  405 , which is configured to be of a certain known volume. The act of releasing the button  404  fills the metering cavity  405  to substantial capacity. Thus, a metered amount of fluid material  302  is contained within the cavity  405  in preparation for delivery. The size of the metering cavity  405  can be selected according to the type of fluid material  302  to be dispensed and the application therefore and the desired dosage volume. Further depression of the button  404  urges the measured volume of fluid  302  within the metering cavity  405  through the exit pathway  436  and out of exit port  308 , as shown in  FIG. 3 . 
       FIG. 5  shows a perspective bottom view of the metering dispensing system with a one piece pump assembly of the present invention. In this embodiment, the storage container is a transparent pouch  520  having a top sheet  504  of material that forms a top wall of the pouch  520  and a bottom sheet of material  506  sealed to the top sheet  504  such that an interior compartment or pouch  520  for maintaining fluid is formed between the two sheets  504  and  506 . The top sheet  504  has an opening  516  passing therethrough from the interior compartment to the exterior of the pouch. The underside of an integrally formed one-piece pump assembly  526  having a dome button  502 , top portion extension  518  and flapper valve  508  having an arm  506  that extends from the dome button  502  to provide a protrusion is visible through the transparent pouch  520 . The arm  506  of the flapper valve  508  is positioned above the opening  516 . The top portion extension  518  extends to the wall of the pouch  520 . The pump assembly  526  is sealed to the top sheet  504  along the weld line  512 . An exit pathway  522  is formed from the top portion extension  518  and the exterior surface of the top pouch sheet  504 . An exit port  514  is formed where the top portion extension meets the pouch wall. 
     Also, the exit pathway  522  may be equipped with a tear-off closure (not shown) that must be first removed or opened by the user to permit flow of liquid from the exit pathway  522  for use. Essentially, the tear-off closure is preferably a member that is connected to the top portion extension  518  by a weakened or thinned length of material while still sealing the exit port  514 . This permits the tear-off closure to be removed with little effort by the user but not so easily that it will disconnect by accident, such as during transport. The tear-off closure is particularly useful to prevent leakage during transport of a dispenser that uses the pump assembly  526  prior to a first use. Such a tear-off closure may be employed in any of the embodiments of the present invention. 
     Alternatively, to further help prevent unwanted dispensing and leakage from a dispenser equipped with the pump mechanism of the present invention, a re-sealable closure as described and shown in FIG. 17 of U.S. 2008/0264973 A1, incorporated herein by reference, may be used. Further, the re-sealable closure may be used in any of the embodiments of the present invention. 
     It should also be understood that these described closure mechanisms are just examples of the many different types of closures that can be used while still being within the scope of the present invention. 
     In summary, a new and novel dispenser is provided that can deliver consistent metered dosages of fluid material. The dispenser has a greatly improved construction. Namely, a number of components can be integrally formed to better incorporate a metered dome pump into a given application and to simplify the manufacturing and assembly of the pump and dispenser into which it is installed. Further, improved valving prevents accidental or inadvertent dispensing of liquid when pressure is placed on the flexible dome housing or body of the storage container or pouch. It would be appreciated by those skilled in the art that various changes and modifications can be made to the illustrated embodiments without departing from the spirit of the present invention. All such modifications and changes are intended to be covered by the appended claims