Abstract:
An electrostatic spraying device being configured and disposed to electrostatically charge and dispense a product from a supply to a point of dispersal. This device has a reservoir configured to contain the supply of product and a nozzle to disperse the product. A channel is disposed between the reservoir and the nozzle, wherein the channel permits the electrostatic charging of the product upon the product moving within the channel. A positive displacement mechanism is used to move the product from the reservoir to the nozzle. A portion of the high voltage electrode being disposed between the reservoir and the nozzle is used to electrostatically charge the product within the channel at a charging location. A mixing mechanism may be disposed between the reservoir and the nozzle to reconstitute any product which may have separated. The high voltage contact may be spring biased in direction towards the high voltage electrode. The high voltage electrode may be annular to improve contact with the high voltage contact.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation-in-part of our earlier applications, U.S. Ser. No. 09/377,332, filed on Aug. 18, 1999, now U.S. Pat. No. 6,318,647, and U.S. Ser. No. 09/377,333, filed on Aug. 18, 1999, now U.S. Pat. No. 6,311,903. 
    
    
     TECHNICAL FIELD OF INVENTION 
     This invention relates to a disposable cartridge for a portable electrostatic spray device designed for personal use. More particular, this invention is focused on improvements for product mixing and maintaining a superior high voltage connection. 
     BACKGROUND OF THE INVENTION 
     In U.S. Pat. No. 4,380,786, Kelly offers a refillable reservoir system. However, the system described by Kelly does not integrally include a nozzle with the delivery system. The system, as described, would cross contaminate the liquid delivery system when it would be desired to use multiple liquids as Kelly&#39;s delivery system is simply a piston operated pump with a dip tube extending into the product reservoir. To avoid cross-contamination this system would necessitate an added cleaning step with a specialized cleaning solution. Furthermore, Kelly does not include a positive displacement system. Rather, Kelly has a non-continuous delivery system in that fluid is delivered in response to user actuation of lever arm 266. As such, Kelly&#39;s flow rate will be variable because the rate at which the lever is depressed may vary due to inconsistent actuation force from the user. Kelly&#39;s system also does not recognize the need and therefore does not offer a solution to limiting electrical current passing through the product reservoir. Lastly, Kelly does not offer a means by which to mix the product in the reservoir. 
     In U.S. Pat. No. 6,079,634, Noakes offers a disposable reservoir system. The Noakes system is not a “clean” design, as the electrode stays connected with the device and would be a common element for all reservoirs in communication with the device. Noakes&#39; electrode is a source for cross-contamination between products from different reservoirs. Further, Noakes&#39; electrode design is a thin metal wire, which has an increased breakage potential. Further, the system described by Noakes is a non-continuous delivery system. Further, Noakes does not recognize or offer a solution for the problem of limiting electrical current passing through the product reservoir. Further, Noakes does not offer a method to incorporate a mixing feature in the reservoir to mix product. Finally, Noakes does not address the problem of removing or re-using a partially filled reservoir. With the reservoir being punctured by the electrode, removal of a partially filled reservoir may be messy. Further, when the partially filled reservoir is desired for use again, one would need to align the electrode with the previous puncture site, or create a different puncture and then devise a way to prevent product leakage from the previous puncture site. 
     SUMMARY OF THE INVENTION 
     A disposable cartridge for an electrostatic spraying device which is configured and disposed to electrostatically charge and dispense a product from a supply to a point of dispersal. The electrostatic spraying device has a reservoir configured to contain the supply of product and a nozzle to disperse the product. The nozzle being disposed at the point of dispersal. The nozzle has an exit orifice. A channel is disposed between the reservoir and the nozzle, wherein the channel permits the electrostatic charging of the product upon the product moving within the channel. A positive displacement mechanism is used to move the product from the reservoir to the nozzle. A power source supplies an electrical charge. A high voltage power supply, high voltage contact, and high voltage electrode are used. A portion of the high voltage electrode being disposed between the reservoir and the nozzle is used to electrostatically charge the product within the channel at a charging location. A mixing mechanism may be disposed between the reservoir and the nozzle to reconstitute any product which may have separated. The mixing mechanism may be a mixing ball, static mixer, disc having at least one hole, baffle having at least one opening, prop mixer. 
     The high voltage contact may be spring biased in direction towards the high voltage electrode. The high voltage electrode may be annular to improve contact with the high voltage contact. A locking mechanism may be added to secure the connection between the high voltage contact and the high voltage electrode. A locking feature may be added to secure the disposable cartridge within the device. An ejection feature may be added to release the disposable cartridge from the device. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     While the specification concludes with claims particularly pointing out and distinctly claiming the present invention it is believed that the same will be better understood from the following description, taken in conjunction with the accompanying drawings, in which: 
     FIG. 1 is an exploded isometric view of a disposable cartridge for a hand-held, self-contained electrostatic spraying device; 
     FIG. 2 is a cross-sectional view of the disposable cartridge within FIG. 1; 
     FIG. 3 is a cross-sectional view of a disposable cartridge having a static mixer; 
     FIG. 4 is an isometric view of a disposable cartridge having at least one disc for increasing turbulent mixing; 
     FIG. 5 is an isometric view of a disposable cartridge having at least one baffle for increasing turbulent mixing; 
     FIG. 6 is a cross-sectional view of a disposable cartridge having a prop mixer; 
     FIG. 7 is an exploded isometric view of a hand-held, self-contained electrostatic spraying device having a disposable cartridge; 
     FIG. 8 is an assembled isometric view of the device within FIG. 7; 
     FIG. 9 is a cross-sectional view of the exiting portion of the device within FIG. 1; 
     FIG. 10 is an exploded isometric view of the insert sleeve and accompanying parts within FIG. 1; and 
     FIG. 11 is an isometric view of a disposable cartridge having a prop mixer which is unattached. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to FIGS. 1 and 2, a hand-held, self-contained electrostatic spraying device  5  having a disposable cartridge  200  is shown. Disposable cartridge  200  may contain a variety of product, including but not limited to, cosmetics, skin creams, and skin lotions. The product in disposable cartridge  200  may be positively displaced (discussed infra) and powered by gearbox/motor component  10 . Gearbox/motor component  10  may be fixed onto a left or first housing  30 . The gearbox/motor component  10  can be affixed into place mechanically, adhesively, or by any other suitable technique. Gearbox/motor component  10  preferably comprises a precision motor  10   a  connected to a gearbox  10   b . Power source  20  provides power to the device. An example of a suitable power source  20  includes, but is not limited to, two “AAA” type batteries. The power source  20  provides power to the device through the control circuit  60 , the high voltage power supply  40 , and then the high voltage contact  50 , which contacts the disposable cartridge  200 . High voltage power supply  40  is powered and controlled by control circuit  60  (discussed infra). Power-on switch  80  permits the user to cause an interruption between power source  20  and circuit control  60 . Power-on switch  80  is designed such that voltage is supplied to the remainder of the circuit only when switch  80  is in the “ON” or closed position. Apply switch  70  permits the user to selectively activate motor  10   a , thereby activating the delivery and spraying of the product. Gearbox/motor component  10  has a driver  90  fastened to a shaft (not shown in FIGS. 1 &amp; 2, see FIG. 3) of gearbox  10   b , for example, with a set screw (not shown). Driver  90  has a number of protruding fingers, for example, three, which can fit into the matching recesses on the back of actuator  240 . 
     Alternatively, the product reservoir  220  may be formed of a conductive material and used to maintain the product reservoir at a high potential instead of having a separate conductive shield around the reservoir  220 . A cartridge insulator  260  can prevent discharge from the conductive product reservoir  220  to points having a lower potential that are in close proximity to the product reservoir  220 . The product reservoir  220  can be molded of an electrically conductive material plastic such as acrylonitrile butadiene styrene (ABS) filled with 10% carbon fibers. The cartridge insulator  260  provides an insulating cover to prevent discharge from the conductive product reservoir  220  to objects within the device having lower electrical potentials. In this embodiment, the conductive shield  210  is not required. 
     A first aspect of this invention relates to a means of mechanically mixing and re-suspending separated material within either product reservoir  220  or within the subsequent product delivery pathway. In a first embodiment, as exampled in FIG. 2, one or more mixing balls  290  are placed within product reservoir  220 . Disposable cartridge  200  is then shaken by the operator which causes mixing ball  290  to move within product reservoir  220 . The movement of mixing ball  290  within product reservoir  220  achieves turbulent mixing of the product within product reservoir  220 , thereby reconstituting any separated product. It may be appreciated that the shaking of disposable cartridge  200  may occur while it is either inside or outside of the intended electrostatic spraying device. 
     In yet another embodiment that provides for product mixing, as exampled in FIG. 3, a static mixer  400  is placed in fluid communication between product reservoir  220  and nozzle exit orifice  280 . Static mixer  400  is designed such that it creates a high degree of turbulent mixing within the fluid flow path in comparison to a straight fluid flow path. The turbulent mixing achieved within the fluid flow path should reconstitute any separated product. Static mixers  400  include, but are not limited to: 
     1. a helical type structure, as exampled in FIG. 3, although other geometries may be appreciated; 
     2. at least one disc  500 , as exampled in FIG. 4, having at least one hole  510 . Disc  500  being inserted within the product flow path. A plurality of discs  500  may be inserted, and more preferably with their holes  510  not being in axial alignment in order to increase turbulent mixing. It may be appreciated that one skilled in the art may change the diameter of holes  510 , the location of holes  510 , and/or the number of holes  510  in order to alter the degree of turbulent mixing. The diameter of hole  510  in the embodiment of FIG. 4 is approximately 0.030″ diameter. 
     3. at least one baffle  600 , as exampled in FIG. 5, having at least one opening  610 . Baffle  600  being inserted within the product flow path. A plurality of baffles  600  may be inserted, more preferably with their openings  610  not being in axial alignment in order to increase turbulent mixing. It may be appreciated that one skilled in the art may change the change the size of baffles  610 , the location of baffles  610 , and/or the number of baffles  610  in order to alter the degree of turbulent mixing. 
     In yet another embodiment, as exampled in FIGS. 6 and 11, a prop mixer  700  is added within product reservoir  220  in order to provide product mixing. Prop mixer  700  may take the form of a paddle connected to piston  230 . As piston  230  rotates up or down, so does prop mixer  700 , thereby creating turbulent mixing within product reservoir  220 . It may also be appreciated by one skilled in the art that such prop mixer  700  need not necessarily be attached to a piston  230 . Such alternative configurations include, but are not limited to: 
     1. prop mixer  700  being attached to another rotating member (e.g. threaded shaft  250 ) within either the product reservoir  220  or subsequent product delivery pathway; or 
     2. prop mixer  700  is unattached but yet still contained in said disposable so as to allow prop mixer  700  to rotate about a longitudinal axis to said disposable cartridge in response to product flow. 
     Referring to FIGS. 7 and 8, a hand-held, self-contained electrostatic spraying device  5  having a disposable cartridge  200  is shown. Disposable cartridge  200  may contain a variety of product, including but not limited to, cosmetics, skin creams, and skin lotions. The product in disposable cartridge  200  may be positively discharged (discussed supra) and powered by gearbox/motor component  10 . Gearbox/motor component  10  may be fixed onto a left or first housing  30 . The gearbox/motor component  10  can be affixed into place by either mechanically, adhesively, or by any other suitable technique. Gearbox/motor component  10  preferably comprises a precision motor  10   a  connected to a gearbox  10   b . Power source  20  provides power which ultimately operates precision motor  10   b . Examples for suitable power source  20  include, but is not limited to, two “AAA” type batteries. The power from power source  20  is channeled through circuit control  60  and high voltage power supply  40 , and then to high voltage contact  50  where it comes into contact disposable cartridge  200 . High voltage power supply  40  is powered and controlled by control circuit  60  (discussed infra). Power-on switch  80  permits the user to cause an interruption between power source  20  and circuit control  60 . Power-on switch  80  is designed such that voltage is supplied to the remainder of the circuit only when switch  80  is in the “ON” or closed position. Apply switch  70  permits the user to selectively activate motor  10   a , thereby activating the delivery and spraying of the product. Gearbox/motor component  10  has a driver  90  fastened to a shaft (not shown in FIGS. 1 &amp; 2, see FIG. 3) of gearbox  10   b , for example, with a set screw (not shown). Driver  90  has a number of protruding fingers, for example, three, which can fit into the matching recesses on the back of actuator  240 . 
     Yet another aspect of this invention relates to maintaining contact between high voltage contact  850  and conductive shield  210  on disposable cartridge  200 . For the class of electrostatic spraying devices with removable/replaceable product reservoirs, the ability to maintain the high voltage connection between the device itself and the disposable cartridge  200  is paramount for maintaining a consistent, steady state spray. When interruptions exists in the connection between the high voltage contact  850  and conductive shield  210  (or any other similar electrodes), spraying is interrupted and/or an undesirable spray is produced. In one embodiment, as exampled in FIG. 1, conductive shield  210  is of substantially circular geometry and has an annular electrode contact portion  300 . Annular electrode contact portion  300  improves the intimate contact between the high voltage contact  850  and conductive shield  210  which is particularly important when the product reservoir  220  is rotated or moved within device  5 . Such rotation and/or movement results in a period of interrupted supply of the high voltage power source, which leads to interruptions in spray performance. The addition of annular electrode contact portion  300  helps to minimize this problem. In an alternative design (not shown), it may also be appreciated by one skilled in the art to construct the high voltage contact  850  in a substantially circular geometry in order to achieve similar results. One skilled in the art would appreciate the use of spring biasing to improve contact between the high voltage contact  850  and conductive shield  210 , as exampled in FIG.  7 . In FIG. 7, high voltage contact  850  is configured as a ‘leaf spring’ such that when a disposable cartridge  200  is loaded into device  5 , the leaf spring is biased to maintain contact with conductive shield  210 . In yet another embodiment which improves the intimate contact between the high voltage contact  850  and conductive shield  210  is shown in FIGS. 9 and 10, further described below. 
     Yet another aspect of this invention, as exampled in FIGS. 9 and 10, is incorporating both locking and ejection features into disposable cartridge  200  and spraying device  805 . In this embodiment, a catch mechanism  1020  is used to secure disposable cartridge  200  into insert sleeve  910  at a clasp location  1010 . Catch mechanism  1020  also provides a positive tactile and audible signal to the user that disposable cartridge  200  is properly installed within device  5 . Locking mechanism  1000  consists of actuator button  1050 , locking slide  1030  and locking spring  1040 . Locking mechanism  1000  may be connected to the underside of disposable cartridge  200  or any other suitable location. Locking slide  1030  is biased in the “UP” position by locking spring  1040 . When a disposable cartridge  200  is installed, locking slide  1030  is moved down and disposable cartridge  200  is placed within insert sleeve  910 . When disposable cartridge  200  is completely within insert sleeve  910 , locking slide  1030  will slip into locking lug  310  (shown in FIG.  1 ), thereby causing an audible click and securely locking disposable cartridge  200  inside of insert sleeve  910 . Actuator  240  moves electrode cover  1070  in the same direction of disposable cartridge  200  insertion, thereby exposing high voltage contact  850  (not shown in FIG. 10) inside of device  5 . Electrode cover  1070  may be mounted within and guided back by slide channel  1080 . While moving back, electrode cover  1070  compresses bias spring  1060 . When a user desires to remove disposable cartridge  200  from insert sleeve  910 , the user actuates actuator button  1050  to move locking slide  1030  down, thereby disengaging it from locking lug  310 . Disposable cartridge  200  is then moved forward within insert sleeve  910  by the decompression of bias spring  1060 . The user can then finish removing disposable cartridge  200  from device  5 . Once installed and secured in place, locking mechanism  1000  will prevent disposable cartridge  200  from being inadvertently removed through shaking and handling of device  5  during usage and storage. 
     Having shown and described the preferred embodiments of the present invention, further adaptions of the present invention as described herein can be accomplished by appropriate modifications by one of ordinary skill in the art without departing from the scope of the present invention. Several of these potential modifications and alternatives have been mentioned, and others will be apparent to those skilled in the art. For example, while exemplary embodiments of the present invention have been discussed for illustrative purposes, it should be understood that the elements described will be constantly updated and improved by technological advances. Accordingly, the scope of the present invention should be considered in terms of the following claims and is understood not to be limited to the details of structure, operation or process steps as shown and described in the specification and drawings. 
     Incorporation by Reference: 
     Relevant electrostatic spray devices and cartridges are described in the following commonly-assigned, concurrently-filed U.S. patent applications, and hereby incorporated by reference: 
     “Electrostatic Spray Device”, filed as application Ser. No. 09/759,552, which is assigned Attorney Docket No. 8394. 
     “Electrostatic Spray Device”, filed as application Ser. No. 09/759,551, which is assigned Attorney Docket No. 8395. 
     “Electrostatic Spray Device”, filed as application Ser. No. 09/759,550, which is assigned Attorney Docket No. 8396.