Abstract:
A re-fillable liquid spray dispenser useful as a fragrance atomizer includes a re-filling valve apparatus that is cooperative with a discharge nozzle of a liquid reservoir. A main chamber into which liquid may be filled in the spray dispenser is cyclically vented in unison with liquid injection through the re-filling valve apparatus. In this way, the liquid spray dispenser is accurately and efficiently vented during a liquid filling operation.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. provisional patent application Ser. No. 61/563,302 filed on Nov. 23, 2011 and entitled “Perfume Atomizer,” the content of which being incorporated herein in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to liquid dispensers generally, and more particularly to a re-fillable liquid spray dispenser having a mechanism for re-filling the dispenser without risk of liquid spillage, as well as an efficient mechanism for venting air as the dispenser is re-filled with liquid. 
     BACKGROUND OF THE INVENTION 
     Manual liquid dispensers of various sorts have been widely implemented in a variety of applications. One type of liquid dispenser is a manually operated pump that is arranged to dispense a liquid in a fine mist. Such liquid dispensers are commonly referred to as “atomizers”, in that the liquid is dispensed in very small liquid droplets. A common application for such liquid spray dispensers is in the dispensing of fragrance. 
     Liquid spray dispensers typically utilize a reciprocating pump that is manually operated by an external force applied against a restorative spring force of an expansion spring, with the application and removal of the external force being sufficient to generate pressure changes in the liquid chamber of the dispenser to alternately cause liquid dispensation and intake of liquid for the next pumping cycle. Liquid forced under pressure through a spray nozzle generates a dispersed mist of very small liquid droplets. Typically, liquid spray dispensers of this type comprise a pump mechanism which contains a liquid chamber, and a piston that is manually reciprocated in the pump mechanism. The piston is mounted for reciprocating movement in the liquid chamber, such that movement of the pump against a spring force causes the piston to move in the liquid chamber to thereby exert a compression force on the liquid in the chamber. Such force causes the liquid to move through a liquid passage to the spray outlet. Release of the external downward force to the pump permits the spring to expand under its restorative force, and to thereby return the pumping mechanism to its extended position. This movement of the pump mechanism causes the piston to move in the liquid chamber in a manner which expands the interior volume of the chamber. The negative pressure created by such movement draws liquid into the liquid chamber. Valve assemblies are typically employed in controlling the flow of liquid into the liquid chamber as its interior volume is increased by the movement of the pump mechanism. 
     In some cases, it has been found beneficial to be able to re-fill the liquid chamber in liquid spray dispensers. The ability to re-fill the liquid chamber permits re-use of the dispenser. Not only does re-use of the dispenser promote conservation of the materials employed in manufacturing the dispenser, but also permits the manufacture of more expensive dispensers, both in form and function. One particular example is a reusable fragrance atomizer having an overall size that is suitable for storage in a pocket or small purse. While such small dimensions are useful for portability, the fragrance capacity is compromised. Thus, it may be beneficial to be able to re-fill the liquid chamber in such portable dispenser. 
     A number of approaches have been implemented for re-filling a liquid chamber in a liquid spray dispenser. One approach is to merely open the liquid chamber and pour in the replacement liquid with the use of a funnel. This technique, however, is time-consuming and can result in spillage of the refilling liquid. Another approach is a liquid inlet valve incorporated with the liquid spray dispenser for injecting replacement liquid into the liquid chamber. The liquid inlet valve is configured for engagement with a dispensing nozzle of a large liquid reservoir. While various designs for inlet valve systems to liquid spray dispensers have been implemented, conventional designs do not establish quality liquid seals, thereby resulting in liquid leakage and/or are difficult or expensive to manufacture. 
     It is therefore an object of the present invention to provide a re-fillable liquid spray dispenser that is easy to operate, reliably seals the liquid chamber, and which improves manufacturability. 
     SUMMARY OF THE INVENTION 
     By means of the present invention, re-filling of a liquid spray dispenser may be consistently performed without liquid leakage. The dispenser of the present invention utilizes a valve body with a resilient sealing gasket that is adapted to sealingly engage a dispensing nozzle from a liquid reservoir. The valve body retains a liquid seal throughout the injection liquid process through a multiple-seal arrangement. Moreover, the valve body is synchronously movable with a venting rod to open and close a vent gasket in the liquid chamber with the opening and closing of the liquid inlet valve. In this manner, the air vent valve is open only when the liquid inlet valve is open. 
     In one embodiment, the re-fillable liquid spray dispenser of the present invention includes a vessel defining a main chamber and a pump apparatus having a liquid chamber and an air passage venting the main chamber. The pump apparatus defines a central axis that defines mutually perpendicular axial and radial directions. The spray dispenser further includes a piston rod having a hollow interior defining a liquid passage and a piston positioned at the liquid chamber and being axially movable in the pump apparatus by the piston rod to pump liquid from the liquid chamber into the liquid passage, and to draw liquid from the main chamber into the liquid chamber through a first check valve in the pump apparatus. A vent gasket is secured to the pump apparatus, and has a flange portion resiliently contactable with the pump apparatus to releasably seal the air passage. A valve body sealingly engages within an opening of the vessel, and has a first portion with an inlet passage permitting liquid flow through the valve body into the main chamber, and a second portion adapted to receive a discharge nozzle from a liquid reservoir. The valve body is biased into a first position to close the inlet passage. A venting rod is movable by the valve body to disengage the flange portion of the vent gasket from the pump apparatus to open the air passage. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1A-1C  are a sequential schematic illustration of a liquid filling operation to a liquid spray dispenser of the present invention; 
         FIG. 2A  is a cross-sectional isolation view of a discharge nozzle of the present invention; 
         FIG. 2B  is a schematic illustration of the discharge nozzle of  FIG. 2A  in operation with a liquid spray dispenser of the present invention; 
         FIG. 3  is a cross-sectional view of a liquid spray dispenser of the present invention; 
         FIG. 4A  is a cross-sectional isolation view of a portion of the liquid spray dispenser illustrated in  FIG. 3  in a dispensing condition; 
         FIG. 4B  is a cross-sectional isolation view of a portion of the liquid spray dispenser illustrated in  FIG. 3  in a non-dispensing condition; 
         FIG. 5  is a cross-sectional view of a portion of the liquid spray dispenser illustrated in  FIG. 3 ; 
         FIG. 6A  is a cross-sectional view of a liquid spray dispenser of the present invention in a non-filling condition; 
         FIG. 6B  is a cross-sectional view of a liquid spray dispenser of the present invention in a filling condition; and 
         FIG. 7  is an exploded component view of a liquid spray dispenser of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     With reference now to the drawing figures, and first to  FIGS. 1A-1C , a refillable liquid spray dispenser  10  of the present invention is illustrated in a refilling sequence to fill or re-fill a liquid chamber of dispenser  10  with a liquid  8  contained in a liquid reservoir  1 , which may be a container with a discharge  2 , such as in the case of a relatively large-volume fragrance container with a spray head  2 A. As illustrated in  FIG. 1B , dispenser  10  may be engaged with discharge  2  of reservoir  1  to transfer liquid  8  from reservoir  1  into dispenser  10 . Spray head  2 A may be removed in the illustrated embodiment, such that the stem of discharge  2  engages with dispenser  10  to direct liquid  8  out from reservoir  1  upon a reciprocal pumping action by dispenser  10 , as indicated by pumping direction arrows  6 A,  6 B. The volume of the injected liquid  8  into dispenser  10  may be monitored through a window  12 . Once dispenser  10  is desirably filled with liquid  8 , dispenser  10  may be disengaged from discharge  2  of reservoir  1  without leakage of liquid  8 , either from reservoir  1  or dispenser  10 . The liquid level within reservoir  1  is schematically depicted in  FIGS. 1A-1C  as being reduced in the process of transferring liquid  8  to dispenser  10 . 
     In some embodiments, a discharge nozzle  3  may be employed in fluidly coupling reservoir  1  to dispenser  10 . Discharge nozzle  3  may therefore constitute an adaptor that is sealingly securable to discharge  2  of reservoir  1 , and to dispenser  10 , as will be described in greater detail hereinbelow. While a variety of configurations for discharge nozzle  3  are contemplated by the present invention, an example arrangement is illustrated in  FIG. 2A , wherein discharge nozzle  3  includes a base portion  4  having an adaptor gasket  5  that resiliently and sealingly engages discharge  2  to establish a liquid-tight seal thereat. Due to the resilient property of adaptor gasket  5 , base portion  4  of discharge nozzle  3  is capable of sealingly engaging with discharges  2  of various dimensions. It is known that liquid reservoirs employ various-sized discharges  2 , such that base portion  4  of discharge nozzle  3  is capable of functionally adapting to a variety of reservoir discharges. Insert portion  7  of discharge nozzle  3  may be specifically configured for sealing engagement with a valve body and valve gasket of dispenser  10  to discharge liquid  8  into dispenser  10 . Insert portion  7  may therefore include a nipple  7   a  and a shoulder  7   b  for sealing engagement and operational cooperation with the valve body of dispenser  10 . Liquid  8  passes through a channel  9  extending axially through discharge nozzle  3 . The discharge channel  3  is illustrated in  FIG. 2B  as interfacing between discharge  2  of reservoir  1  and dispenser  10 . 
     A detailed cross-sectional view of an embodiment of liquid spray dispenser  10  is illustrated in  FIG. 3 . A vessel  14  defines a main chamber  16  in which a volume of liquid  8  may be held for dispensation out from spray nozzle  18 . In the illustrated embodiment, vessel  14  may comprise an open, substantially cylindrical plastic body with a side wall  14 A and an end wall  14 B. Other configurations, however, for vessel  14  are contemplated as being useful in the present invention. 
     To vessel  14  is secured a pump apparatus  20 , which is shown in isolation in  FIGS. 4A and 4B . Pump apparatus  20  includes a cylinder  22  defining a liquid chamber  24 . Pump apparatus  20  further includes an attachment member  26  defining an air passage  28  venting main chamber  16  to an exterior environment. Pump apparatus  20  further defines a central axis  30  that itself defines mutually perpendicular axial and radial directions  31 ,  32 . Attachment member  26  of pump apparatus  20  may include an outer brace portion  34  and an inner brace portion  36 , with air passage  28  defined between outer and inner brace portions  34 ,  36  of attachment member  26 . Outer brace portion  34  may be secured to vessel  14  to substantially enclose main chamber  16 , with the exception of air passage  28 . Outer brace portion  34  may be threadably or otherwise engagable with an inner surface  14 C of vessel  14  at engagement portion  15  of vessel  14 . Thus, outer brace portion  34  may include threads or other surface modifications at connection portion  35  for retainably securing pump apparatus  20  to vessel  14 . In one embodiment, outer brace portion  34  may be press-fit within vessel  14 , with an annular protrusion  38  arresting the insertion of attachment member  26  into main chamber  16  by contacting an upper rim  15   a  of vessel  14 . In one embodiment, attachment member  26  may be a unitary body molded into a single structure annularly arranged about central axis  30 . 
     Attachment member  26  may be secured about cylinder  22 , with an annular ridge  40  of cylinder  22  being received in an annular channel  42  of attachment member  26 . Cylinder  22  may assume a variety of configurations, but may include a radially-stepped outer diameter to accommodate the operation of the components of pump apparatus  20  described herein. Cylinder  20  includes an inlet  44  which may accommodate a dipper tube  46  for intake of liquid  8  from main chamber  16 . Cylinder  22  may also form a lower seat  48  upon which a ball  50  may operably engage to establish a first check valve  52  of pump apparatus  20 . 
     A piston rod  54  may include a hollow interior defining a liquid passage  56  for communicating liquid between liquid chamber  24  and spray nozzle  18 . Piston rod  54  may be reciprocally actuated along axial direction  31  by a manual pumping force axially applied to cap  58 . The axial pumping force applied to piston rod  54  acts initially against piston  64 , and secondarily against the restorative forces of an upper spring  60  and a lower spring  62  to depress piston  64  into liquid chamber  24  to thereby increase pressure within liquid chamber  24 . Release of the pumping force at cap  58  permits the restorative forces of upper and lower springs  60 ,  62  to push piston  64  axially out from liquid chamber  24  to thereby decrease the fluid pressure in liquid chamber  24 . Piston  64  is therefore positioned at liquid chamber  24 , and is axially movable along axial direction  31  in pump apparatus  20  by piston rod  54  to pump liquid  8  from liquid chamber  24  into liquid passage  56 , and to draw liquid  8  from main chamber  16  into liquid chamber  24  through first check valve  52 . 
     A downward pumping stroke of pump apparatus  20  is illustrated in  FIG. 4A , wherein a downward force applied to cap  58  is translated to piston rod  56  for downward axial motion of piston rod  54  along axial direction  31 . Piston rod  54  bears upon shoulder  65  of piston  64  to force piston  64  downwardly into liquid chamber  24 . A pump gasket  66  is slidably secured about piston rod  54 , such that relative motion between pump gasket  66  and piston rod  54  is created in the reciprocal motion of piston rod  54  described above. Such relative motion, however, is limited by upper spring  60  having a restorative force acting to oppose the relative upward motion of pump gasket  66  with respect to piston rod  54  upon downward movement of piston rod  54 . Upper spring  60  is calibrated to permit a desired extent of relative motion of pump gasket  66  with respect to piston rod  54  in order to open a liquid channel  68  that communicates liquid chamber  24  into liquid passage  56  within piston rod  54 . Increased fluid pressure within liquid chamber  24  caused by the downward movement of piston  64  forces ball  50  against lower seat  48  of cylinder  22 , thereby closing first check valve  52 , and forcing liquid within liquid chamber  24  through liquid channel  68  and liquid passage  56  for dispensation out through spray nozzle  18 . 
     A second part of the pumping cycle is illustrated in  FIG. 4B , wherein downward force against cap  58  is removed, thereby permitting upper and lower springs  60 ,  62  to expand with their respective restorative force, and to push piston  64 , pump gasket  66 , and piston rod  54  axially upward out from liquid chamber  24 . The relative motion of pump gasket  66  with respect to piston rod  54 , driven by the restorative force of upper spring  60  moves pump gasket  66  downwardly with respect to piston rod  54  against shoulder  65  of piston  64  to close liquid channel  68 . As a consequence, air is prevented from being drawn into liquid chamber  24 , and a pressure reduction is produced by the retreating piston  64 . The negative pressure within liquid piston  24  lifts ball  50  from lower seat  48  of cylinder  22  to open first check valve  52 , to thereby permit liquid  8  inflow from main chamber  16  through dipper tube  46  and inlet  44 . Piston rod is arrested from further upward axial movement by cap shoulder  70 . Once upward movement of the piston rod/piston combination is halted, fluid pressure in liquid chamber  24  normalizes with fluid pressure in main chamber  16 , thereby permitting ball  50  to be acted upon by gravity and a weight of liquid above it in liquid chamber  24  to seat against lower seat  48  of cylinder  22 , closing first check valve  52 . 
     A vent gasket  72  is secured to pump apparatus  20 , and includes a flange portion  74  that is resiliently contactable with pump apparatus  20  to releasably seal closed air passage  28 . In the illustrated embodiment, stem portion  76  of vent gasket  72  is secured between inner brace portion  36  of attachment member  26  and an outer surface  25  of cylinder  22 . Stem portion  76  may be friction fit between inner brace portion  36  and cylinder  22 . Flange portion  74  of vent gasket  72  may be resiliently contactable with an inner surface  35  of outer brace portion  34 , such that flange portion  74  resiliently seals against outer brace portion  34  to releasably close air passage  28  between outer and inner brace portions  34 ,  36  of attachment member  26 . Vent gasket  72  may be fabricated from any desirable resilient material such as various plastics, rubbers, and the like. In one embodiment, vent gasket  72  is silicone. 
     A valve body  78  is sealingly engaged to vessel  14  in an opening  80  of vessel  14 . In the illustrated embodiment, opening  80  may be disposed in base wall  14 B. However, it is contemplated that opening  80  may be otherwise disposed in vessel  14 . Valve body  78  includes a first portion  82  with an inlet passage  84  permitting liquid flow through valve body  78  into main chamber  16 , and a second portion  86  adapted to receive discharge  2 , such as discharge nozzle  3  from liquid reservoir  1 . A valve body spring  88  has a restorative force which acts to urge valve body  78  axially outwardly along direction  31  into a first position  90  ( FIG. 6A ) closing inlet passage  84 . 
     Opening  80  of vessel  14  defines a recess having a side wall  92 , an end wall  94 , and an annular flange  96 , which, in combination, define an annular grove  98  annularly arranged about central axis  30 . Valve body spring  88  may be positioned in annular groove  98  between end wall  94  and strut portion  79  of valve body  78  to urge valve body  78  downwardly toward first position  90 . Valve body  78  is sealingly engaged to vessel  14  at annular flange  96  through first and second sealing rings  100 ,  102 , which may comprise resilient o-rings secured to valve body  78  at retention grooves  104 A,  104 B. First and second sealing rings  100 ,  102  may be axially spaced across inlet passage  84 , such that inlet passage  84  is disposed axially between first and second sealing rings  100 ,  102 . In this manner, valve body  78  remains sealingly engaged with annular flange  96  of vessel  14  when valve body  78  is actuated into second position  91  through an upward force applied thereto by discharge nozzle  3  of reservoir  1 . The two distinct sealing rings  100 ,  102  provide separate and distinct sealing locations for valve body  78  in sealing engagement with vessel  14  at annular flange  96 . Therefore, in first position  90 , valve body  78  may be sealingly engaged to annular flange  96  at both first and second sealing rings  100 ,  102 , which resiliently contact both first portion  82  of valve body  78  and annular flange  96  of vessel  14 . When valve body  78  is forced axially upward as a result of the liquid injection process described above with respect to  FIGS. 1-2 , first sealing ring  100  is axially pushed out of contact with annular flange  96  to open inlet passage  84  permitting liquid passage from reservoir  1  through discharge nozzle  3 , and through inlet passage  84  into main chamber  16 . However, even though first sealing ring  100  is no longer in sealing engagement between first portion  82  of valve body  78  and annular flange  96  of vessel  14 , second sealing ring  102 , which is arranged axially outwardly from inlet passage  84 , remains in sealing engagement between first portion  82  of valve body  78  and annular flange  96  of vessel  14 . Such sealing engagement prevents liquid leakage out from main chamber  16  between valve body  78  and annular flange  96 . 
     A resilient valve gasket  106  may be provided at an inner surface  81  of valve body  78  to provide for sealing engagement with nipple  7   a  of discharge nozzle  3  and/or discharge  2  of reservoir  1 . Resilient valve gasket  106  is manufactured from a resilient material to establish a liquid-tight seal about nipple  7   a  and/or discharge  2  to prevent liquid leakage from the engagement between discharge  2 /discharge nozzle  3  and valve body  78 . 
     In one embodiment, resilient valve gasket  106  includes a tapered portion  108  that may be configured for sealing engagement with shoulder  7   b  of discharge nozzle  3 . With reference back to  FIG. 2B , transfer of liquid  8  into main chamber  16  of dispenser  10  may be accomplished by pressing downwardly upon dispenser  10  when discharge  2  or discharge nozzle  3  is sealingly engaged at valve body  78 . Downward force upon dispenser  10  causes increased pressure between tapered portion  108  of valve gasket  106  and shoulder  7   b  of discharge nozzle  3 , which increased pressure overcomes the restorative force of spring  88  to cause valve body  78  to move axially upwardly against the restorative force of spring  88  to thereby open inlet passage  84 . The downward force placed upon dispenser  10  concurrently transmits the downward force to discharge  2  of reservoir  1 , resulting in downward movement of discharge  2  to pump liquid  8  out from reservoir  1  into channel  9  of discharge nozzle  3 , and subsequently through nipple  7   a  of discharge nozzle  3  to inlet passage  84  at valve body  78 . Removal of the downward force upon dispenser  10  relieves pressure between shoulder  7   b  and tapered portion  108  of valve gasket  106 , thereby permitting the restorative force of valve body spring  88  to move valve body  78  axially downwardly with respect to the recess in vessel  14 , and closing inlet passage  84  to prevent backflow of liquid  8  from main chamber  16  into channel  9  of discharge nozzle  3 . The relieved downward force upon dispenser  10  also permits a spring within discharge  2  to expand and move discharge  2  axially upwardly to prepare for the next pumping cycle. In this manner, liquid  8  may be uni-directionally transferred from reservoir  1  to main chamber  16  of dispenser  10 . 
     Filling or re-filling of liquid  8  into main chamber  16 , as described above, relies upon a venting capability to remove an amount of air from main chamber  16  assuming a volume equivalent to the added liquid volume. The enclosed main chamber  16 , in the absence of such a venting capability, would prevent liquid addition in the sealed manner described above. Thus, it is an important aspect of the present invention to provide a mechanism for temporarily venting main chamber  16  simultaneous with liquid transfer to main chamber  16 . 
     To accomplish the venting of main chamber  16  described above, a venting rod  110  is movable by valve body  78  to disengage flange portion  74  of vent gasket  72  from pump apparatus  20  to thereby open air passage  28 . As illustrated in  FIG. 5 , lower portion  112  of venting rod  110  may be secured to connecting portion  83  of valve body  78 , such that venting rod  110  is synchronously movable with valve body  78 . As described above, valve body  78  may be axially movable upon forces generated between valve gasket  106  and discharge nozzle  3  as a consequence of a downward force on dispenser  10  relative to reservoir  1 . When valve body  78  is axially moved upwardly into main chamber  16  to transfer liquid  8  through inlet passage  84  into main chamber  16 , venting rod  110  correspondingly moves axially upwardly to simultaneously disengage flange portion  74  of vent gasket  72  from resilient contact with outer brace portion  34  of attachment member  26 . Upper portion  114  of venting rod  110  is in sliding engagement with inner surface  35  of outer brace portion  34 , such that the upward axial movement driven by valve body  78  causes upper portion  114  to contact flange portion  74  of vent gasket  72 . Continued upward axial movement of venting rod  110  causes upper portion  114  to displace the resilient flange portion  72  of vent gasket  72  out from contact with inner surface  35  of outer brace portion  34 . Such displacement opens air passage  28  to main chamber  16 , and air is permitted to escape therethrough to vent main chamber  16 . A driving force for venting air from main chamber  16  is provided by the injection of liquid  8  into main chamber  16  through inlet passage  84 . The volume of liquid injected into main chamber  16  increases the air pressure in the head space in main chamber  16  above the filled liquid  8 . Such increase air pressure drives the air venting out through the opened air passage  28 . 
     The opening and closing of air passage  28  by the releasable contact of venting rod  110  with flange portion  72  of vent gasket  72  is illustrated in  FIGS. 6A and 6B , wherein valve body  78  being axially biased outwardly of main chamber  16  to a first position  90  is illustrated in  FIG. 6A , such that venting rod  110  is out of displacing contact with flange portion  74 . However,  FIG. 6B  illustrates valve body  78  being pushed axially upwardly into a second position  91  to corresponsingly axially upwardly move venting rod  110  to displacingly contact flange portion  74 , and to thereby open air passage  28  to vent main chamber  16 . Urging of valve body spring  88  against valve body  78  to reposition valve body  78  in first position  90  correspondingly moves upper portion  114  of venting rod  110  out of displacing contact with flange portion  74  of vent gasket  72 , thereby permitting re-establishment of resilient sealing contact between flange portion  74  and inner surface  35  of outer brace portion  34  to close air passage  28 . Thus, venting rod  110  cyclically opens and closes air passage  18  through synchronous motion with valve body  78  corresponding to the liquid filling cycle described above. Therefore, when liquid  8  is not being injected into main chamber  16 , vent gasket  72  is typically in sealing engagement with outer brace portion  34  of attachment member  26  to seal closed air passage  28 . This arrangement provides for an enclosed main chamber  16  to aid in dispensing liquid  8  out through spray nozzle  18 . 
     In some embodiments, an outer casing  120  may be provided for decorative and/or protective purposes. In one embodiment, outer casing  120  may be fabricated from a high-grade aluminum material. 
     An exploded component view of liquid spray dispenser  10  is illustrated in  FIG. 7 . 
     The invention has been described herein in considerable detail in order to comply with the patent statutes, and to provide those skilled in the art with the information needed to apply the novel principles and to construct and use embodiments of the invention as required. However, it is to be understood that various modifications may be accomplished without departing from the scope of the invention itself.