Abstract:
A disposable molded dispenser for a non-pressurized container capable of dispensing a variety of fluid materials having a deformable spout chamber with an integral outlet valve through which fluid is expelled as the spout is selectively depressed compressing the chamber. A molded inlet valve serves to permit fluid to be pushed by ambient air pressure from a container into the spout chamber when pressure on the spout is removed and the spout chamber is restored to an initial configuration.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims the priority of applicant&#39;s U.S. Provisional Application Ser. No. 61/416,646, filed on Nov. 23, 2010. The content of applicant&#39;s Provisional Application is hereby incorporated by reference as thought set forth at length. 
    
    
     BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present invention relates to a device for dispensing fluid material from a non-pressurized container. More particularly, the invention relates to a dispenser for liquids and gels from a non-pressurized container configured preferably from a single molded piece operable to be secured to the container body with an over-cap, ring or bayonet lock. Moreover the dispenser spout itself with molded internal inlet and outlet check valves functions as an operational pump. This enables efficient, cost effective manufacture from a single mold material. In addition, use of a single material enhances recycling considerations. The inexpensive nature of a integral molded dispenser enables the dispenser to be inexpensively produced and is thus disposable. In one preferred embodiment the dispenser head and a container retaining ring can be molded in one piece with a single molding operation 
     The use of conventional pump action devices for dispensing fluid, flowable materials from a non-pressurized container has been known for years. With the rising popularity of pump-dispensed products on the market, consumers have grown to expect this convenience. Multiple part pump dispensers, however, tend to be somewhat expensive to manufacture and often constitute the highest cost component of a store ready product. Moreover dispensers combining plastic and metal components or different compositions of plastic impede recycling efforts. 
     Most conventional dispensers utilize a compressible fluid chamber in cooperation with pressure responsive supply and discharge check valves to define a fluid pathway between a non-pressurized container and a fluid outlet. The reverse action of the two check valves, one opening as the other is closing, cooperate with a compressing and then expanding chamber to establish a pump action. 
     One previously known dispenser comprises a disposable spout affixed to a hollow, cylindrical plunger axially sliding into a receiving, complementary accumulator with integral discharge and supply one-way check valves. This assembly communicates with a pick-up tube for material retrieval from the container. In operation a user depresses a finger spout, substantially reducing the pump chamber internal volume, to expel its contents under pressure through a one-way outlet valve in the spout. When released, a helical spring returns the chamber back to a pre-compressed volume creating a vacuum that induces a flow of more dispensable material through the one-way inlet valve. The dispenser is once again ready. 
     Other types of finger or palm action dispensing pumps utilize resiliently biased, deformable elements to provide compressible pumping chambers. These elements may be simple dome-shaped walls, or foldable bellows used in conjunction with a series of single directional check valves to create pumps. The mechanics of such devises to return to a pre-compressed state relies on a biased nature of plastic, and in some instances assistance from a metal spring. Though these designs utilize fewer components, they require assembly with leak concerns as most snap together, require gluing, or some form of heat welding. Some versions involve difficult molding techniques—such as over-molding. Although dissimilar materials can be used to achieve a resiliently deformable portion abutting a rigid structural base element along a seam this elevates mold and molding costs and involves secondary assembly steps and makes recycling problematic. 
     The drawbacks of these and other similar designs are the consequential costs associated with manufacture and assembly of several components in the past. In addition a dissimilarity of materials makes recycling less efficient or unacceptable. The subject one piece molded fluid dispenser can be produced for a fraction of the cost of multi-part pump action dispensers, is disposable and can be facially recycled and green friendly. 
     The relatively expensive nature of prior art assemblies renders them less disposable. This is apparent from the widespread availability of “refills” for many dispensers. Reuse of the dispensers, however, can become problematic due to exposure to environmental contaminants. This is of special concern in hygienic environments such as research labs and medical theatres. Disinfecting and refilling of the devices and storage of the dispensing materials becomes a cost issue. 
     Although previously known hand action pumps have received considerable attention, it would be highly desirable to provide a pump which could be cheaply molded from a single piece, easy to use, inexpensive to manufacture, recyclable, and adequate to accommodate various dispensable materials. 
     The difficulties and limitations suggested in the preceding and desired features are not intended to be exhaustive but rather are among many which may tend to reduce the effectiveness and user satisfaction with prior finger or palm action fluid dispensing pumps. Other noteworthy problems and limitations may also exist; however, those presented above should be sufficient to demonstrate that fluid dispensing pumps appearing in the past will admit to worthwhile improvement. 
     BRIEF SUMMARY 
     A preferred embodiment of the invention which is intended to address concerns and accomplish at least some of the foregoing objectives comprises a dispenser capable of being disposable and dispensing a variety of fluid materials. In a preferred embodiment the dispenser has a resiliently biased, deformable chamber with an integral outlet valve through which fluid is expelled as a spout is selectively depressed compressing the spout chamber. An integral inlet valve serves to permit fluid to be pushed by ambient air pressure from a container into the spout chamber when pressure on the spout is removed and the chamber is restored to an initial open configuration. 
    
    
     
       DRAWINGS 
       Other objects and advantages of the present invention will become apparent from the following detailed description of preferred embodiments thereof taken in conjunction with the accompanying drawings wherein: 
         FIG. 1  is an axonometric view of a molded dispenser in an open posture in accordance with one embodiment of the subject invention; 
         FIG. 2  is an axonometric view of the subject invention in a closed state for storage or on the shelf sale; 
         FIG. 3  is an expanded view of the embodiment shown in  FIGS. 1 and 2  in an as molded state; 
         FIGS. 4 ,  5 , and  6  are cross-sectional views of  FIGS. 1 ,  2 , and  3 , respectively; 
         FIG. 7  is a cross-sectional detail view of an inlet check valve displaying the relationship of a reed, a cooperating seat, and a bridge; 
         FIGS. 8 and 9  are cross-sectional detail views of an upper outlet check valve in an as molded and as deployed configuration respectively. 
         FIGS. 10 and 11  are views of the internal components or the dispenser in a ready and closed posture. 
         FIG. 12  is a cross-sectional representation of the relationship of a cap, a base, and a chamber floor with internal components. 
         FIG. 13  is an axonometric view of a vent valve in a molded state; and 
         FIGS. 14 and 15  are cross-sectional views of an alternative preferred embodiment with the main variation being an integral molded cap with a spout. 
     
    
    
     DETAILED DESCRIPTION 
     Referring now particularly to the drawings, wherein like reference characters refer to like parts, and initially to  FIG. 1 , there will be seen an axonometric view of a deployable fluid dispenser  10  in accordance with a preferred embodiment of the invention. The dispenser  10  is shown secured to the top of a pressure-less container  12  in an upright or open posture ready for use.  FIG. 2  shows the dispenser  10  with a body portion  16  in a fully collapsed position for storage, transport and on shelf sale. 
       FIG. 3  is an exploded view of the pump-action dispenser  10  that is broken away to illustrate its basic components in an as molded posture. The dispenser  10  is defined by three molded components: a base  18 , a chamber floor  20 , and a compressible spout  22 . In a preferred embodiment these three components are all molded as an integral one piece unit. In this, during assembly the chamber floor  20  is pivoted counterclockwise in the direction of arrow “A” so that the chamber floor  20  is brought into intimate sealed engagement with the base  18 . The dispenser  10  internally includes all the necessary components of an operating pump. 
     Separately molded in one embodiment is a sealing over-cap  14  which permits full rotational orientation of the dispenser body  16  relative to the container  12 . Internal threads (note  FIG. 4 ) of the cap  14  cooperate with the external threads  24  of the container neck  26  to fascinate additional sealing abutment between the dispenser body base  18  and the chamber floor  20  of the molded fluid dispenser  10 . 
     Cross-sectional views of  FIGS. 1 ,  2 , and  3  are shown by  FIGS. 4 ,  5 , and  6 , respectively. In a preferred embodiment, the dispenser  10  defines a fluid pathway commencing with a dip tube  30 , passing through a positive displacement pump, and exiting an outlet passageway  32 . The compressible, pivotal spout  22  and the chamber floor  20  in cooperation with unidirectional inlet and outlet valves,  34  and  36  respectively, form a pump. 
     The chamber floor  20  is rotated about a living hinge  38  (note  FIG. 6 ) to abut a base surface  40  completing a pump chamber  42 . These components are held in sealed engagement by retaining element  44 . The retaining element is composed from a tapered, base outer wall extension  46  fitting into a correspondingly tapered, retaining groove  48  encircling the chamber floor  20  with an upwardly clamping tension (note also  FIGS. 6 and 12 ). 
     The pivotal spout  22  is defined by a rigid spout spine  50 , a resiliently biased thin wall section  28 , an upper collar  52 , and an outlet passageway  32 . As the spout  22  is pivotally depressed about a living hinge  56 , a resiliently biased, thin, chamber wall  28  folds to reduce the internal volume of the spout chamber  42 . This pressurizes and expels the spout chamber contents through a unidirectional outlet valve  36  and passageway  32 . Once the spout  22  is released, the thin wall section  28  returns to an initial, resiliently biased configuration increasing the internal volume of the spout pump chamber  42 . This reduces the internal pressure of the chamber and new material for dispensing is drawn up from the container  12  via dip tube  30  and an extension tube (not shown) that descends to the internal base of the container  12 . 
     The fluid flow direction is controlled by uni-directional inlet and outlet check valves  34  and  36  respectively of the chamber  42 . Enlarged cross-sectional views are provided by  FIGS. 7 ,  8 , and  9 . The air-tight, pressure sensitive inlet valve  34  permits fluid to flow into the expanding pump chamber  42  when the pressure within the chamber falls below the adjoining container  12  and maintains the compression pressure generated by the folding pump chamber  42 . The air-tight, pressure sensitive outlet valve  36  allows the discharge of the pressurized contents from the compressed pump chamber  42  and maintains the vacuum created by the expanding pump chamber  42 . The valve sealing members are reeds  60  and  62  with free ends  64  and  66  abutting valve seats  68  and  70  to form air-tight seals. In a preferred embodiment these seats are elevated to enhance the air-tight seal in a viscous fluid flow environment. As these reeds  60  and  62  experience pressure differentials, the free ends  64  and  66  resiliently displace from the elevated valve seats  68  and  70  permitting fluid passage. The elevated seats  68  and  70  permit the reeds  60  and  62  to compress the dispensable material encircling the seats  68  and  70  to insure proper seals. 
     In one preferred embodiment, both reeds  60  and  61  are molded vertically and pivoted upwardly into position. In the case of the inlet reed  60 , it is positioned by the chamber floor  20  as it is rotated into position in the direction of arrows “A” and “B” in  FIG. 6 . The outlet reed  62  is seated by pressing it through the valve seat opening  72  with the placement pad  74 . The outlet valve seat  70  is integrally molded onto the upper spout collar  52 . This collar  52  is a structural transition sustaining the thin wall  28  upper configuration and supporting the outlet valve  58  and passageway  32 . Closing tensions are imparted on the reeds by their resiliently biased living hinges,  76  and  78 . 
     The living hinge  76  of the inlet reed and the immediate surrounding thin wall region  80  are slightly thicker than the remaining thin wall region to ensure a sealing engagement with the valve seat  68  is maintained with the thin wall  28  movement. In addition to this tensioning, both reeds  60  and  62  must flex another structural component from rest when opening. The inlet reed  60  must flex the thin wall section  28  of the chamber and the tensioning foot  82  of the outlet reed  62  must flex the hinged lower wall  84  of the spout outlet  32  about living hinge  78 . This enables the dispenser  10  to overcome plasticity concerning its valve reeds  60  and  62  tensioning components. When the dispenser  10  is closed there is a bridge  88  beneath the inlet reed  60  to prevent distortion resulting from vertical pressure from the folded thin wall member  28  (note  FIG. 7 ). 
     Variations in material thickness of different components, depending on functionality, allow the use of a single material throughout the dispenser  10 . The thin material thickness in the thin wall region  28  allows elastic flexibility for folding, whereas the comparatively thick spout spine  50  ensures rigidity. Selective variations in the material thickness of this thin region  28  are to provide adequate resiliency for the thin wall  28  to return to an initial biased resilient configuration once the pressure on the spout  22  is released. The operable posture angle “C” of the pivotal spout  22  is necessary to initiate downward movement when depressed. 
     In instances when dispensing high viscous materials and/or following a prolonged closed period the resiliently deformable portion of the thin chamber wall  28  may not be sufficiently resilient to reestablish the initial operable posture of the spout  22  following folding. In such case, extra resilience can be provided by an integral leaf spring stanchion component  90 —see particularly  FIGS. 6 and 12 . Preferably this spring component  90  is a resiliently deformable stanchion within the chamber  42 , which flexes when the chamber  42  is momentarily compressed and then urges the depressed spout  22  back to an upright operable posture. When dispenser  10  is either in the ready posture or totally compressed for storage or transporting this leaf spring element  90  is at rest. This and an additional stop stanchion  92  cooperate to maintain this desired, ready posture by overcoming the resilient biased nature of a molded part returning to its initial, resiliently biased molded form or an adopted compressed form due to plasticity after a prolonged closed period. These two stanchions,  90  and  92 , are integrally molded onto the chamber floor  20  in recess  94 . 
     A posture lever  96  at the base of the rigid spout spine  50  is entrapped between the leaf spring  90  and the stop stanchion  92  to maintain the angular “C” ready posture of the spout  22 . The posture lever  96  is semi-rigid only allowing lateral movement to clear a latch  98  as the spout  22  is fully depressed. The two stanchions  90  and  92  cooperate with the posture lever  96  and all three exhibit a degree of operative flexibility to achieve the desired result. At full depression, this posture lever  96  rests in a like-formed recess  100  within the a support wall  102  as shown in  FIG. 11 . This posture lever  96  cooperates with the rigid spout spine  50  to limit the closure of the spout  22  preventing excess pressure on the thin wall  28  against the base  18  during storage or transporting. Alternately, a spring element may be positioned within recess  94  in the chamber floor  20  which is operable to receive an external spring element. 
     The dispenser  10  is held in a closed position by the internal latch  98  as shown in  FIGS. 6 ,  11  and  12 . Two latch levers  104  are formed at the base of the rigid spout spine  50  alongside and structurally similar to the posture of lever  96  with upward engaging surfaces  106  as revealed in  FIGS. 10 and 11 . Upon closing, these resiliently biased levers  104  slightly flex inwardly as they pass the inwardly sloped, leading surfaces  108  of the latch  98  which are integrally molded into the back support wall  102  as shown in  FIG. 11 . Preferably, abutting surfaces,  110  and  106 , of these two details are flat and sufficient to releasably secure the dispenser  10  in the closed position. Alternatively, the posture and latch levers,  108  and  104 , could be combined into one with some adaptations to the latch members  108  and  110  in the back support wall  102  to allow lateral flexing. 
     In a closed posture the inlet check valve  34  of the pumping chamber is held closed by the folded thin chamber wall  28  preventing release of any contents from the container  12 , while the outlet check valve  36  is held closed by the resiliently deformable bottom spout wall  84  entrapping any remaining chamber contents. Both valve reeds  60  and  62  are in neutral positions with minimal closure pressures provided by their resiliently biased living hinges  76  and  78 . 
     As shown in  FIG. 13 , a container venting valve  112  cooperates with a vent channel  114  on a base surface  116  to equalize internal and external pressure of the container  12  as fluid is drawn into the dispenser  10 . This venting valve  112  is integrally molded onto the chamber floor surface and is pivotally positioned about a living hinge  120  when the chamber floor surface  118  is securely abutted against the dispenser body surface  40  and the leading mitered edge of the tapered wall extension  46  contacts a corresponding mitered edge of a vent reed  122 . It is further secured by abutting the container lip  124 , note  FIG. 7 , when dispenser  10  is affixed atop container  12 . The valve free end  126  of resiliently biased reed  122  sealingly abuts an elevated valve seat  128  and flexes downward to balance the internal and external pressure of the container  12 . 
     The dip tube  30  is integrally formed with the chamber floor  20  as noted above. A free end of the dip tube  30  is positioned anywhere within the container  12  depending on the manner in which the dispenser  10  is used. The dip tube  30  typically is fitted with an extension having a length sufficient to extend to a bottom corner of a tilted container  12  to retrieve all of the fluid contents. Alternately, the pick-up tube may be affixed over the inlet nipple or inserted into a recess and held with friction. Ultrasonic or thermal welding or applying an adhesive may be additional securing options for a dip tube extension. 
     A tapered, snap retainer wall  130 , note  FIG. 10 , flanking the over-cap  14  opening snaps onto a complementing tapered wall of the spout  22  to maintain the pump body assembly  16  when the over-cap  14  is loosened as shown in  FIG. 7 . Once the spout orientation is determined, tightening the over-cap  14  further secures the sealing abutment of the base surface  40  with an upper chamber floor surface  134  and a lower chamber floor surface  136  with the container lip  124 . 
     The dispenser  10  may be formed from a number of suitable materials such as for example polypropylene or polyethylene. The material needs to be resilient and flexible to enable the resilient folding of at least a portion of the body to facilitate compression of the chamber  42 . The extent of the elastic flexibility of the plastic in any given area dependents on the thickness of the area. Thick sections provide structural rigidity to support resiliently thinner sections and functional movement. 
       FIGS. 14 and 15  represent cross-sectional views of an alternative embodiment molded entirely as one part.  FIG. 14  reveals a cross-sectional view of a disposable dispenser and  FIG. 15  is the embodiment in a molded form. The functioning features are identical with the prior embodiment with the exceptions of an internally threaded cap  142  which is integrally molded with the dispenser body  110  and the container vent  146  configuration. 
     The chamber floor  148  of this embodiment pivots with extension arm  150  about living hinges  152  and  154  to abut with dispenser body  144  at surfaces  156  and  158  respectively. This rotation completes the pump chamber  160  and positions an inlet valve reed  162  about a living hinge  164  atop the elevated valve seat  166 . This pivoting also positions a vent valve reed  168  about living hinge  170  on the elevated vent valve seat  172  when positioning foot  174  of the reed  168  contacts an inner surface  176  of a vent channel  178  within the threads  142  of the integrally molded cap  180 . The reed  168  positioning is finished upon contacting the container lip as the dispenser  140  is affixed atop the container  184 . 
     The threads  188  of the integral cap  180  in cooperation with the complementing threads  190  of the container  184  sealingly secure the chamber floor  148  to the dispenser body  144 . 
     In describing preferred embodiments of the invention it will be appreciated that the spout body  22  itself in cooperation with inlet  34  and outlet  36  check valves comprises a functioning fluid pump 
     In the subject application reference has been made to the term “living hinge.” In this application applicant is using the term in a conventional sense of a relatively thin flexible web of plastic material that joins two relatively ridged bodies together. A living hinge made with polyethylene or polypropylene usually never fail. In the subject application a plastic elastic hinge that is capable of flexing hundreds of times should be sufficient although it is envisioned that in certain circumstances that a fully elastic hinge capable of flexing thousands of times will be used or where a shorter life span is satisfactory a living hinge can be composed a fully plastic hinge which is capable of flexing only a few cycles may be sufficient. 
     In the specification the expression “approximately” is intended to mean at or near and not exactly such that the exact location is not considered critical. 
     In the claims reference has been made to use of the term “means” followed by a statement of function. When that convention is used applicant intends the means to include the specific structural components recited in the specification and the drawings and in addition other structures and apparatus the will be recognized by those of skill in the art as equivalent structures for performing the recited function and not merely structural equivalents of the structures as specifically shown and described in the drawings and written specification. 
     In describing the invention, reference has been made to preferred embodiments. Those skilled in the art, however, and familiar with the disclosure of the subject invention may recognize additions, deletions, substitutions, modifications and/or other changes which will fall within the purview of the invention as defined in the following claims.