Abstract:
An atomizing fluid dispenser for delivering, via a spray nozzle, a substantially equal metered dose of fluid material for each dispensing operation is disclosed. The fluid dispensing device includes a container with an interior fluid storage region therein. A metering housing, when depressed, generates a one-way flow from the interior fluid storage region of the container that serves to fill the predetermined volume of the chamber within the metering housing. When the metering housing is depressed a second time a substantially equal volume of fluid is dispensed from the container, while upon release, the metering housing is refilled by drawing fluid from the fluid storage region. A spray nozzle or atomizer is attached to the exit port of the dispensing device so that the liquid is delivered in metered fashion in spray form.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is related to and claims priority from earlier filed U.S. Provisional Patent Application No. 60/889,075 filed Feb. 9, 2007. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    This invention relates generally to product packages that include integrated dispensing devices. More specifically, the present invention relates to product packages containing fluid media that include metering dispensing devices that can controllably dispense the fluid media from the product package containing the fluid media. 
         [0003]    Various types of fluid material and media are employed for different purposes throughout commerce and industry. For example, there are various products in the areas of personal care, home care, air care, transportation care and food industries that require a fluid material to be dispensed in some manner from a source of such material. 
         [0004]    Further, when this material is sold in commerce, it must be contained and stored in some type of container while awaiting use. Ultimately, when that product is used, it must be dispensed from its storage container to the desired location for use. 
         [0005]    In the prior art, there are many different types of dispensers that are employed for the delivery of a stored fluid material to their 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 (ketchup) out from 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 the how much the user actually squeezes 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. 
         [0006]    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. 
         [0007]    In addition to the above noted need for simply dispensing a volume of fluid material, there is also a desire for the ability to immediately apply the dispensed fluid material, such as to a surface. In the prior art, the solution was to provide squeezable container bodies that are equipped with some type of applicator head for this purpose. For example, in the personal care industry, body wash devices commonly include some type of squeezable container body and an abrasive applicator material, such as fabric or foam, applied to the output port thereof. Thus, when the fluid material is dispensed to the exterior of the container body, it is dispensed onto the applicator and the applicator assists in spreading the material on the body of the user providing a better and more even distribution thereof. Applicators are particularly useful for even distribution in personal care industry, such as for applying shoe polish, to ensure a quality even and smooth coat. 
         [0008]    In addition to the provision of applicator disposed at the outlet of the container, there have been attempts in the prior art to provide a dispenser that can easily deliver fluid material to an applicator that is positioned about the entire exterior surface of a container body. These prior art devices employ, for example, spring-loaded buttons that open an exit port in the main container body to permit flow of the fluid contained therein to an outer applicator material layer. This is in contrast to requiring the user to squeeze the entire body of the container. However, these devices are incapable of delivering a substantially equal dose of fluid with each dispensing operation because they simply open up the container body and permit the fluid to flow into the surrounding applicator material by gravity. Further, this construction requires that the fluid material exit through an opening at a lower side of the container. Therefore, it is not possible to dispense fluid on more than one side of the container or in a direction opposite to that of gravity. To dispense fluid material without concern for gravity, squeezable container bodies must be employed in connection with all of the disadvantages, as described above. 
         [0009]    In view of the foregoing, the fluid dispensing and devices of the prior art suffer from various disadvantages that make them difficult and awkward to use. Further, these prior art dispensers often provide a user with unexpected results. Therefore, there is a need for a fluid dispenser that is easy to operate. There is a further need for a fluid dispenser that is capable of delivering a metered dose of fluid with each dispensing operation in order to produce predictable flow and a better application of the fluid material. There is also a need for such a dispenser that can operate independent of gravity. There is an additional need for the fluid to be capable of being delivered in a manner that allows the fluid to exit at any point on the surface of container. There is still a further need for a dispenser to include an applicator that facilitates even distribution and even application of the fluid material, as desired. Many of these needs are met by commonly owned, co-pending U.S. patent application Ser. No. 11/074,817, filed on Mar. 8, 2005 and U.S. patent application Ser. No. 11/951,351, filed on Dec. 6, 2007, which are incorporated herein by reference. This application sets forth a device for dispensing liquids in a metered fashion and provides for an exit port that can be located at any position on the fluid container. However there is still a further need to controllably deliver fluid from the exit port, namely, in an atomized or spray form. 
       BRIEF SUMMARY OF THE INVENTION 
       [0010]    In this regard, the present invention preserves the advantages of prior art dispensing devices. In addition, the present invention provides new advantages not found in currently available devices and overcomes many disadvantages of such currently available devices. The present invention is generally directed to a novel and unique atomizer dispenser for delivering, via a spray nozzle, a substantially equal metered dose of fluid material for each dispensing operation. 
         [0011]    The main flexible pouch and metering mechanism employed within the present invention is substantially similar to that found in the above noted U.S. patent application Ser. Nos. 11/074,817 and 11/951,351. The fluid dispensing device includes a container with an interior fluid storage region therein. A metering housing, having a preferably flexible construction, is disposed in fluid communication with the fluid storage region and a first one-way valve is disposed between the container and the flexible metering housing. When the flexible metering housing is depressed and released a vacuum action generates a one-way flow from the interior fluid storage region of the container that serves to fill the predetermined volume of the chamber within the metering housing. A second valve, in fluid communication with the metering housing output port, 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 upon release, the metering housing is refilled by drawing fluid from the fluid storage region. 
         [0012]    Further, in the context of the present invention, a spray nozzle or atomizer is attached to the exit port of the dispensing device after the second valve so that the liquid is delivered in metered fashion in spray form. It is also possible that the neck of the atomizer may be flexible to facilitate dispensing of the fluid. 
         [0013]    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 in spray form from each dispensing operation. It is also an object of the present invention to provide a fluid dispensing device with a spray nozzle that is insensitive to gravity. It is a further object of the present invention to provide a metered fluid dispensing device that includes a spray applicator to ensure desired delivery of the fluid material. It is still a further object of the present invention is to provide a fluid dispensing device that can deliver spray flow at any point from the device. Finally, it is an object of the present invention to provide a fluid dispensing device that can deliver spray flow at multiple locations from the device. 
         [0014]    These together with other objects of the invention, along with various features of novelty that characterize the invention, are pointed out with particularity in the claims annexed hereto and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated a preferred embodiment of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0015]    In the drawings which illustrate the best mode presently contemplated for carrying out the present invention: 
           [0016]      FIG. 1  is a top perspective view of the dispensing device of the present invention; 
           [0017]      FIG. 2  is a bottom perspective view of the dispensing device of the present invention; 
           [0018]      FIG. 3  is a cross-sectional view through the line  3 - 3  of  FIG. 1 ; 
           [0019]      FIG. 4  is a close-up perspective view of the metering housing with stand-off legs; 
           [0020]      FIG. 5  is a close-up perspective view of the metering housing with coil spring; 
           [0021]      FIG. 6  is a top plan view of an alternative embodiment of the present invention; 
           [0022]      FIG. 7  is a front perspective view of another embodiment of the invention; and 
           [0023]      FIG. 8  is a cross-sectional view through the line  8 - 8  of  FIG. 7 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0024]    Now referring to the drawings, the dispensing device of the present invention is shown and generally illustrated at  10  in the figures. As can be seen at  FIGS. 1 and 2 , the dispensing device  10  of the present invention is shown to include an outer covering, generally referred to as  12 , which serves as an applicator material. This applicator material  12  can be formed of any type of material to suit the application at hand. For example, as seen in  FIGS. 1 and 2 , the outer covering  12  is preferably formed from of two different types of material  12   a ,  12   a  allowing it to serve two purposes when in use. Preferably, the top section  12   a  is of a foam material while the bottom section  12   b  is of a mesh or “pouf” material. The top section  12   a  can be secured to the bottom section  12   b  by, for example, welding. A snap-fit cover  14  seals a re-fill port  16 , as will be described in more detail in connection with  FIG. 3 . A hang strap or cord  18  can also be provided. The configuration of the outer cover  12  applicator material is just one of many different types of applications of the present invention which will be discussed in more detail below. 
         [0025]    Turning now to  FIG. 3 , a cross-sectional view through the line  3 - 3  of  FIG. 1  is shown to illustrate the internal construction of the dispensing device  10  of the present invention. A container body  20  is provided which includes a fluid storage region  22  that contains a volume of fluid material  24  therein. The container  20  is preferably made of a flexible material, such as plastic or nylon. Thus, as fluid material  24  is evacuated from within the container body  20 , it will collapses gradually for a compact structure. 
         [0026]    A metering housing  26  is provided at a first opening  28  of the container body  20 . The metering housing  26  includes an intake one-way valve  30 , such as a check valve, to pull fluid  24  from the fluid storage region  22  of the container body  20  into a metering chamber  32  of a predetermined size. Any type of valve can be used to suit the given application. The intake valve  30  is positioned in a base plate  34  of the metering housing  26 . Thus, fluid  24  can only flow in one way from the fluid storage region  22  into the metering chamber  32 . The metering chamber  32  is defined by a flexible membrane  36  in the form of a button or bulb that is accessible and manipulateable through a gap  38  in the applicator material  12 . The button  36  is preferably clear to provide an indicator to the consumer when the metered dosage of fluid material  24  is ready for delivery. 
         [0027]    An output valve  40  is provided in fluid communication with the metering chamber  32  of the metering housing  26 . Thus, the fluid residing in the metering chamber can only exit through the output valve  40 . Also, a fluid conduit  42  is provided to direct the exit of fluid  24  at any location through the container body. Preferably, as seen in  FIG. 3 , the fluid conduit  42  connects the output valve  40  of the metering housing  26  to an exit port  44  located on the bottom of the container body. This permits the metering housing  26  to be on an opposite side as the side through which the fluid  24  exits. The fluid conduit  42  can be directed and located to exit at any point through the container body  20  depending on the application at hand. Also, the output valve  40  may be located at the exit port  44 , as an alternative depending on the requirements of the application. 
         [0028]    In accordance with the metering dispensing flexible pouch with spray nozzle of the present invention, a spray nozzle member  60  is attached to the exit port  44 . The spray nozzle  60  may be installed directly into the exit port  44  or may be installed at the end of a leader tube  62  to allow the user additional directional control of the fluid  24  dispensed by the nozzle  60 . It can also be appreciated by one skilled in the art that the exit port  44  can be located anywhere on the dispensing device  10 , as is shown below in  FIGS. 7 and 8 . Also, the spray nozzle  60  can be of any configuration that can deliver the liquid in a spray or atomized form. The spray nozzle  60  can be modified to provide different type of spray shapes and densities, according to the application desired and type of liquid being dispensed. Further, the spray nozzle  60  can be provided with an adjustment feature to allow the end user to adjust the spray pattern  64  with each use if desired and the leader tube  62  may be rigid or flexible. 
         [0029]    In accordance with the present invention, each press of the flexible membrane  36  causes a metered amount of liquid  24  to be forced through the spray nozzle  60  to provide the desired atomized delivery application. This button/membrane  36  can be placed anywhere on the device, as needed. Further, the main pouch can be of any configuration, such as a flat pouch or stand up pouch (SUP), for example. In addition, further layers can be provided, such as laminations of foam, fabric, paper, plastic, and the like, to enhance the touch and appearance of the overall device. 
         [0030]    Still referring to  FIG. 3 , the operation of the dispensing device  10  is further explained which is applicable to the present invention which includes a spray nozzle  60  attached to a leader tube  62  that extends from the exit port  44 . The button  36  of the metering housing  26  is depressed to initiate a vacuum operation. More specifically, when the button  36  is further released, fluid  24  is pulled from the fluid storage region  22  of the container body  20  into the metering chamber  32  which is configured to be of a certain known volume. The act of releasing the button  36  fills the metering chamber  32  to substantial capacity. Thus, a metered amount of fluid material  24  is contained within the metering chamber  32  in preparation for delivery. The size of the metering chamber  32  can be selected according to the type of fluid material  24  to be dispensed, the application therefor and the desired dosage volume. 
         [0031]    A further depression of the button  36  urges the measured volume of fluid  24  within the metering chamber  32  to exit out through the output valve  40  of the metering housing  26 . This known amount of fluid material  24  is then either directly routed to the applicator  12  for use or through a fluid conduit  42 , as seen in  FIG. 3 , for more targeted introduction into the applicator  12 . In this case, it is preferred that the metered volume of fluid material  24  be routed to the spray nozzle  60 . The fluid exiting the spray nozzle  60  can then be directed onto a desired surface or back into the applicator  12  as indicated by the intended use. 
         [0032]    Referring back to  FIG. 1 , an efficient method of manufacturing a quality dispensing device  10  is to employ heat welding to construct the container  20  and the applicator material  12  thereon. For example, a top portion  20   a  is typically heat welded to a bottom portion  20   b  about their periphery  20   c  to form a container  20  with an interior fluid storage region  22  therein. The applicator material  12  is similarly secured to the container  20  by heat welding or other similar process, such as gluing, either about its periphery or its entire contact surface with the container  20 . 
         [0033]    Turning now to  FIGS. 4 and 5 , further enhancements to the metering housing  26  construction are shown in detail. As seen in  FIG. 4 , a number of stand-off legs  50  emanate downwardly from the base plate  34  of the metering housing  26 . These legs  50  prevent the base plate  34  from completely bottoming out against the container  20  wall thereby blocking flow of fluid material  24  into the intake valve  30 . The stand-off legs  50  are particularly useful when the volume of fluid material  24  left in the container  20  is running low and the container  20  is becoming relative flat in configuration. In this situation, there is a possibility that the aforesaid bottoming out may occur. However, the use of the stand-off legs  50  of  FIG. 4  prevent this from occurring. 
         [0034]      FIG. 5  illustrates a further modification of the metering housing  26  to ensure that maximum suction is achieved and that the entire metering chamber  32  is filled upon each depression and release of the button  36 . A spring-biasing structure  52  resides within the button or bulb structure  36  of the metering housing  26 . Thus, the button  36  recovers quickly while providing a strong suction or vacuum to fill the interior of the metering chamber  32  with the desired metered volume of fluid material  24 . A coil spring is preferred for the spring-biasing structure  52  but other spring-biasing structures, such as leaf springs and foam material may be employed for this purpose. Further, while various spring-biasing structures  52  are shown, it is also within the scope of the invention that the resiliency of the bulb structure  36  material is selected to exhibit sufficient memory to return to its original shape quickly without the need for spring-biasing structures  52 . In this manner, the present invention clearly provides for an overall construction that requires dramatically less parts for operation as compared to the prior art conventional spray dispensers. 
         [0035]      FIG. 6  illustrates a further alternative embodiment  200  of the present invention where a container, such as container  220  or  120 , includes a series of tabs  202  that emanate outwardly from the container  220 . An outer frame or skeleton  204  is connected to the container  220  via the tabs  202 . Applicator material  206 , such as “poof” or fabric material, is then attached to the frame  304  with the container  220  residing therein. This embodiment  200  is particularly well-suited to permit free flowing of fluid material about the dispenser  200 . 
         [0036]    Turning now to  FIGS. 7 and 8 , details are shown of a another alternate device  300  that includes the improved valving of the present invention that prevents inadvertent or accidental dispensing of liquid  302  even when pressure is placed on the dome pump  326  or storage container  320 .  FIG. 8  illustrates a perspective view of a metering dispenser  300  that employs the improved valving 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, or a tube of material. A metering pump, generally referred to as  326 , pulls liquid  302  from the storage container  320 , meters it, and then dispenses it via an exit port  308  into a leader tube  310  and ultimately out of a spray nozzle  312 . 
         [0037]    In the dome pump  326  of the present invention, the base plate  410 , through which the flow through aperture  412  passes, is preferably slightly convex, although it may be flat, if desired. Resting above the aperture  412  and within the cavity  405  of the dome is a flapper valve  408  of preferably thin film construction. It is possible that this flapper valve  408  be configured of a normally open condition but also may be configured to lie flat when at rest. As long as the plate  410  with the aperture remains convex, the flapper valve  408  does not seal against the aperture  412  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 flexible pump housing  404  will tend to simply flow back through the inlet aperture  412  to the reservoir within the storage container itself, as indicated by the arrow in  FIG. 8 , rather than flow undesirably out through the exit valve to outside of the dispenser  300 . In use, if a person has the dispenser in their pocket or purse and pressure is accidentally or unintentionally placed on the flexible housing  404  of the dome pump  426 , liquid will not flow outside the dispenser thereby preventing a mess from being made due to unintentionally dispensed product. 
         [0038]      FIG. 8  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 invert the base plate  410  from convex to concave, by application of force against the stand-off legs  424 , 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 aperture  412  thereby closing the liquid flow passage back into the reservoir  434  of the storage container  320 . It is also possible that the base plate  410  is concave and then is inverted to a convex configuration. Other fingers of the user may be used to carry out this operation. Thus, the only path for the liquid  302  contained within the cavity  405  of dome  404  is to exit through the one-way outlet valve  436  for intended dispensing of the product, as indicated by the arrows in  FIG. 8 . 
         [0039]    It should be understood that the stand-off legs  422  on the bottom of the flexible dome housing  404  and the stand-off legs  424  on the bottom of the base plate  410  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 aperture  412  through the base plate  410  to provide a good seal of the flapper valve  408  to the base plate  410 . 
         [0040]    The dispensing device  10  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. 
         [0041]    For example, the personal care industry has particular application in the controlled and metered dispensing of bath and shower gels. Also, medicines, cosmetics, hair care products, such a 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  10  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 device can employ the present invention. 
         [0042]    The device with a spray nozzle  60  of the present invention has particular application in dispensing liquid that is best suited for being sprayed or atomized for delivery. For example, the present invention is very well suited for dispensing air freshener, which is typical sprayed for delivery. As an advance over the prior art, the present invention provides controlled metering of the sprayed liquid, which is not found in the prior art. 
         [0043]    Still further, cleaning products can be dispensed in a controlled fashion, such as those for cleaning cars, bikes, planes and trucks. The food industry has numerous potential applications, particularly for the dispensing of condiments, sauces and vitamins. These items can be sprayed as well. 
         [0044]    To employ the dispensing device  10  of the present invention, the size and construction of the metering housing  26  as well as the positioning of where the fluid material  24  is delivered to the surface of the device can be easily modified to suit the given application. The materials used for the container  20  and the metering housing  26 , while preferably flexible plastic, can be any suitable material for the application at hand. Also, the container  20  can be made of a different material than the metering housing  26 . 
         [0045]    The applicator material  12  can be foam, such as open cell foam, fabric, blended material, co-extruded material and combinations thereof. It should be understood that these materials are just examples of the types of materials that can be used in connection with the dispenser  10  of the present invention. The specific material is determined by the given application and the type of material to be dispensed. Non-woven materials or fibers may also be employed as the material for the applicator  12  on one or both sides of the device. For example, reticulated foam may also be employed. These materials would be well-suited as applicators  12  for more harsh chemicals, such as tire cleaner and paint remover where toughness is required. Also, more abrasive material can be provided on one side of the device for more aggressive cleaning, for example, while the opposing side has a polishing type surface. In general, the size, density and wicking action of the cells and overall size of the applicator  12  can be modified to suit the particular fluid to be applied. 
         [0046]    Any type of spray nozzle  60  can be used to deliver the liquid in a spray form. The type shown on the attached invention disclosure is just one example of the type of spray nozzle  60  that can be used in the present invention. 
         [0047]    In summary, a new and novel dispenser  10  is provided that can deliver consistent metered dosages such fluid material  24  in an atomized spray form. The dispenser  10  has a greatly improved construction where the fluid material  24  is even distributed throughout the applicator material  12  for a more efficient and more effective fluid dispensing. The dispenser includes a unique spray nozzle  60  to deliver the metered liquid in a spray form, which is new in the art. 
         [0048]    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.