Patent Publication Number: US-2005133525-A1

Title: Lockout device for viscous liquid dispenser

Description:
BACKGROUND OF THE INVENTION  
      Viscous liquid dispensers are well known in the art for dispensing any manner of viscous liquid, for example lotions, soap, and the like. The conventional dispensers utilize a wide variety of pumping mechanisms that allow a user to depress or manipulate a pump actuator in order to dispense liquid from the dispenser. Exemplary devices are shown, for example, in U.S. Pat. Nos. 5,810,203; 5,379,919; 5,184,760; and 4,174,056.  
      Conventional dispensers and pump mechanisms are often configured with locking mechanisms to reduce leakage during shipment or storage. However, locking mechanisms may fail to fully stop leakage, especially in those pumps having a pump mechanism at or below the level of the liquid in the dispenser. During shipping or other transport of the dispenser, vibration or other movement of the pump actuator can often result in partial activation of the pump mechanism that results in undesirable leakage.  
      Therefore, there remains a need in the art for a dispenser with improved capability to prevent leakage during shipment thereof.  
     SUMMARY OF THE INVENTION  
      Advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.  
      The present invention provides a dispenser having a leak protection lockout device that is particularly well suited for viscous liquid dispensers, for example, soap dispensers, lotion dispensers, and the like. The leak protection device is particularly suited to prevent leaks during shipment or extended storage of the dispenser.  
      In accordance with one embodiment of the present invention, a dispenser for dispensing metered amounts of a viscous liquid is disclosed that includes a housing defining a liquid reservoir, a pump cylinder, a pump cylinder actuator operably connected to the housing; and a tool removably and rotatably attached to the pump cylinder, the tool including a lockout member, wherein the lockout member substantially inhibits actuation of the pump cylinder. The pump cylinder is slidably disposed and retained in a pump chamber and includes a first opening in communication with the reservoir, a second opening in communication with the exterior of the housing, and a dispensing channel disposed therebetween and through the cylinder. The pump cylinder is slidable and rotatable within the pump chamber between a locking position and a dispensing position. Desirably, substantially the entire tool is positioned between the housing and the actuating member.  
      In one aspect, the pump cylinder rotating tool may further include a head portion and a handle portion attached to the head portion. The handle may include a central recessed portion that may additionally include openings having shapes such as, for example, a directional arrow. The head portion is removably attached to the pump cylinder, while the lockout member extends from the head portion. The head portion may include first and second jaws defining an inside surface shaped to removably attach to an exterior portion of the pump cylinder. The first and second jaws may include inwardly projecting hooks, while the exterior portion of the pump cylinder may define notches sized and shaped for engagement by the inwardly projecting hooks. Desirably, the first and second jaws resiliently flex to permit removal of the tool from the cylinder.  
      In a further aspect, the pump cylinder extends from a front wall of the pump mechanism, while the lockout member extends further from the front wall than the pump cylinder. Desirably, the end of the lockout member is further from the front wall of the pump mechanism than the end of the pump cylinder is from the front wall of the pump mechanism.  
      In an even further aspect, the tool further includes at least one extension member attached to and extending from the head portion. Desirably, the tool further includes at least two extension members attached to and extending from the head portion. Even more desirably, the tool further includes first and second extension members attached to and extending from the first jaw, and third and fourth extension members attached to and extending from the second jaw. Desirably, the extension members present contact the front wall of the pump mechanism. The extension members are desirably substantially rigid to resist buckling upon contact between the actuator and the lockout member. Additionally, the extension members may resiliently flex during rotation of the tool about the axis of the pump cylinder.  
      In a still further aspect, rotation of the tool about the axis of the pump cylinder causes rotation of the pump cylinder from the locking position to the dispensing position. Desirably, continued rotation of the tool about the axis of the pump cylinder past the position where the pump cylinder reaches the dispensing position thereof results in separation of the tool from the pump cylinder.  
      In accordance with another embodiment of the present invention, a leak-resistant dispenser in condition for shipping is disclosed that includes a housing defining a liquid reservoir, a pump cylinder having a first opening in communication with the reservoir, a second opening in communication with the exterior of the housing, and a dispensing channel disposed therebetween, a pump cylinder actuator operably connected to the housing; and a pump cylinder rotating tool removably attached to the pump cylinder. The tool includes a means for substantially preventing contact between the actuator and the pump cylinder. The pump cylinder is rotatably disposed and retained in a pump chamber at a locking position and is rotatable to a dispensing position.  
      Desirably, the actuator comprises an inside surface defining a notch aligned to engage the means for substantially preventing contact between the actuator and the pump cylinder upon activation of the actuator.  
      In accordance with still another embodiment of the present invention, a method of removing a lockout device from a self-contained viscous liquid dispenser is disclosed that includes the steps of:  
      providing a dispenser including a housing defining a liquid reservoir, a pump cylinder having a first opening in communication with the reservoir and a second opening in communication with the exterior of the housing, a pump cylinder actuator operably connected to the housing; and a tool removably and rotatably attached to the pump cylinder, the tool comprising a lockout member that substantially inhibits actuation of the pump cylinder;  
      rotating the tool about the axis of the pump cylinder to rotate the pump cylinder to the dispensing position; and  
      continuing to rotate the tool until the tool disengages from the pump cylinder.  
      The invention will be described in greater detail below through embodiments illustrated in the figures. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  is a prospective view of a viscous liquid dispenser according to the invention;  
       FIG. 2  is a cross sectional view of the pump mechanism taken along the lines indicated in  FIG. 1 ;  
       FIG. 3   a  is a partial perspective and cross sectional view of an embodiment of the pump mechanism;  
       FIG. 3   b  is a partial perspective and cross sectional view of the pump mechanism shown in  FIG. 3a  particularly illustrating a locking feature thereof;  
       FIG. 4  is a partial perspective view of an embodiment of the pump mechanism;  
       FIG. 5  is a prospective view of a leak protection device according to the present invention;  
       FIG. 6  is a partial cross sectional operational view of an embodiment of the dispenser;  
       FIG. 7  is a partial cross sectional operational view of the leak protection device. 
    
    
     DETAILED DESCRIPTION  
      Reference will now be made in detail to embodiments of the invention, one or more examples of which are provided in the drawings. Each example is provided by way of explanation of the invention and not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment may be utilized with another embodiment to yield still a further embodiment. It is intended that the present invention include such modifications and variations as come within the scope of the appended claims and their equivalents.  
      The present invention relates to a leak protection device for use with any manner of user activated liquid dispenser. The leak protection device is particularly well suited for use with any manner of viscous liquid dispenser, for example soap dispensers, lotion dispensers, and the like. The present invention also encompasses a dispenser utilizing the leak protection device according to the invention. Examples of dispensers that may benefit from the leak protection device of the present invention are described in WO 02/49490 A1 as well as U.S. Pat. No. 6,516,976 to Lewis et al., U.S. Pat. No. 6,533,145 to Lewis et al., U.S. Pat. No. 6,543,651 to Lewis et al., U.S. Pat. No. 6,575,334 to Lewis et al., and U.S. Pat. No. 6,575,335 to Lewis et al., and U.S. patent application publications 2002/0074354A1 and 2002/0074355A1, the entireties of which are incorporated herein by reference.  
       FIG. 1  illustrates a viscous liquid dispenser  10  that is particularly suited as a liquid soap dispenser. The dispenser  10  comprises a housing, generally  14 . The housing  14  may comprise any number of components. For example, the housing  14  may include a front housing member  16  that is connected to a back housing member  18 . The dispenser  10  illustrated in  FIG. 1  is configured as a disposable liquid soap dispenser that can be removably attached to a wall mounted bracket or the like. For this purpose, mounting structure, generally  12 , is integrally formed on the back side  18  of the housing  14 . Desirable wall mounting brackets, for example, are disclosed in concurrently filed U.S. patent application Ser. No. ______, Express Mail Number EL 955701957 US, docket number 19422, the entirety of which is incorporated herein by reference.  
      Referring to  FIG. 2 , the dispenser  10  includes a liquid reservoir, generally  20  ( FIG. 2 ). A dosing pump is configured with the dispenser to dispense metered doses of the viscous liquid contained within the reservoir  20  upon a user depressing or manipulating a pump actuator. The pump actuator may be any structural member that is configured with or connected to a pump mechanism to dispense the viscous liquid from the dispenser  10 . The pump mechanism will be described in greater detail below. In the illustrated embodiments, the pump actuator, generally  60 , is illustrated as a panel member  62 . The panel member  62  adds to the aesthetically pleasing overall configuration of the dispenser  10  and may take on any shape. The panel member  62  is pivotally attached to the front component  16  of the housing  14  by way of protrusions  64  that reside in recesses  66  defined in the front component  16 .  
      The dosing pump apparatus  24  includes a channel  28  defining a pump chamber  26  defined by any manner of structural components. For example, wall members that are molded or otherwise formed on an internal surface, i.e., the bottom surface  22  of the housing  14 , may define the pump chamber  26 . In this embodiment, the pump chamber  26  is thus disposed completely within the housing  14 . In alternate embodiments, structural wall members that are attached to the outside surface of the housing member by any conventional means may define the pump chamber. In either case, the pump chamber  26  is in liquid communication with the reservoir  20 . For example, the pump chamber  26  may include a back wall  36  having an opening  38  defined therethrough and placing the pump chamber  26  in liquid communication with the reservoir  20 . In the embodiment of  FIG. 2 , an end cap member  35  having the opening  38  defined therethrough defines the back wall  36  of the pump chamber  26 . This configuration may be used when it is necessary to insert the pump mechanism into the pump chamber  26  prior to sealing the chamber  26 .  
      The pump chamber  26  has an internal volume that essentially defines the metered amount or dose of liquid to be dispensed therefrom. In this regard, the pump chamber can be configured with any desired volume depending on the intended use of the dispenser  10 .  
      A dispensing orifice  40  is also provided in the pump chamber  26  and defines the exit path for the viscous liquid from the pump chamber  26 . In the embodiment illustrated in  FIG. 2 , the dispensing orifice  40  is defined in a member of the pump mechanism, particularly a cylinder  42  that extends through an opening  32  in a front wall  30  of the pump chamber  26 . The pump mechanism of  FIG. 2  will be described in greater detail below. Other desirable pump mechanisms, for example, are disclosed in copending U.S. patent application Ser. No. 10/675,034, filed Sep. 30, 2003, the entirety of which is incorporated herein by reference.  
      As mentioned, the pump apparatus  24  includes a pump mechanism  25  that is operably configured with the pump chamber  26  to pressurize the viscous liquid contained within the pump chamber upon a user actuating the pump mechanism. Various configurations of devices may be utilized in this regard. For example, the pump mechanism  25  may be a cylinder member  42  that is slidable within the pump chamber  26 , as illustrated in  FIG. 2 . The cylinder  42  extends through an opening in the front wall  30  of the pump chamber and is prevented from being pulled out of the chamber  26  by a flange or piston member  50 . The piston member  50  also sealingly engages against the walls of the pump chamber  26 . An O-ring may be provided on the piston member  50  for this purpose. The cylinder  42  has a longitudinal dispensing channel  48  defined therethrough. The channel  48  terminates at the dispensing end of the cylinder  42  at the dispensing orifice  40 . Thus, in this embodiment, the dispensing orifice  40  is actually defined in the moveable pump cylinder  42 .  
      The cylinder  42  is moveable from a rest position to a pressurized or dispensing position. The cylinder  42  is biased to its rest position by any conventional device, for example a spring  56  disposed within the pump Express Mail: EL  955701815  US Docket Number:  19 , 371  chamber  26 . The spring  56  has a forward end fitted in a recess  54  defined by a conical flange member  52 . The rear end of the spring  56  is fitted around a cylindrical extension  37  of the end cap member  35 .  
      Still referring to  FIG. 2 , the actuator  60  configured as a panel member  62  is disposed in close proximity to the forward end of the cylinder  42  so that upon a user depressing the panel member  62  from the front side of the dispenser  10 , the cylinder  42  is caused to move rearward within the pump chamber  26 . As the cylinder  42  moves into the pump chamber  26 , a check valve mechanism (described in greater detail below) seals the opening  38  in the rear wall  36  of the pump chamber in response to an increase in liquid pressure within the chamber. As the pressure of the liquid increases within the chamber, the liquid is eventually dispensed out of the dispensing orifice  40 . In the embodiment of  FIG. 2 , the liquid is caused to travel through the longitudinal channel  48  to be dispensed out of the dispensing end of the cylinder  42 .  
      Upon release of the actuator  60 , the cylinder  42  is caused to return to its rest position. As the cylinder moves to the right, a vacuum is drawn within the pump chamber  26  that causes the check valve mechanism to unseat. Liquid from the reservoir  20  is then free to flow into the pump chamber  26  to be dispensed upon the next subsequent actuation of the pump mechanism.  
      As mentioned, a check valve mechanism, generally  68 , is operably disposed in the opening  38  between the pump chamber  26  and the reservoir  20  to seal the opening upon actuation of the pump mechanism  25 . The check valve mechanism  68  may be, for example, an elongated shuttle valve  88 . The shuttle valve  88  is slidable within the opening  38  in the end cap member  35  and has a plurality of radially extending arms  90 . Liquid from the reservoir  20  is free to flow past the arms  90  and into the pump chamber  26  so long as the shuttle valve  88  is not sealed against the opening  38 . In that regard, the shuttle valve  88  includes a cap  92  that sealingly engages against the end cap member  35  upon actuation of the pump mechanism  25 . The cap  92  prevents the liquid contained within the reservoir  20  from escaping through the opening in the chamber  26  and back into the reservoir  20  upon actuation of the pump mechanism  25 . Upon release of the pump mechanism  25 , the shuttle valve  88  moves into the chamber  26  and thus unseals the opening  38 . The static head pressure of the liquid within the reservoir  20  should be sufficient to cause the shuttle valve  88  to unseat and move into the pump chamber  26  to allow the chamber  26  to refill with liquid from the reservoir  20 . The vacuum drawn in the chamber  26  upon return of the cylinder  42  to its rest position will further aid unseating of the shuttle valve  88 . Other types of check valves known to those skilled in the art may be used.  
      The pump apparatus also includes a restriction device, generally  94 , operably disposed across the dispensing orifice  40 . The restriction device  94  may include at least one resilient flap member  98 , and desirably a plurality of flap members  98  defined by slits (not shown). The resilient flaps  94  have a concave configuration, and the restriction device  94  is disposed within the dispensing orifice so that the concave flaps are oriented upwards or towards the pump chamber  26 . Upon sufficient pressure within the pump chamber  26 , the liquid causes the resilient flaps  98  to buckle towards the dispensing orifice  40 , and the liquid flows through the dispensing orifice  40 . Upon release of the pump mechanism  25  and return of the mechanism to its rest position, the resilient flaps move back into engagement against themselves. However, due to the vacuum drawn in the pump chamber as the pump mechanism returns to its rest position, the flaps are pulled slightly apart and towards the pump chamber  26 . The flaps move apart just enough so that the pump chamber is vented as the pump mechanism  25  returns to its rest position. Once the pump mechanism  25  has returned to its rest position, the flaps  98  again completely seal against each other and prevent leakage or drippage of liquid from the pump chamber.  
      The restriction device  94  provides a relatively simple means of reducing leakage from the pump chamber, particularly in embodiments of the invention wherein the pump chamber is horizontally disposed at the bottom portion of the pump reservoir where static pressure of the liquid within the reservoir is greatest. The restriction device  94  also provides a relatively simple means for venting the pump chamber  26  and eliminates the need to vent the pump mechanism around the pump shaft or cylinder that may result in leakage problems. Additionally, the pump mechanism may be incorporated with unvented dispensers since a vent path is defined through the pump mechanism. If a vent is needed, desirable vent mechanisms, for example, are disclosed in concurrently filed U.S. patent application Ser. No. _______, Express Mail Number EL 955701965 US, docket number 19372, the entirety of which is incorporated herein by reference.  
       FIGS. 3   a  and  3   b  illustrate a locking feature of the cylinder  42 . A longitudinal channel  104  is defined in the top surface of the cylinder  42  and is engaged by a tab  34  of the front wall  30 . The cylinder  42  thus slides along the tab  34  upon depression of the actuator  60  and is prevented from rotating in use. The orientation of the dispensing orifice  40  is thus ensured. A partial circumferential groove  106  is also defined in the surface of the cylinder  42 . The groove  106  is located at a position that corresponds essentially to the fully depressed position of the cylinder  42 . Once the cylinder  42  has been fully depressed, the cylinder  42  may be rotated such that the tab  34  engages the groove  106 . The cylinder  42  is then locked into position. This locking feature is particularly useful during shipment of the dispenser.  
       FIG. 4  illustrates an additional feature of the cylinder  42  of the pump apparatus  24 . Notches  200  are defined upon a first side  202  and a second side  204  opposed to the first side of the cylinder  42  at first and second edges  212 . The notches  200  are shaped to accept and engage the jaws of a tool (see  FIG. 5 ) designed to facilitate rotation of the cylinder  42  into and out of its locked position. The notches  200  have an engagement surface  206 . The engagement surface  206  is angled such that a sufficient force applied to the engagement surface will have a radial component that will cause the cylinder  42  to rotate into or out of its locked position. The notches  200  may have side surfaces  208  that are useful for aligning and maintaining the jaws of the tool in the correct position along the length of the cylinder  42 .  
       FIG. 5  illustrates an embodiment of a tool that may be used to rotate the pump cylinder  42  into or out of its locked position. The tool or wrench  220  includes a head portion  222  having first and second jaws  228 . The jaws  228  together define an inside surface  224 . The inside surface  224  is desirably shaped to fit closely around an exterior portion  210  of the cylinder  42  disposed between the notches  200  on the cylinder. The jaws  228  define a gap  230  therebetween that is sized to accept the exterior portion  210  disposed between the notches  200  on the cylinder  42 . At an end  232  of each jaw  228  is disposed an inwardly projecting hook  234 . The hooks  234  have an engaging surface  236  that extends from and partially faces the inside surface  224  of the head portion  222 . Desirably, the engaging surfaces  236  are disposed substantially perpendicular to the inside surface  224  of the head  222 . When the tool or wrench  220  is installed on the cylinder  42 , the engaging surfaces  236  on the hooks  234  contact the complementary engagement surfaces  206  in the notches  200  on the cylinder  42 . When the tool  220  is rotated about the axis of the cylinder  42 , the interaction between the engagement surface  206  and the engaging surface  236 , as well as that between the inside surface  224  of the head portion  222  and the exterior portion  210  on the cylinder, causes the cylinder  42  to rotate about its axis.  
      On the end  232  of each jaw  228  is an outwardly facing surface  238 . On each jaw  228 , between the engaging surface  236  and the outwardly facing surface  238  is a tip  240 . The distance between the tip  240  on the first jaw and the tip  240  on the second jaw is less than the distance between the first and second edges  212  of the notches  200  on the cylinder  42 . Thus, as the tool  220  is installed on the cylinder  42 , the outwardly facing surfaces  238  on the ends  232  of each jaw  238  contact the edges  212  of the notches  220  on the cylinder. As the tool is pushed against the cylinder  42 , the jaws  228  temporarily flex outwardly until the tool snaps into place, allowing the hooks  234  to engage the notches  200  on the cylinder.  
      The tool  220  further includes a handle or grip portion  250 . The handle portion  250  may be grasped and used to rotate the cylinder  42  to its open or closed position. The handle portion  250  may also be grasped and used to place or remove the tool  220  on or from the cylinder  42  of the dispenser  10 . The handle  250  is desirably of sufficient length to allow a user to readily develop sufficient torque to rotate the cylinder  42 . However, the handle  250  is also desirably compact enough to fit under the actuator  60  so as to not extend from the housing  14  and add to the overall size of the dispenser  10 . The handle  250  may have any shape that is easily grasped by a user. In a desirable embodiment, the handle has a recessed central portion  251  with a ridge  252  at its periphery  253  to reduce the likelihood of the handle slipping from the fingers of a user. The recessed central portion  251  may define openings  254 . The openings  254  may have the shape of a directional arrow. The handle  250  may have an expanded portion  256  at the end of the handle for ease of grasping.  
      The tool  220  further includes a lockout member  270 . The lockout member  270  is attached to and extends from an upper surface  272  of the wrench  220 . The lockout member extends past the end of the cylinder  42  when the wrench  220  is installed on the cylinder. An end  274  of the lockout member  270  is positioned such that activation of the actuator  60  while the wrench  220  is present on the dispenser  10  results in the actuator contacting the end of the lockout member rather than contacting the end of the pump cylinder  42 . The lockout member  270  is desirably shaped to match the shape of the head portion  220 . The lockout member  270  desirably has a length “L” sufficiently long that the lockout member will readily prevent accidental contact of the actuator  62  with the pump cylinder  42 . The lockout member  270  desirably has a width “W” sufficiently wide to prevent deflection or buckling of the lockout member that may result in contact of the pump cylinder  42  by the actuator  60  despite the presence of the lockout member.  
      The tool  220  further includes one or more lockout extension members  300 . In a particularly desirable configuration, the tool  220  includes four lockout extension members  300 . The lockout extension members  300  are attached to and extend from a lower surface  301  of the tool  220 . Desirably, the lockout extension members  300  are attached to and extend from the head portion  222 . Even more desirably, tool  220  includes two lockout extension members  300  that extend from each of the first and second jaws  228 . The lockout extension members  300  provide additional support to the tool  220  while it is removably attached to the cylinder  42 . The lockout extension members  300  have ends  302  that contact the front panel  30  of the pump apparatus  24  when the tool  220  is installed on the cylinder  42 . The lockout extension members  300  are sufficiently rigid to substantially prevent deflection or buckling upon application of force by the actuating mechanism  60 . However, the lockout extension members  300  desirably will deflect slightly to the side to facilitate rotation of the tool  220  and/or installation or removal of the tool.  
       FIG. 6  illustrates an embodiment of the dispenser  10 . The dispenser  10  has a hingedly attached actuator  60 . In operation of the dispenser  10 , actuation of the actuator  60  causes an inside surface  304  of the actuator to contact the end of the pump cylinder  42  and depress the cylinder in the pump apparatus  24  to cause flow of liquid from the dispensing orifice  40  defined in the cylinder extending from the front wall  30  of the pump mechanism.  
       FIG. 7  illustrates the operation of the leak protection device on the dispenser. When the tool  220  is installed on the dispenser  10 , activation of the actuator  60  causes the inside surface  304  of the actuator to contact the lockout member  270  rather than the end of the pump cylinder  42 . A notch  306  desirably defined on the inside surface  304  of the actuator  62  may be positioned to engage the end  274  of the lockout member  270 . The notch  306  substantially prevents the actuator  62  from slipping from the end  274  of the lockout member  270 . Additionally, the notch  306  substantially prevents the tool  220  from moving laterally after the actuator  60  engages the lockout member  270 . The ends  302  of the lockout extension members  300  contact the front wall  30  of the pump apparatus  24  to anchor the tool  220 . When the tool  220  is in place, the tool substantially prevents the actuator  60  from contacting and moving the pump cylinder  42 , thus substantially reducing the potential for leakage. However, after installation of the dispenser  10  at its intended destination, the tool  220  is readily used to unlock the pump cylinder  42  as described above and then removed from the pump cylinder  42  to enable normal operation of the dispenser.  
      It should be appreciated by those skilled in the art that various modifications or variations can be made in the invention without departing from the scope and spirit of the invention. It is intended that the invention include such modifications and variations as come within the scope of the appended claims and their equivalents.