Patent Publication Number: US-10787306-B2

Title: Dispenser for viscous materials

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present application is a continuation-in-part application of and claims priority from U.S. patent application Ser. No. 16/152,511 filed Oct. 5, 2018, the disclosure of which is incorporated herein by reference. 
    
    
     FIELD 
     The present disclosure generally relates to dispensers and, more particularly, pertains to hand-held dispensers for discharging viscous materials. 
     BACKGROUND 
     A variety of hand-held, manually operated dispensers are known for selectively dispensing thick, flowable viscous materials, such as paste-like extrudable materials in the form of gels, foams, adhesives, and the like. One area in which dispensers of the present disclosure have particular application is the food industry where pre-packaged charges of viscous food products, such as cheese, whipped topping, icing, and food condiments, are to be dispensed. 
     Many of these food product dispensers include a housing or body for replaceably receiving a flexible package of a food product to be dispensed. The dispenser typically has a dispensing end and a piston slideably mounted within the body. Dispensers of this type usually include a handle having a pivotably mounted trigger which is squeezed by a user to activate a piston advancing arrangement. Such piston advancing arrangement commonly includes an elongated rod that is advanced by a pawl mechanism linking the rod and the piston. One portion of the rod is adapted for contact with the piston and propels the piston as the user manipulates the trigger. As the piston is advanced, the food product is dispensed from the dispensing end. 
     To refill the dispenser with a new flexible package, the dispenser is disassembled and the new flexible package is inserted. While refilling the dispenser, residual food product at the dispensing end may spill out or be cleaned from the dispensing end. Accordingly, the residual food product is lost thereby increasing costs and refill frequency. 
     In other common applications, a dispenser is provided that includes an open cavity that receives a food product that is not provided in a flexible package. In such embodiments, the food product is poured into the open cavity. When the supply of food product is emptied from the open cavity, the open cavity is refilled with the food product. Presently, dispensers are not available that can handle both flexible pouches and poured-in food products. 
     There remains a need for a dispenser that efficiently dispenses the food product received in either a flexible pouch or as a pour-in supply, such that little or no residual food product is lost or wasted when the dispenser is refilled. Furthermore, there remains a need for a dispenser with an efficient mechanism for driving the rod and the piston to thereby dispense the food product from the dispenser that is easy to use and clean. Through research and experimentation, the present inventors have developed the dispensers of the present disclosure that increase efficiency of the mechanism that drives the piston to thereby dispense the food product. 
     SUMMARY 
     This Summary is provided to introduce a selection of concepts that are further described below in the Detailed Description. This Summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter 
     In certain examples a dispenser for dispensing a viscous material contained in a flexible package includes a body extending along a longitudinal axis that has a first end, an opposite second end, a cavity configured to receive the flexible package, and a handle assembly coupled to the first end. The handle assembly has a fixed handle, a trigger pivotally coupled to the fixed handle, and a rod extending between the fixed handle and the trigger into the cavity along the longitudinal axis. A plurality of dispensing valves are positioned at the second end of the body and configured to dispense the viscous material, and a piston is movably disposed in the cavity for engagement with the flexible package. As the trigger is pivoted toward the fixed handle, the rod moves along the longitudinal axis toward the piston such that the piston engages the flexible package and the viscous material dispenses through the plurality of dispensing valves. 
     In certain examples, a dispenser for dispensing a viscous product contained in a flexible package includes a body extending along a longitudinal axis and having a first end, an opposite second end, a cavity configured to receive either the flexible package or a pour-in supply of product, and a handle assembly coupled to the first end. The handle assembly has a fixed handle, a trigger pivotally coupled to the fixed handle, a rod extending between the fixed handle and the trigger into the cavity along the longitudinal axis, a pawl member pivotally coupled to the fixed handle, and a gasket coupled to the first end of the body through which the rod slides. The gasket applies a radially inwardly force on the rod to thereby prevent movement of the rod away from the piston as the trigger is pivoted. A plurality of dispensing valves are positioned at the second end of the body, and a piston is movably disposed in the cavity for engagement with the flexible package. As the trigger is pivoted toward the fixed handle, the trigger pivots the pawl member such that pawl member engages the rod and axially moves the rod along the longitudinal axis. Accordingly, the rod moves the piston into engagement with the flexible package such that the viscous material dispenses through the plurality of dispensing valves. 
     Various other features, objects and advantages of the invention will be made apparent from the following description taken together with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The drawings illustrate modes presently contemplated of carrying out the present disclosure. In the drawings: 
         FIG. 1  is a perspective view of a dispenser in accordance with the present disclosure; 
         FIG. 2  is an exploded view of the dispenser shown in  FIG. 1 ; 
         FIG. 3  is a side view of the dispenser shown in  FIG. 1 ; 
         FIG. 4  is an end view of the dispenser shown in  FIG. 1 ; 
         FIG. 5  is a cross sectional view of the dispenser shown in  FIG. 1  along line  5 - 5  on  FIG. 4 ; 
         FIG. 6  is a perspective view of a diverter insert of the present disclosure; 
         FIG. 7  is a top plan view of the diverter insert shown in  FIG. 6 ; 
         FIG. 8  is a bottom plan view of the diverter insert shown in  FIG. 6 ; and 
         FIGS. 9-10  are cross sectional views of the diverter insert shown in  FIG. 6  along line  9 - 9  and line  10 - 10  on  FIG. 7 . 
         FIG. 11  is an exploded view of a handle assembly of the present disclosure; 
         FIGS. 12A-12B  are partial cross sectional view of the dispenser that depict operation of the handle assembly. 
     
    
    
     DETAILED DESCRIPTION 
     Depicted in  FIGS. 1-5  is a dispenser  10  for dispensing viscous materials according to the present disclosure. The dispenser  10  has a body  18  that extends along a longitudinal axis  20  and defines a cavity  19  in which a flexible package  14  ( FIG. 5 ) containing a food product is received. The flexible package  14  is typically pre-filled with a thick, flowable food product, such as ketchup, cheese or other similar product. The flexible package  14  is closed at first and second end walls  16 ,  17  to retain the food product within the flexible package prior to dispensing. The second end wall  17  of the flexible package  14  includes a dispensing fitment  23  and the portion of the end wall  17  aligned with the fitment  23  is weakened and thus designed to burst in response to a pressure applied to the first end wall  16  by a piston  52  so that the food product will flow out of the dispenser  10 . Although the present disclosure is shown and described as being used with a flexible package  14 , the cavity  19  could also receive a pour-in supply of food product to be dispensed. In such an embodiment, a fitment  23  could be placed in the cavity  19  and the flexible package would be eliminated. 
     The body  18  has a first end  21 , an opposite, threaded second end  22 , and a sidewall  31  extending between the ends  21 ,  22 . The sidewall  31  has an interior surface  32  and an opposite, exterior surface  33 . A wall member  24  ( FIG. 5 ) extends radially inwardly from the interior surface  32  into the cavity  19  to divide the cavity  19  into a first cavity portion  19   a  (e.g. package receiving cavity) and second cavity portion  19   b  (e.g. insert receiving cavity). The wall member  24  has a first wall surface  26  positioned next to the package receiving cavity  19   a , an opposite second wall surface  27  positioned next to the insert receiving cavity  19   b , and a passage  25  extending between the surfaces  26 ,  27  such that the package receiving cavity  19   a  is in fluid communication with the insert receiving cavity  19   b . The passage  25  is sized to receive the fitment  23  as illustrated. 
     The body  18  includes a handle assembly  40  that is removably coupled to the first end  21  of the body  18  and is operated by an operator to dispense food product from the dispenser  10 . The handle assembly  40  includes a fixed handle  41  integrally joined to a cap  42  that engages with the first end  21  of the body  18 . The cap  42  has a flange  44  that extends parallel to the longitudinal axis  20  in a direction away from the fixed handle  41 . The flange  44  has threads that engage with corresponding threads on the exterior surface  33  of the sidewall  31 . The fixed handle  41  has a first cutout  104  and the trigger  46  has a second cutout  105  that corresponds with the first cutout  104  such that when the trigger  46  is pivoted toward the fixed handle  41  the first and second cutouts  104 ,  105  define a passageway  106  ( FIG. 12A ) through which a rod  50  (described further herein below) slides. In one examples, the cutouts  104 ,  105  are semi-circular such that the resulting passageway  106  is circular. The shape of the passageway  106  corresponds to the shape or diameter of the rod  50  such that the rod  50  can freely slide through the passageway  106 . to thereby couple the handle assembly  40  to the body  18 . 
     Referring to  FIGS. 11 and 12A-12B , the handle assembly  40  is shown in greater detail. The handle assembly  40  includes a trigger  46  pivotably attached to the fixed handle  41  such that the operator can pivot the trigger  46  into and between an open position ( FIG. 12B ) and a closed position ( FIG. 12A ). In operation, the operator pivots the trigger  46  relative to the fixed handle  41  to thereby dispense food product from the dispenser  10 . The trigger  46  is pivotably attached to the fixed handle  41  by a pivot pin  47  which extends through respective aligned holes (not shown) in the trigger  46  and the fixed handle  41 . The trigger  46  is pivoted into and out of a recess  45  defined in the fixed handle  41 . The trigger  46  is normally biased by a first spring  48  ( FIG. 5 ) to the open position as ( FIG. 12B ) and is designed to be moved against the bias of the first spring  48  to the closed position ( FIG. 12A ) substantially within the recess  45  and/or against the fixed handle  41 . In certain examples, a second spring  49  (described further herein) is included to further bias the trigger  46  toward the open position ( FIG. 12B ). In the example depicted in  FIGS. 12A-12B , the springs  48 ,  49  are spaced apart from each other along the rod  50 . 
     The trigger  46  has a boss  55  that extends from the interior surface  56  of the trigger  46  toward the fixed handle  41 . The boss  55  has a first surface  57  that contacts a pawl member  58  which is pivotally coupled to the fixed handle  41 . In particular, the pawl member  58  has a first end  59   a  that is received in a channel  61  defined by the fixed handle  41 . The pawl member  58  has an opposite second end  59   b  with a second surface  91 . The pawl member  58  also has a hole  92  in which the rod  50  slides, and the hole  92  is defined by an edge surface  93  that selectively contacts the rod  50  when the trigger  46  pivots (described hereinbelow). The shape of the pawl member  58  can vary, and in the example depicted the pawl member  58  is “L”-shaped. A guide member  94  is also coupled to the trigger  46 , and the guide member  94  has a hole  95  in which the rod  50  slides. As the trigger  46  pivots toward the fixed handle  41 , the guide member  94  compresses the second spring  49  against the first end  21  of the body  18 . A gasket  96  at the cap  42  prevents debris from entering the cavity  19   a  while still allowing the rod  50  to slide there through. A clip  97  is connected to the cap  42  to thereby prevent over rotation or pivoting of the trigger  46  away from the fixed handle  41  (see arrow B on  FIG. 12B ) as the first spring  48  returns to an uncompressed state (see  FIG. 12B ). 
     An elongated reciprocating rod  50  is mounted for axial movement along the longitudinal axis  20  in the package receiving cavity  19   a  as the trigger  46  is pivoted. A piston  52  is within the package receiving cavity  19   a  is incrementally moved by the rod  50  such that the piston  52  applies a pressure to the flexible package  14  and thus food product dispenses from the dispenser  10 . 
     Referring back to  FIG. 5 , the piston  52  has an extended portion  78  with an opening that receives the rod  50  and a bearing surface  54  which acts on the flexible package  14 . The shape of the bearing surface  54  corresponds to the shape of the first wall surface  26  of the wall member  24 . When the piston  52  is moved into close proximity with the wall member  24 , the bearing surface  54  and the first wall surface  26  sandwich the flexible package  14  there between such that substantially all of the food product is forced from the flexible package and through the passage  25 . In an embodiment where the food product is a pour-in food product and the flexible package  14  is eliminated, the piston  52  would push the food product out of the cavity  19 . Accordingly, little or no food product is trapped in the package receiving cavity  19   a.    
     In the example depicted in  FIG. 5 , the bearing surface  54  is flat and circular with a protruding center section and the first wall surface  26  of the wall member  24  is flat and circular with a recessed center section that corresponds with the protruding center section of the bearing surface  54 . In another example (not shown), the bearing surface  54  and the first wall surface  26  are funnel-shaped and sloped toward the second end  22  of the body  18 . In contrast, if the bearing surface  54  does not correspond to the first wall surface  26  of the wall member  24 , an amount of food product becomes trapped there between in the package receiving cavity  19   a . For instance, if the bearing surface  54  is circular and flat and the first wall surface  26  of the wall member  24  is funnel-shaped and sloped toward the second end  22  of the body  18 , food product will become trapped between these surfaces  26 ,  54  due the bearing surface  54  contacting the wall member  24  before all the food products thereby stopping movement of the piston  52 . 
     The food product passing through the fitment  23  centered in the passage  25  in the wall member  24  is received into a diverter insert  70 . The diverter insert  70  is retained in the insert receiving cavity  19   b  by a removable collar assembly  60  that is coupled to the second end  22  of the body  18 . The collar assembly  60  includes a dispensing disc  62  having a plurality of one-way flexible dispensing valves  63 . Each of the dispensing valves  63  allows the food product to exit from the dispenser  10 . A cover  64  engages with the threaded second end  22  of the body  18  to hold the dispensing disc  62  in place. The cover  64  forces the dispensing disc  62  into contact with the diverter insert  70  such that a fluid tight seal is formed between the diverter insert  70  and the dispensing disc  62  and between the diverter insert  70  and the wall member  24 . The dispensing disc  62  can include any number and size of dispensing valves  63 . In the example depicted in  FIG. 4 , the dispensing disc  62  includes three circular dispensing valves  63 . The dispensing valves  63  are designed as one-way valves having a slit opening near the center and are formed from a flexible material, such as silicone. The dispensing disc  62  is interchangeable with other dispensing discs depending on the desired dispensing pattern for the dispenser  10 . The dispensing valves  63  are each radially offset from the longitudinal axis  20 . In the embodiment shown in  FIG. 2 , the dispensing disc  62  includes alignment bosses  66  which facilitate alignment of the diverter insert  70  with the dispensing disc  62  and the included dispensing valves  63 . One of the alignment bosses  66  is larger and shaped differently than the other alignment bosses  66  to ensure proper alignment of the diverter insert  70  and the dispensing disc  62 . 
     The diverter insert  70  disposed in the insert receiving cavity  19   b  is configured to receive the food product passing through the passage  25  and divert the food product to each of the dispensing valves  63 . The diverter insert  70  is centered on the longitudinal axis  20 . As shown in  FIGS. 6-10 , the diverter insert  70  includes an inlet end  71  having an inlet opening  72  through which the food product in received into a chamber  74  defined in the diverter insert  70 . The chamber  74  is tapered from the inlet opening  72  to a transition area  73 . At the transition area  73 , the material enters into one of a plurality of dispensing sections  83  which extend through the lower portion of the diverter insert  70  and each terminate at an outlet end  80 . Each of the dispensing sections  83  terminates at one of the plurality of outlet openings  81  through which the food product is dispensed to one of the dispensing valves  63 . 
     The chamber  74  has a first interior sidewall  75  that radially inwardly slopes from the inlet opening  72  toward the longitudinal axis  20  and terminates at a second interior sidewall  85  which radially outwardly slopes away from the longitudinal axis  20  and toward the outlet openings  81 . The first interior sidewall  75  radially inwardly diverts the food product toward the longitudinal axis  20  and the second interior sidewall  85  radially outwardly diverts the food product toward the dispensing valves  63 . The outlet openings  81  are each shaped such that food product is directed toward one of the dispensing valves  63 . For example, as shown in  FIG. 8 , the outlet end  80  has three dispensing sections  83  that terminate in the outlet openings  81  and are equally radially spaced apart from each other relative to the longitudinal axis  20 . The dispensing sections  83  and the corresponding outlet openings  81  generally align with the four dispensing valves  63  (see  FIG. 4 ) of the dispensing disc  62  (note that the dispensing valves  63  are shown in dashed lines on  FIG. 8 ). The outlet openings  81  define an inner edge  90  that is undulated or wavy. Furthermore, each dispensing section  83  directs the flow of material to the corresponding outlet opening  81 , which is generally shaped to match the shape of the dispensing valves  63 , and the second interior sidewall  85  includes smooth, curved surfaces that allow the food product easily flow through the chamber  74  and through the outlet openings  81 . 
     The outlet end  80  of the diverter insert includes alignment holes  88  that receive the alignment bosses  66  on the dispensing disc  62  to align the dispensing sections  83  with the dispensing valves  63 . One of the alignment holes  88  is larger and shaped differently than the other alignment holes  88  to ensure proper alignment of the diverter insert  70  and the dispensing disc  62 . Proper alignment of the dispensing sections  83  and the dispensing valves  63  is also important to ensure efficient and effective flow of the food product through the diverter insert  70  and to the dispensing valves  63 . The dispensing sections  83  are in fluid communication with each other (e.g. there are no barrier structures between the dispensing sections  83 ). 
     Referring to  FIGS. 11 and 12A-12B , an example operation of the dispenser  10  is described herein below, and a person of ordinary skill in the art will recognize that the operation of the dispenser  10  can vary. 
     To load the dispenser  10  with the flexible package  14 , the handle assembly  40  is decoupled from the body  18  and the flexible package  14  is inserted into the package receiving cavity  19   a  and the fitment  23  is located within the passage  25  (see  FIG. 5 ). The handle assembly  40  is then coupled to the body  18  thereby confining the flexible package  14  in the package receiving cavity  19   a.    
     To dispense the food product, the trigger  46  is squeezed towards the fixed handle  41  (see arrow A on  FIG. 12A ) such that the first surface  57  of the boss  55  contacts and acts on (e.g., cams) the second surface  91 . Accordingly, the pawl member  58  pivots in the first direction (see arrow C on  FIG. 12A ). As the pawl member  58  pivots in the first direction (see arrow C), the edge surface  93  engages (e.g., frictionally contacts) the rod  50  and thereby axially moves (e.g., pushes) the rod  50  and the piston  52  toward the flexible package  14  (see arrow D on  FIG. 12A ). As such, the rod  50  and the piston  52  incrementally advance within the packaging receiving cavity  19   a  thereby causing the food product to dispense from the dispenser  10 . In addition, as the trigger  46  is squeezed towards the fixed handle  41 , the guide member  94  compresses the second spring  49  against the first end  21  of the body  18  and guides the rod  50  is the axial direction to thereby prevent radial movement of the rod  50 . Furthermore, as the rod  50  axially moves in a direction toward the piston  52 , the rod  50  incrementally slides through the gasket  96 . The gasket  96  is sized and/or shaped to exert radially inwardly directed compression forces on the rod  50 . Accordingly, when the trigger  46  moves toward the open position ( FIG. 12B ) the gasket  96  prevents longitudinal movement of the rod  50  away from the piston (see arrow E on  FIG. 12B ). Thus, the piston  52  remains in contact with and maintains pressure on the flexible package  14 . Accordingly, pressure is constantly applied to the flexible packaging during repeated squeezing and releasing of the trigger  46  thereby increasing the efficiency and operation of the dispenser  10 . 
     When the trigger  46  is released, the first spring  48  applies a spring force to the pawl member  58  such that the pawl member  58  pivots in a second direction (see arrow F on  FIG. 12B ) and the second spring  49  applies a spring force to the guide member  94  such that the guide member  94  moves in a second direction (see arrow E on  FIG. 12B ). As the pawl member  58  pivots in the second direction (arrow F), the second surface  91  acts on (e.g., cams) the first surface  57  of the boss  55  to thereby pivot the trigger  46  away from the fixed handle  41  (see arrow B on  FIG. 12B ). Furthermore, as the pawl member  58  pivots toward the open position ( FIG. 12A ) the edge surface  93  is spaced apart from (e.g., does not contact) the rod  50  and thus the pawl member  58  freely passes along the rod  50 . Accordingly, the pawl member  58  does not act on (e.g., pull) the rod  50  away from the piston  52  or the flexible container  14 . Repeated squeezing and releasing of the trigger  46  will enable the rod  50  and the piston  52  to be moved toward the flexible package  14  until the food product is fully forced from the flexible package  14 . 
     The initial incremental movement of the piston  52  toward the flexible package  14  exerts a pressure on the flexible package  14  which will cause bursting of the second end wall  17  of the flexible package  14  at the location of the fitment  23 . Further incremental movement of the piston  52  compresses the flexible package  14  causing the food product to be forced out of the flexible package  14  and through the passage  25  defined in the wall member  24 . The food product is then received into the chamber  74  of the diverter insert  70 . The chamber  74  fills with food product, and after the chamber  74  is completely filled with food product, additional food product received into the chamber  74  causes food product to be diverted into the dispensing sections  83 , which divert the food product toward one of the dispensing valves  63 . The trigger  46  is repeatably squeezed to dispense the food product from the dispenser  10 . 
     To reload or refill the dispenser  10  when the flexible package  14  is empty, the handle assembly  40  is decoupled from the body  18  so that the used flexible package  14  can be removed and a new flexible package  14  can be inserted into the package receiving cavity  19   a . To reset the handle assembly  40 , the piston  52  and the rod  50  are moved to its original position by applying a force in an axial direction away from the body (see arrow E on  FIG. 12B ) to the piston  52  and/or the rod  50  that overcomes the compression forces exerted by the gasket  96 . Thereafter, the handle assembly  40  is recoupled to refilled body  18 , as described above. While the new flexible package  14  is inserted into the package receiving cavity  19   a , the food product in the chamber  74  is retained in the chamber  74  due to the vicious properties of the food product and the shape of the chamber  74 . If for instance, the dispenser  10  is inverted to remove the used flexible package  14  the food product in the chamber  74  remains in the chamber  74  and does not spill out. As new food product is forced into the chamber  74 , the residual food product in the chamber  74  is dispensed through the dispensing valves  63 . As such, food product in the diverter insert  70  is not wasted or lost when the dispenser  10  is refilled. 
     The present inventors have found that the dispenser  10  and the diverter insert  70  of the present disclosure greatly reduces the amount of food product which must be cleaned/removed from the dispenser  10  each time the dispenser is refilled. In conventional dispensers, an amount of residual food product is often trapped below the piston and above the dispensing opening due to the piston not fully compressing the flexible package and dispensing the food product there from. Accordingly, when the nearly emptied flexible package is removed from the dispenser the residual food product is trapped in the flexible package and/or in the dispenser between the piston and the dispensing holes. This residual food product is often placed in the trash or cleaned from the dispenser prior to a new flexible package being added to the dispenser. In contrast, the dispenser  10  of the present disclosure minimizes or eliminates the amount of residual food product that is wasted. Accordingly, the dispensing efficiency of the dispenser  10  of the present disclosure is greater than conventional dispensers. The diverter insert  70  of the present disclosure increases the flow rate of the food product between the flexible package  14  and the dispensing valves  63  and reduces buildup of large particles that may normally collect in at the sides or corners of conventional dispensers with conventional nozzles. 
     In the present disclosure, certain terms have been used for brevity, clarity and understanding. No unnecessary limitations are to be inferred therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed. The different systems, apparatuses and method steps described herein may be used alone or in combination with other systems, apparatus and method steps. It is to be expected that various equivalents, alternatives and modifications are possible within the scope of the appended claims. Each limitation in the appended claims is intended to invoke interpretation under 35 USC § 112(f), only if the term “means for” or “step for” are explicitly recited in the respective limitation.