Abstract:
An actuator for a pump wherein the actuator may be made of a single molded part or multiple molded parts wherein each part or component may define a portion of the spin mechanics of the actuator.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to and the benefit of U.S. Provisional Application No. 61220647, entitled “PUMP ACTUATOR AND METHODS FOR MAKING THE SAME,” filed Jun. 26, 2009, and incorporates the same herein by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates to actuators and more particularly to actuators or dispensing heads used with fluid delivery devices. 
         [0004]    2. State of the Art 
         [0005]    Generally, a fluid product dispenser includes a container containing a fluid product to be dispensed and a dispensing device attached to or in communication with the container. The dispensing device may include a valve or a pump fastened to the container and having a dispensing opening through which fluid is dispended from the dispensing device. An actuator or dispensing head may be attached to the pump to actuate the pump and to pump fluid from the container through the pump. Such devices are well known and many examples of pumps and dispensing devices are available. 
         [0006]    While many different actuators for pumps are available, most include multiple parts. Each of these parts must be manufactured or molded and then assembled into the final actuator unit. In many cases, the costs associated with producing an actuator or pump may be dependent upon the number of parts that are molded and that are assembled to make the device. For instance, many actuators include actuator shells into which an orifice cup may be inserted to supply spin mechanics to a fluid exiting the actuator. Additional parts may be needed to deliver fluid to the orifice cup. Each of the parts, and the assembly of those parts, adds costs to the device. In addition, the size of the actuator may be mandated by the part sizes and the capabilities of the assembly equipment to handle small parts for assembly. In order to avoid higher costs, parts may be made larger than necessary to facilitate assembly. The larger parts are not necessarily aesthetically desirable. 
         [0007]    Therefore, it may be beneficial to develop actuators having fewer parts and slimmer or smaller profiles than existing actuators. 
       BRIEF SUMMARY OF THE INVENTION 
       [0008]    According to embodiments of the invention, an actuator may include a base and a cap portion. The base and cap portion may include spin mechanics formed therein, such as by being molded therein. Assembly of the base and cap portion together provides an actuator that may be used with a pump or dispensing device. 
         [0009]    In some embodiments, the base and cap portion may be molded as a single unit or solitary device wherein the base and cap portion are connected by a living hinge or other connection. The cap portion may be folded over onto the base portion and connected to the base portion to form an actuator. In other embodiments, the base and cap may be molded separately. 
         [0010]    In various embodiments of the invention, the spin mechanics of the actuator may be formed in the base, the cap, or both the base and the cap of the actuator. When the base and cap are connected together, the spin mechanics may be defined. 
         [0011]    In still other embodiments of the invention, an actuator formed of a base and a cap may be overmolded to provide a head shape over the actuator. In some embodiments, a base and cap portion of an actuator may be molded as a single unit. Through mold movement or an external mechanism, the base and cap may be combined, forming the actuator and the actuator may be closed back in the mold for the molding or formation of a head shape over the actuator. In this manner, an actuator having a distinct head shape may be produced. In addition, the overmolding of the actuator to form the head shape may prevent the base and cap from separating. 
         [0012]    In still other embodiments of the invention, an actuator may be enclosed or surrounded by a sleeve. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]    While the specification concludes with claims particularly pointing out and distinctly claiming particular embodiments of the present invention, various embodiments of the invention can be more readily understood and appreciated by one of ordinary skill in the art from the following descriptions of various embodiments of the invention when read in conjunction with the accompanying drawings in which: 
           [0014]      FIG. 1  illustrates an actuator according to embodiments of the invention; 
           [0015]      FIG. 2  illustrates an actuator according to embodiments of the invention; 
           [0016]      FIG. 3  illustrates a rear perspective view of an actuator according to embodiments of the invention; 
           [0017]      FIG. 4  illustrates a front perspective view of an actuator according to embodiments of the invention; 
           [0018]      FIG. 5  illustrates a front perspective view of an actuator according to embodiments of the invention; 
           [0019]      FIG. 6  illustrates an actuator sleeve according to embodiments of the invention; 
           [0020]      FIG. 7  illustrates a bottom perspective view of the actuator sleeve of  FIG. 6 ; 
           [0021]      FIG. 8  illustrates an actuator sleeve fitted over an actuator according to embodiments of the invention; 
           [0022]      FIG. 9  illustrates a bottom perspective view of the actuator sleeve and actuator illustrated in  FIG. 8 ; 
           [0023]      FIG. 10  illustrates a cross-sectional view of an unassembled actuator according to embodiments of the invention; 
           [0024]      FIG. 11  illustrates a cross-sectional view of an actuator being assembled according to embodiments of the invention; 
           [0025]      FIG. 12  illustrates an assembled actuator according to embodiments of the invention; 
           [0026]      FIG. 13  illustrates a secondary molding process over an assembled actuator according to embodiments of the invention; 
           [0027]      FIG. 14  illustrates an actuator and head combination according to embodiments of the invention; and 
           [0028]      FIG. 15  illustrates a molding process for an actuator according to embodiments of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0029]    According to various embodiments of the invention, an actuator for a pump may comprise a molded plastic actuator  100  as illustrated in  FIG. 1  or  2 . The actuator  100  may include a base  110  and a cap  120  wherein the cap  120  may be fitted or secured to the base  110  to form the actuator  100 . According to some embodiments of the invention, the base  110  and cap  120  may be molded together as a single unit. In such embodiments, a living hinge  112  connecting the base  110  and cap  120  may allow the cap  120  to be folded over and to fit over a portion of the base  120 . The cap  120  may be secured to the base  110  by any known method. According to other embodiments of the invention, the base  110  and cap  120  may be molded as separate components and the cap  120  may be fitted or secured to the base  110  by any known method. 
         [0030]    According to some embodiments of the invention, the spin mechanics  130  of the actuator  100  may be molded or formed in the base  110  of the actuator. For example, the spin mechanics  130  of the actuator  100  illustrated in  FIG. 1  are formed in the base  110  of the actuator  100 . When the cap  120  of the actuator  100  illustrated in  FIG. 1  is folded over and fitted to or secured with the base  110 , the spin mechanics  130  may be aligned with an orifice  122  in the cap  120 . In other embodiments, the spin mechanics  130  may be formed by a combination of a lower spin mechanic portion  132  and an upper spin mechanic portion  134 . For example, the spin mechanics  130  may be formed by the positioning of a lower spin mechanic portion  132  in a base  110  of the actuator  100  with an upper spin mechanic portion  134  in a cap  120  of the actuator  100  as illustrated in  FIG. 2 . When the cap  120  of the actuator  100  illustrated in  FIG. 2  is folded over and fitted to or secured with the base  110 , the spin mechanics  130  are formed by the positioning of the lower spin mechanic portion  132  and the upper spin mechanic portion  134 . 
         [0031]    According to embodiments of the invention, when a cap  120  is fitted to a base  110 , an orifice  122  or opening in the cap  120  may be in line with the spin mechanics  130  such that a desired spray or distribution pattern of fluid exiting the actuator  100  is achieved. The placement or positioning of the orifice  122  may be altered as desired and may be sized, shaped, or otherwise configured to provide a desired spray pattern in combination with the spin mechanics  130  of the actuator  100 . 
         [0032]    An actuator  100  according to embodiments of the invention may also include a fluid path opening  142  and one or more fluid paths  140 . The fluid path opening  142  and one or more fluid paths  140  may be used or configured to deliver fluid from a pump to the spin mechanics  130  and out of an orifice  122  in the actuator  100 . For instance, the actuators  100  illustrated in  FIGS. 1 and 2  include a fluid path opening  142  which may be in communication with a pump or fluid flow path. Fluid communicated to, or through, the fluid path opening  142  flows along fluid path  140  and is then distributed or forced through the spin mechanics  130  and out orifice  122 . When cap  120  is positioned over base  110 , the fluid path  140  is defined such that fluid entering the fluid path  140  may travel along the fluid path  140  to the spin mechanics  130 . 
         [0033]    According to various embodiment of the invention, the fluid path  140  may branch into two or more paths to deliver fluid to the spin mechanics  130  as illustrated in  FIGS. 1 and 2 . Although the fluid path  140  illustrated in  FIGS. 1 and 2  is shown as being formed completely in the base  110 , it is understood that a fluid path  140  may also be formed completely in the cap  120  or may be formed by partial paths formed in the base  110  and the cap  120  which communicate when the base  110  and the cap  120  are joined together to form an actuator  100 . 
         [0034]    In various embodiments of the invention, the configuration of the cap  120  relative to the base  110  or the configuration of fluid paths  140  through the cap  120 , base  110 , and spin mechanics  130  may be altered as desired to create a desired turbulence in the fluid flowing through the fluid paths  140 . For example, projections, walls, barriers, eddies, and other features may be added to the fluid paths  140  or in the spin mechanics  130  to alter the flow of fluid through the fluid paths  140  and out the actuator  100 . 
         [0035]    When the actuator  100  illustrated in  FIG. 1  is assembled such that the cap  120  fits over the base  120 , the actuator  100  may be attached to a pump. Fluid communicated from the pump and through the fluid path opening  142  of the actuator  100  may then flow through fluid path  140  until it splits into two paths feeding the spin mechanics  130 . Fluid entering the spin mechanics  130  is forced through the spin mechanics  130  where the fluid may become turbulent before exiting the actuator  100  through an orifice  122  in communication with the spin mechanics  130 . 
         [0036]    Although particular configurations for the spin mechanics  130  are illustrated in the various Figures herein, it is understood that any desired configuration of the spin mechanics  130  may be used with embodiments of the invention. As illustrated in  FIG. 1 , the spin mechanics  130  may be configured in the base  110  as desired. The spin mechanics  130  could also be configured or formed in just the cap  120 . It is also understood, as illustrated in  FIG. 2 , that the spin mechanics  130  may be formed from a joining of the base  110  with the cap  120 . In any embodiment, the spin mechanics  130  may be produced in any desired shape or form to impart the desired spin or characteristics to fluid exiting the actuator  100 . 
         [0037]    As illustrated in  FIGS. 1 and 2 , a base  110  may include a skirt extending up to a shelf  115  or ledge and a recessed portion  114  mounted over the shelf  115  and having a smaller diameter than the remainder of the actuator  100 . The spin mechanics  130 , fluid path  140 , a fluid path opening  142  may be formed in the recessed portion  114  of the base  110 . A cap  120  may include a cap rim  124  configured such that an interior portion of the cap rim  124  may abut at least a portion of the recessed portion  114  of the base  110  when the cap  120  is positioned over the base  110 . A base portion of the cap rim  124  may rest on the shelf  115  when a cap  120  is fitted to a base  110 . 
         [0038]    While the actuators  100  illustrated in  FIGS. 1 and 2  are round, it is understood that other shapes could also be made according to embodiments of the invention. For instance, a base  110  and cap  120  could have a square, rectangular, oval, triangular, or other shape as desired. 
         [0039]    An actuator  200  according to other embodiments of the invention is illustrated in  FIGS. 3 and 4 . The actuator  200  may include a base  210  and a cap  220  which may be joined together to form an actuator  200  according to embodiments of the invention. The base  210  may include one or more base voids  214  in at least a portion of the base  210  and the cap  220  may include at least one or more cap rims  224 . The cap  220  may be fitted to the base  210  such that the one or more cap rims  224  fit into corresponding one or more base voids  214 . Fitment or joining of the cap rims  224  with the base voids  214  may help to secure the cap  220  to the base  210 . 
         [0040]    As illustrated in  FIGS. 3 and 4 , the base  210  and cap  220  may be joined by a living hinge  212 . The living hinge  212  may allow the cap  220  to be folded over, and connected with the base  220 . Formation of an actuator  200  having both the base  210  and cap  220  connected as illustrated in  FIGS. 3 and 4  allows a single mold to be used to form an actuator  200 . However, in other embodiments of the invention, the base  210  and cap  220  may be made separately, such as by two different molds, and combined. 
         [0041]    The actuator  200  illustrated in  FIGS. 3 and 4  includes spin mechanics  230  formed in a portion of the cap  220 . In particular, the spin mechanics  230  may be formed in a portion of the cap rim  214  as illustrated. In other embodiments of the invention, the spin mechanics  230  may be formed in the base  210  or another portion of the cap  220 . The spin mechanics  230  may also be formed by the combination of an upper spin mechanic portion  234  located in a portion of the cap  220  and a lower spin mechanic portion  232  located in a portion of the base  210  as illustrated in  FIG. 5 . 
         [0042]    As illustrated in  FIGS. 3 ,  4  and  5 , an orifice  222  may be positioned in the base  210  of the actuator  200 . The orifice  222  may be configured to match with the spin mechanics  230  of the actuator  200  to produce a desired spray pattern. The actuator  200  may also include one or more fluid paths  240  in communication with the spin mechanics  230  and with one or more fluid path openings  242 . The one or more fluid path openings  242  may deliver fluid to the one or more fluid paths  240  from a pump to which the actuator  200  is connected or in communication with. 
         [0043]    According to some embodiments of the invention, the cap rim  224  may include one or more fluid path holes  244  through the cap rim  224 . When the cap  220  and base  210  are connected, the fluid path holes  244  in the cap rim  224  may allow fluid passing along the fluid paths  240  to flow through the cap rim  224  and into the spin mechanic  230  region of the actuator  200 . For example, fluid passing through the fluid paths  240  illustrated in  FIGS. 3 ,  4 , and  5 , may be distributed through the fluid path holes  244  and into the spin mechanics  230  region before exiting the actuator  200  through the orifice  222 . 
         [0044]    As with other embodiments of the invention, the actuators  200  illustrated in  FIGS. 3 ,  4 , and  5  may include spin mechanics  230  configured to provide a desired spray pattern or profile for the actuator  200 . In addition, the cap  220  and base  210  portions of the actuator  200  may be combined or fitted together using any desired means, including snap-fit means, glue, welding, or other securing methods. 
         [0045]    The actuators according to embodiments of the invention may also be made or constructed to be smaller than know actuators. For example, many known actuators require the assembly of an orifice cup into the actuator to provide spin mechanics. Because the spin mechanics of the actuators of the present invention are molded or constructed with the base, cap, and/or combination thereof, large openings in the actuator are not necessary to allow for assembly of an orifice cup. Therefore, actuators according to embodiments of the invention may be made smaller than other actuators. 
         [0046]    The actuators according to embodiments of the invention may be fitted or configured to fit with any desired pump or pumping device. According to embodiments of the invention, single, molded components wherein a cap and base may be fitted together to form an actuator provide a cheaper alternative to multiple piece actuators. In addition, any variety of spin mechanics may be formed by molding the spin mechanics into the base, the cap, or partially into the base and the cap such that joinder of the base and cap produces a desired spray pattern. 
         [0047]    According to other embodiments of the invention, a sleeve  300  may be fitted over an actuator according to embodiments of the invention. For example, the sleeve  300  illustrated in  FIGS. 6 and 7  may be fitted over the actuator  100  illustrated in  FIGS. 1 and 2  or over the actuator  200  illustrated in  FIGS. 3 ,  4 , and  5 . An orifice hole  322  may be configured to be positioned over an orifice of an actuator such that the orifice of the actuator is not blocked. The sleeve  300  may also include one or more ribs  350 , detents, or other features configured to secure an actuator within the sleeve  300 . The sleeve  300  may help to hold the cap and base of an actuator together such that the cap and base do not separate during use. 
         [0048]      FIGS. 8 and 9  illustrate a sleeve  300  according to embodiments of the invention positioned over an actuator such as actuator  100  or actuator  200  illustrated in  FIGS. 1  though  5 . For example, an actuator  100  may be positioned within sleeve  300  such that orifice  122  is visible through orifice hole  322 . Ribs  350  may hold the actuator  100  within an interior compartment of the sleeve  300 . The actuator  100  may include one or more flat surfaces  101  or one or more recesses  103  onto or into which a spring or other biasing device of a pump may positioned. The recess  103  or flat surface  101  may improve the union of a spring or biasing member with the actuator  100 . 
         [0049]    According to embodiments of the invention, a sleeve  300  may be made of metal, plastic, a resin material, plastic and metal, or any other desired material. For example, a metal sleeve  300  may be used to impart a desired finish to an actuator over which the sleeve  300  is positioned. 
         [0050]    According to still other embodiments of the invention, an actuator may be overmolded to provide a head shape over the actuator. The molding of a head shape over an actuator may occur during the molding process or following the molding and assembly of an actuator. 
         [0051]    For example, according to certain embodiments of the invention, an actuator  400  having a base  410  and a cap  420  as illustrated in  FIG. 10  may be molded as a single part. Once molded, the cap  420  and base  410  of the actuator  400  may be closed or combined as illustrated in  FIGS. 11 and 12  to form the actuator  400 . Once the actuator  400  is formed, a second molding process may be performed to produce a molded head design over the actuator  400  as illustrated in  FIG. 13 . During the second molding process, mold slides  505 ,  510 , and  520  may encase hold the actuator  400  in position for an overmolding. The material  490  molded over the actuator  400  thereby forms a shell or sleeve over the actuator and may provide a distinct head shape for the actuator and molded head combination  450  as illustrated in  FIG. 14 . 
         [0052]    According to some embodiments of the invention, a method for forming an actuator may include the steps illustrated in  FIG. 15 . In a first step  1100 , a base and a cap for an actuator according to embodiments of the invention is molded. The mold is then opened in a second step  1200 . The cap and base may then be assembled in a third step  1300 . A mold may be closed around the assembled cap and base in a fourth step  1400  and a head shape or form may be defined by the mold closed around the assembled cap and base. In a fifth step  1500  the head shape may be molded around the assembled actuator to produce, for example, an actuator and molded head combination  450  as illustrated in  FIG. 14 . 
         [0053]    In some embodiments of the invention, the method steps illustrated in  FIG. 15  may occur in a single mold. For instance, a mold having cavities for both a base and cap of an actuator may be used to mold the base and cap. Upon the opening of the mold  1200 , the base and cap may be assembled. Assembly of the base and cap may be accomplished by slides in the mold or by an external mechanism capable of assembling the base and cap in the mold. The mold may then be closed  1300  over the assembled base and cap, leaving room for a new mold shot whereby a distinct head design is molded  1500  to the assembled base and cap. During the molding of the actuator head  1500 , slides in the mold may cover the orifice, spin mechanics, or both to prevent the overmolding of the orifice and spin mechanics. For example, the slide  505  illustrated in  FIG. 13  may protect the orifice during the molding of the actuator head  1500 . 
         [0054]    According to various embodiments of the invention, the overmolding of an assembled base and cap may include overmolding using plastic, resin, metal, combinations thereof, or other materials. In addition, the overmolding may be decorated in the molds using sublimation techniques. Further, bi-injection of the overmolding may be desired and performed to create head designs having different materials or different colors. 
         [0055]    According to embodiments of the invention, an actuator such as actuator  100  illustrated in  FIGS. 1 and 2 , actuator  200  as illustrated in  FIGS. 3 ,  4 , and  5 , the sleeve  300  and actuator illustrated in  FIGS. 8 and 9 , or the actuator and molded head combination  450  illustrated in  FIG. 14  may be connected to a pump which may be connected to a container. When the actuator is actuated, the actuator may impart a force on the pump resulting in the delivery of fluid to a fluid path opening and through the actuator where it is expelled through an orifice. 
         [0056]    Having thus described certain particular embodiments of the invention, it is understood that the invention defined by the appended claims is not to be limited by particular details set forth in the above description, as many apparent variations thereof are contemplated. Rather, the invention is limited only be the appended claims, which include within their scope all equivalent devices or methods which operate according to the principles of the invention as described.