Patent Description:
The present invention relates generally to foaming dispenser for squeezable containers, and, more specifically, to a venting seal closure associated with such dispensers.

An increasing number of liquid products, including soaps, cleaning solutions, and other fluids, find enhanced utility when dispensed from a container as a foam. Consequently, a wide array of containers having foaming dispensers are now available.

Generally speaking, foaming dispensers rely upon mixing the liquid fluid with a corresponding (and usually predetermined) volume of air in a specially designed mixing chamber. The liquid and air can be urged into the chamber by way of a pump mechanism. However, one drawback to these mechanisms is that they often require a number of specially designed parts, which can increase costs and/or the likelihood of a failure in one of the components.

As a result, a number of dispensers discharge foam by a simple squeeze action applied to the sidewalls of a deformable, resilient container. This squeezing urges the liquid into the mixing chamber while simultaneously allowing air to be drawn in through vents/inlets formed in the container, usually in or proximate to its cap (where the foaming mechanism is typically located).

<FIG> generically illustrates a foaming dispenser associated with a typical squeeze container. Dispenser <NUM> includes a cap <NUM> positioned over the closure <NUM> and dispenser nozzle <NUM>. When the cap is removed, air inlets <NUM> formed permit make-up air to re-enter the container (not shown) after a squeezing action. In particular, liquid from the container is urged past the valve <NUM> by way of inner flaps <NUM> deflecting upward. The liquid then enters the foaming chamber <NUM> and is urged out of the nozzle outlet <NUM>. The resilient sidewalls of the container (not shown) expand, drawing the outer flaps <NUM> downward and allowing air to pass back into the container's interior. Other, similar approaches to foaming valves can be found in <CIT>and <CIT>.

In these designs, the valve includes resilient, deformable flaps that are temporarily displaced to permit the temporary flow of air or liquid. As shown in <FIG>, these flaps attach to an annular upstanding wall so that the flaps effectively possess rigidity and hoop strength. In fact, the upstanding wall is in the form of an circular cylinder that defines a fluidic barrier with the nozzle structure <NUM>, so that the liquid/foam outlet (as defined by chamber <NUM> and outlet <NUM>) remains separated from the air inlets <NUM>. In this manner, the flaps <NUM>, <NUM> attach on opposing sides of the wall at a midpoint so as to allow each flap <NUM> or <NUM> to flex and deform. While this hoop strength ensures a good seal, it also creates significant force which must be overcome to activate the squeeze foamer.

Through finite element analysis, the inventors have discovered the upward slope of flaps <NUM>, <NUM> requires a moderate amount of force, as an example, in the range of approximately <NUM> N. While it is important for the deformable vent to have sufficient strength to avoid unintended activation/foaming, many users would prefer a slightly easier to activate foaming mechanism. More specifically, a vent seal that deformed with less force would be welcome. Also, the strength/stiffness of previous vent designs contributed to relatively loud operation of the foamer (i.e., the excessive force to activate also created more noise).

Document <CIT> discloses a foamer for use in dispensing a liquid product with a foam consistency including a top cap, a closure, a housing, an air-flow diaphragm, a mesh screen and a valve structure.

A sealing vent for a foaming dispenser associated with a squeeze foaming container is described. The vent has an annular structure, with a central aperture encased by a multi-tiered disc section connected to inner facing of a thickened, axial wall. An upward angled, outer flange is connected on an outer facing of the axial wall, and the outer flange is attached at a lower elevation along the axial wall in comparison to the disc section.

Specific reference is made to the appended claims, drawings, and description below, all of which disclose elements of the invention. While specific embodiments are identified, it will be understood that elements from one described aspect may be combined with those from a separately identified aspect. In the same manner, a person of ordinary skill will have the requisite understanding of common processes, components, and methods, and this description is intended to encompass and disclose such common aspects even if they are not expressly identified herein.

Operation of the invention may be better understood by reference to the detailed description taken in connection with the following illustrations. These appended drawings form part of this specification, and any information on/in the drawings is both literally encompassed (i.e., the actual stated values) and relatively encompassed (e.g., ratios for respective dimensions of parts). In the same manner, the relative positioning and relationship of the components as shown in these drawings, as well as their function, shape, dimensions, and appearance, may all further inform certain aspects of the invention as if fully rewritten herein. Unless otherwise stated, all dimensions in the drawings are with reference to inches, and any printed information on/in the drawings form part of this written disclosure. Also, the objects in the drawings are shown in their intended orientation, so that a feature shown in the top of the drawings are oriented toward the upper or topside portion of the mechanism/object, while features at or facing downward likewise at the bottom or underside portion.

In the drawings and attachments, all of which are incorporated as part of this disclosure:.

Reference will now be made in detail to exemplary embodiments of the present invention, examples of which are illustrated in the accompanying drawings. It is to be understood that other embodiments may be utilized and structural and functional changes may be made without departing from the respective scope of the invention. As such, the following description is presented by way of illustration only and should not limit in any way the various alternatives and modifications that may be made to the illustrated embodiments and still be within the spirit and scope of the invention.

As used herein, the words "example" and "exemplary" mean an instance, or illustration. The words "example" or "exemplary" do not indicate a key or preferred aspect or embodiment. The word "or" is intended to be inclusive rather an exclusive, unless context suggests otherwise. As an example, the phrase "A employs B or C," includes any inclusive permutation (e.g., A employs B; A employs C; or A employs both B and C). As another matter, the articles "a" and "an" are generally intended to mean "one or more" unless context suggest otherwise.

With reference to <FIG>, the inventor has discovered that providing a vent seal with a multi-tiered disc concentrically disposed within and attached to the thickened axial wall requires less force to activate a squeeze foaming dispenser, like the ones shown in <FIG> and/or the patents cited above. The vent <NUM> has a cylindrical wall <NUM> with angled discs or flaps <NUM>, <NUM> projecting out from opposing sides of that wall <NUM>. An aperture <NUM> remains in the center. The inner flap has at least three separate sloping portions <NUM>, <NUM>, <NUM> disposed at differing angles, so as to facilitate the movement required of the vent during activation (i.e., squeeze foaming). Further, the attachment points for the inner and outer flaps are at different elevations (relative to wall axis W) along the wall <NUM>, as well as attachment angles I, O relative to the wall axis. Preferably, the inner disc <NUM> will be attached at a higher elevation along the inner facing of the wall <NUM> in comparison to flap <NUM>, while angle I is greater than angle O. This combination of features results in a flap that forms a good, resilient seal with lower activation force required in comparison to the unitary flaps described above.

In operation, the outer most flap <NUM> engages a sealing surface on dispenser structure <NUM>, as described below. As above, flap <NUM> will be drawn inward during activation, thereby admitting make-up air into the sealed container.

Further, the multi-tiered combination of portions <NUM>, <NUM>, <NUM> reduce the initial hoop strength necessary for activation. In particular, with reference to the angles formed on the underside of vent <NUM> as it is pictured in <FIG>, the joint of sections <NUM>, <NUM> forms an acute angle with a peak <NUM> that extends to an axial elevation above the top edge <NUM> of wall <NUM>. In turn, the joint of sections <NUM>, <NUM> forms an obtuse angle with section <NUM> forming a frusto-conical shape that angles upward. In comparison, the terminal, outer-most edge of flap <NUM> is above even with the top edge of wall <NUM>, and it also remains disposed at an upward angle.

The disc portion is multi-tiered. That is, the disc contains three, distinct ramping sections. A ramp section is an angled, inwardly extending annulus. Each ramp section is oriented at a distinct angle relative to any ramp section or sections attached adjacent to it, thereby making each section easily identifiable. Although not intending to be limited by any theory of operation, the distinct angles of these ramp sections may act as hinges to facilitate the upward and downward movement of the inner disc. This facilitated movement, in turn, lowers the activation force required in comparison to the prior art design described above. Additionally, the intersection of at least two of the ramping sections may engage a portion of the nozzle and/or closure body to hold the vent in place and, in some instances, to provide further leverage in facilitating the movement of the vent to admit liquid (as shown in <FIG>) into the foaming chamber.

Thus, the axial wall is formed integrally with the flange and inner disc. However, if considered as a discrete element, the wall can be visualized as a hollow cylinder. The thickness of this wall (i.e., in the radial direction) should be greater than the thickness of either the flange or the inner disc (i.e., in the axial direction). This increased thickness provides the necessary strength and lever-action associated with squeeze foaming activation. The cylinder may have flattened top and/or bottom portions to engage the foaming mechanism. Also, the cross sectional profile of the wall may be consistent or it may allow for one or both terminal ends to taper inward. Preferably, the top terminal end of the cylinder tapers so that the overall thickness of the wall at the flattened end is less than the thickness where the inner disc and/or flange are attached.

The vent <NUM> is integrated within a dispenser <NUM> and, more particularly, in conjunction with a nozzle structure <NUM> that may be connected to (e.g., by way of a threaded engagement mechanism) a closure body <NUM>. Closure body <NUM> is formed to be attachable to a container neck to seal a squeezable or resilient container (not shown). An overcap <NUM> is provided as part of dispenser <NUM>, with the overcap engaging the closure body <NUM> and nozzle structure <NUM> to seal the dispenser <NUM> when it is not in use. The top panel <NUM> of the overcap <NUM> may include one or more concentrically formed sealing cylinder <NUM>. Such cylinders <NUM> protrude axially into the cavity to engage and/or seal specific portions of the closure <NUM> and nozzle <NUM>, as will be described below.

Overcap <NUM> includes an outer sidewall <NUM>. Sidewall <NUM> extends axially downward to define a cylinder, with the interior cavity <NUM> of that cylinder hollowed out to receive the closure <NUM> and/or nozzle <NUM>.

Closure body <NUM> has a cylindrical shape, preferably with a series of progressively inset cylinder sections <NUM>, <NUM> connected by a radial skirt section <NUM>. Threads or engagement mechanisms may be provided on the inner or outer circumference of the sections <NUM>, <NUM> to attach the closure <NUM> to any one of the container, the overcap <NUM>, and/or the nozzle <NUM>. Additionally, one or more concentric cylinders can be formed on either side of the skirt <NUM> for engagement and/or support.

A nozzle structure <NUM> is integrated with the closure body <NUM>. For example, structure <NUM> may comprise a single or multi-piece set of cylinders fitted within the central axis of the body <NUM>. At a minimum, structure <NUM> incorporates a foaming chamber <NUM>, bounded on its top and bottom by mesh inserts <NUM>. A nozzle outlet <NUM> receives the cylindrical body <NUM> of the foaming chamber along the top end of the body <NUM>. Chamber <NUM> is fluidically connected to the interior of the container to receive liquid therefrom and to expel a foamed product out of the nozzle outlet <NUM> when squeeze-dispensing occurs (which is, itself, only possible when the overcap <NUM> is removed). As used herein, "dispensing condition" refers to the flexing, depressing, or squeezing the sidewalls of the container so as to force liquid to flow up from the interior of the container and into the dispenser <NUM>, after which the resilient nature of the container creates sufficient suction to draw make-up air back into the container via the dispenser <NUM>.

Conversely, along the bottom of body <NUM>, a cyldinrical housing <NUM> is attached or fitted into place. Housing <NUM> cooperates with a bottom plate <NUM> and/or an attachment cylinder <NUM> to retain the vent <NUM> within the dispenser <NUM>. In some embodiments, the peak <NUM> formed by/between ramped sections <NUM>, <NUM> rests on an underside of the housing <NUM> (at least during dispensing/squeezing), while the inner flap <NUM> seals with the bottom plate <NUM> to close off the liquid/foam duct <NUM>. In the same manner, outer flap <NUM> sealingly engages the bottom plate to close off the air duct <NUM>, while the contact between the peak <NUM> and the housing <NUM> facilitates the opening of the inner flap to admit liquid into the foaming chamber (thereby reducing the amount of force required to activate the dispenser).

A dip tube <NUM> connects to a transverse duct <NUM>. The duct <NUM> terminates at its most radially distant point in an annular air chamber <NUM> positioned proximate to the underside of flap <NUM>. Duct <NUM> includes apertures leading to liquid/foam duct <NUM>. The dip tube <NUM> itself extends well into the interior of the container to accommodate the flow of air and liquid during the dispensing and air-make/recovery aspects of dispensing, in a manner well known to those in the art. As used herein, the interior of the container abuts the underside of the nozzle <NUM>, while the top of the nozzle includes the nozzle outlet <NUM>. Thus, when the overcap <NUM> is selectively removed (e.g., by way of a screw top or snap-fitting), the outlet <NUM> is exposed to the exterior environment so that foam can be expelled from the dispenser <NUM> during a dispensing condition.

The integration and, preferably, concentric positioning of the nozzle <NUM> within the closure body <NUM> creates an annular gap <NUM> fluidically connect to the air inlet and duct <NUM> that is sealed by vent <NUM>. A terminal edge of cylindrical wall <NUM> fits within the gap <NUM> so as to effectively seal the air inlet when the overcap <NUM> is attached to the dispenser <NUM>. To facilitate its insertion and engagement, circumferential protrusions <NUM>, <NUM> are provided to opposing facings of the cylinders <NUM> and <NUM>. The protrusions <NUM>, <NUM> act as guide ramps to facilitate the mating of the overcap <NUM> to the closure body <NUM>. One or a pair of stops <NUM> may extend radially into gap <NUM> to further assist in this regard. Cylinder <NUM> may flex outwardly along line F during this operation.

In view of the foregoing, a vent according to this invention may include any combination of the following elements: an upright axial wall having a hollow cylindrical shape; an inner flap comprising three contiguous sections attached to an inner facing of the axial wall, said three contiguous sections each sloped at a discrete angle relative to the upright axial wall; an outer flap attached to an outer facing of the axial wall; a central aperture defined by a terminal edge of the inner flap; wherein the inner flap and the outer flap are attached to the axial wall at differing elevations relative to one another; wherein a first sloping section of the inner flap is attached to the upright wall at an acute angle and a second sloping section, disposed between the first and a third sloping section, is at an obtuse angle; wherein the first and third sloping sections are disposed in an upward direction and the second sloping section is disposed in a downward direction; wherein a junction of the first and second sloping sections is at an elevation above a terminal top edge of the upright axial wall; and wherein an angle of attachment between the inner flap and the axial wall is different from an angle of attachment between the outer flap and the axial wall.

In the same manner, a closure for squeeze-activated container having flexible and/or resilient walls is also contemplated. It may incorporate the vent of the preceding paragraph, along with any combination of the following features: a closure body; a nozzle structure, carried within the closure body, having a foaming chamber connected to a nozzle outlet; the vent positioned within the nozzle structure, wherein the inner flap is proximate to the foaming chamber and wherein the outer flap is proximate to an air inlet formed between the nozzle structure and the closure body; an overcap having an interior cavity defined by a peripheral sidewall extending downward from a top panel and wherein the overcap is selectively attached to at least one of the closure and the nozzle structure; wherein the overcap includes a sealing cylinder extending axially downward within the interior cavity and wherein the sealing cylinder is received within a circumferential gap proximate to the air inlet defined by the nozzle structure and the closure; wherein a circumferential surface proximate to a terminal end of the sealing cylinder has an engagement protrusion; wherein an outer wall of the circumferential gap includes an engagement protrusion extending into the circumferential gap; wherein the outer wall resiliently flexes radially outward to receive a portion of the sealing cylinder; wherein the inner flap selectively seals a liquid flowpath from an underside of the nozzle structure through the foaming chamber to the nozzle outlet and wherein the outer flap selectively seals an air flowpath from the air inlet to the underside of the nozzle structure; a dip tube connected to the nozzle structure and wherein the dip tube forms part of the air flowpath; a ball valve is positioned within the dip tube to selectively seal the air flowpath and wherein the ball valve is urged into an open position when the container is subjected to a dispensing condition; wherein the nozzle structure includes an annular air chamber forming part of the air flowpath, said air chamber is selectively sealed by the inner flap; and wherein a transverse duct forms part of the liquid and air flowpaths, said transverse duct connecting to the dip tube.

In the alternative, a closure for squeeze-activated container having flexible and/or resilient walls incorporates the combination of vent arrangements noted above, along with any the following: the vent positioned within the nozzle structure, wherein the junction of the inner flap comes into contact a surface of the nozzle structure to facilitate opening the liquid flowpath during a dispensing condition; wherein the inner flap selectively seals a liquid flowpath from an underside of the nozzle structure through the foaming chamber to the nozzle outlet and wherein the outer flap selectively seals an air flowpath from the air inlet to the underside of the nozzle structure wherein the outer flap is proximate to an air inlet formed between the nozzle structure and the closure body and selectively seals an air flowpath from the air inlet to the underside of the nozzle structure; an overcap having an interior cavity defined by a peripheral sidewall extending downward from a top panel and a sealing cylinder extending axially downward within the interior cavity and wherein the sealing cylinder is received within a circumferential gap proximate to the air inlet defined by the nozzle structure and the closure; wherein a circumferential surface proximate to a terminal end of the sealing cylinder has an engagement protrusion; and wherein an outer wall of the circumferential gap includes an engagement protrusion extending into the circumferential gap and wherein the outer wall resiliently flexes radially outward to receive a portion of the sealing cylinder.

All components should be made of materials having sufficient resilience, flexibility, and structural integrity, as well as a chemically inert nature. As used herein, resilience refers to a structure's ability to return to its original shape, which may include the ability to exert sufficient force to create pressure differentials within a confined space (e.g., the interior of the container). The materials should also be selected for workability, cost, and weight. Common polymers amenable to injection molding, extrusion, or other common forming processes should have particular utility. Any container of sufficient resilience and flexibility can be associated with this design.

Claim 1:
An annular vent (<NUM>) for selectively admitting air into a squeeze-activated foaming mechanism when the mechanism is activated, the vent comprising:
a wall (<NUM>) having a hollow cylindrical shape aligned along a wall axis (W);
an inner flap (<NUM>), wherein, in use, the inner flap selectively seals a liquid flowpath of the squeeze-activated foaming mechanism;
an outer flap (<NUM>) attached to an outer facing of the wall (<NUM>), wherein, in use, the outer flap selectively seals an air flowpath of the squeeze-activated foaming mechanism; and
a central aperture (<NUM>) defined by a terminal edge of the inner flap (<NUM>), and
characterized in that the inner flap comprises three contiguous distinct ramps (<NUM>,<NUM>,<NUM>) attached to an inner facing of the wall (<NUM>), said three contiguous distinct ramps being sloped relative to the wall (<NUM>) at mutually different angles.