Patent Description:
Bottles and other containers having pump-action sprayers are generally known. These mechanisms typically include manually activated levers that draw and fluid carried in the main body and expel that fluid out through a spray nozzle. These nozzles may include open and closed positions to ensure accidental activation of the lever does not result in unwanted spray/discharging of the fluid.

These products generally reach the end-use consumer by means of a retail supply chain or by means of an e-commerce supply chain. Each of these supply chains entails different levels of risk with respect to the need for protective packaging as well as the likelihood of being dropped, subjected to vibration or other impact or simply the results of rough handling.

Trigger sprayer products traveling to the end-use consumer by way of the e-commerce supply chain have higher risks owing to their likelihood of being shipped in small, soft-sided packages and/or as individual containers (rather than in bulk with a large number of identical containers provided in a solid-sided crate or heavily protected skid). Thus, e-commerce products are more likely to have the nozzle of the trigger sprayer moved, jarred, skewed or twisted while in transit, as well as the nozzle being moved closer to the ON position where there would be an open path for product leakage.

Some trigger sprayers have a generally cylindrical form of mating or interfit between the nozzle and the trigger body. As such, it is fairly easy for the end-use customer to turn or rotate the nozzle relative to the trigger body in order to move the nozzle from either an ON position to an OFF position or from an OFF position to an ON position. This ease of rotation of the nozzle for the end-use consumer is facilitated by the generally cylindrical mating structures of the nozzle and of the trigger body. This generally cylindrical mating relationship or engagement between the nozzle and the trigger body is part of what creates the risk of the nozzle being inadvertently moved from an OFF position to an ON position, or at least closer to that ON position, during e-commerce transit.

A design, particularly for use in e-commerce transit, that provides greater resistance to rotation of the nozzle relative to the trigger body would be welcomed. Additionally, a container system that provides positive indication of being in a desired setting or movement between the settings is needed, such be way of an audible and/or tactile indication in the form of a "click" type noise/feel. <CIT> discloses a trigger sprayer according to the prior art.

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.

Various aspects of the invention are described. Notwithstanding these descriptions directed to particular combinations of features, it will be understood that portions of aspects from one described embodiment may still be combined with those from other aspects. With this in mind, one aspect of the invention includes the following:.

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.

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 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.

Exemplary embodiments of the present invention are directed to a construction option for increasing the resistance to rotation of the nozzle relative to the trigger body of a trigger sprayer mechanism that may be attached to containers and other objects for dispensing fluid products. Generally speaking, flatted surfaces of an otherwise generally round cylindrical form in those surfaces mate or engage as the nozzle is assembled onto the trigger body. With four equally-spaced flats on the mating sleeve of the nozzle and with four matching, equally-spaced flats on the mating post of the trigger body, there is a definite and positive indication of proper positioning of the nozzle relative to the trigger body, either in the ON position or in the OFF position. The use of these equally-spaced flats on the outer surface of the mating post and on the inner surface of the mating sleeve could be accomplished with a different number of flats depending on the number of position options for the nozzle. Additionally, the selected structures could be different as the key is to increase the resistance to rotation. However, the use of four equally-spaced flats is considered the preferred embodiment and the preferred option as the nozzle would typically have four surfaces with positions marked.

The specific construction selected for increasing the resistance to rotation is based on providing a surface of increased size as part of the inner post which the outer sleeve must ride up and over in order to move from one position to the next position. When it is desired to rotate the nozzle from one position to another, the engaging sleeve of the nozzle must slide over a surface of the mating post which is radially larger than the mating flat surface. This radially larger surface can be thought of as a raised surface which the nozzle must slide over as it is rotated. This requires the nozzle to flex and distort slightly and creates greater resistance to the turning or rotation than what would otherwise exist without the mating flats on these two engagement surfaces. When the raised surfaces are cleared by continued rotation of the nozzle, the nozzle snaps back as the flexing and distortion are relieved such that the two cooperating sets of four equally-spaced flats are once again aligned with each other. This "snap back" of the rotating nozzle may provide both an audible "click" to the user as well as tactile feedback to the user who is rotating the nozzle.

This increased resistance to rotation of the nozzle relative to the trigger body is not at a level which is considered unacceptable to the end-use customer. While there is greater resistance to rotation, the strength required to rotate the nozzle is well within the capability of all expected end-use customers. However, the increased resistance to rotation of the nozzle relative to the trigger body is at a level which makes it less likely for the nozzle to be inadvertently moved to the ON position during transit, primarily during e-commerce transit where the risks of inadvertent movement of the nozzle relative to the trigger body are believed to be greater.

Referring to <FIG> there is illustrated a trigger sprayer <NUM> which is constructed and arranged to dispense a fluid product in the form of a spray. While there may be a technical different between a spray and a mist in terms of droplet size, any difference or distinction in this regard is not germane to this disclosure. Accordingly, the term "spray" is used with the expressed intention of including within its scope all droplet sizes which might logically emanate from a trigger sprayer, such as trigger sprayer <NUM>.

Trigger sprayer <NUM> includes a nozzle <NUM> (see <FIG>) and a trigger body <NUM> (see <FIG>). It is the engagement between nozzle <NUM> and trigger body <NUM> which is the focus of the exemplary embodiment of the present invention. This engagement focuses on how nozzle <NUM> fits onto post <NUM> as part of the assembly of nozzle <NUM> onto trigger body <NUM>. The manner of engagement or assembly interfit typically found between nozzles and posts of prior art trigger sprayers includes a generally cylindrical sleeve (of the nozzle) with a sliding fit onto a generally cylindrical post (of the trigger body). The exemplary embodiment of the present invention, as disclosed herein, introduces a change to these generally cylindrical forms by adding flatted, spaced-apart surfaces on each of the mating or engaging forms.

The trigger sprayer <NUM>, see <FIG>, is assumed to be of a conventional construction except for the specific features which are disclosed herein as part of the exemplary embodiment. The point to be made is that the specific features which are disclosed herein in order to increase resistance to rotation of the nozzle <NUM> relative to the post <NUM>, as explained in greater detail below, are applicable to virtually any style of trigger sprayer which has the generally cylindrical forms of engagement between the nozzle and the post of the trigger body. Further structures ensure the sprayer <NUM> maintains sufficient rigidity and structural integrity to avoid or mitigate against other conditions in which fluid might otherwise leak or escape from the sprayer <NUM>.

The body <NUM> of the sprayer defines at least one fluid passage through its inner portion to allow fluid to be drawn into the body and then expelled through the nozzle. The body <NUM> also accommodates pumps or other structures to facilitate in this regard in a manner known in this field.

With reference to <FIG>, nozzle <NUM> has a generally square outer body <NUM> with an inner block <NUM> defining a centered engagement sleeve <NUM> which has a generally cylindrical form, except for its four, equally-spaced flats 34a - 34d formed, molded or machined into or as a part of the otherwise generally cylindrical inside diameter surface. Inner block <NUM> and outer body <NUM> are spaced apart and integrally joined by four, equally-spaced webs 36a - 36d. The geometry of this inner diameter sleeve <NUM> formed in the center of inner block <NUM>, has the appearance of a square, but with radius corners which correspond to a circle overlaying the square.

With reference to <FIG>, the post <NUM> of trigger body <NUM> is illustrated showing two of the four equally-spaced flats 38a - 38d. Flats 38a - 38d are sized and arranged to produce an outer surface geometry which is compatible with the inner surface geometry of inner block <NUM> (see <FIG>). These compatible surface geometries, as shown in <FIG> and <FIG>, enable the mating engagement or interfit which has been described and which is illustrated in <FIG>.

Diagrammatic illustrations of the flats on the mating surfaces are provided by <FIG> and <FIG>. Further, in <FIG>, a three dimensional illustration shows the orientation of the flats 38a - 38d as they are distributed around a portion where the post <NUM> connects to the body <NUM>. Correspondingly, <FIG> show isolated views of only the nozzle <NUM>. With reference to <FIG>, the square outer body <NUM> defines the opening in which the inner diameter sleeve <NUM> and flats 34a - 34d are formed. The flats 34a - 34d are distributed in a similar, corresponding configuration to flats 38a - 38d along the post, while sleeve <NUM> may form a concentric fit with the distal end of the post so as to ensure the nozzle <NUM> may rotate along a defined path when twisted relative to the body <NUM>.

The assembly is shown in its final form in <FIG>. When the nozzle is rotated in a clockwise direction based on the <FIG> assembly view, shown in full section, from either an ON or OFF position to the other position (OFF or ON), one side <NUM> must ride up over one radiused corner <NUM>. This "riding up" movement actually occurs at all four locations in a generally concurrent fashion. The shape of inner block <NUM> must flex or distort a little due to the slightly larger radial dimension of corner <NUM> compared to that of side <NUM>. With continued rotation the flats 34a - 34d will line up with flats 38a - 38d. The denotes the point at which the nozzle reaches the desired position relative to the trigger body, either an ON position or an OFF position. The flexed or distorted shape of inner block <NUM> will return to its normal, undistorted shape when the two sets of flats are once again aligned. At the point of reestablishing alignment of the two sets of flats, there may be either an audible "click" to the user or tactile feedback to the user or both. With this increased resistance to rotation of the nozzle relative to the trigger body, there is less likelihood of the nozzle moving either closer to or to the ON position during e-commerce transit.

Additional features are provided to ensure the sprayer <NUM> has sufficient structural strength and rigidity to withstand the forces applied during shipment, particularly without the need for a separate, hard-sided box, package, or crate. With reference to <FIG> and <FIG>, a series of reinforcing members <NUM>, <NUM>, <NUM> may be formed in, along, or proximate surfaces of the body <NUM> at a series of high stress or flexing points. Unwanted movement, cracks or other breakage, or even temporary displacement/separation of the component(s) at these points could lead to rotation of the nozzle <NUM> and/or formation of temporary gaps between the components of the sprayer <NUM> that results in leakage of fluid).

Ribs <NUM> may be formed in a regular pattern along the top facing surface of the body <NUM>, with a more densely packed web closer to where the body <NUM> forms an angle or L-shape. The individual ribs <NUM> may be of the identical or varying thickness, with transverse and lateral individual sections forming a series of right angles.

Rib or ribs <NUM> may also be provided where the body <NUM> provides structures to accommodate the actuator, such as a pump-aciton lever or trigger (not shown), which physically draws fluid from into the sprayer <NUM> and expels it as spray or mist out of the post <NUM>/nozzle <NUM> combination.

Lastly, one or more ribs or wall sections <NUM> having a vertical orientation along the body <NUM> on its distal end (i.e., back end opposite where the post/nozzle are provided). Wall <NUM> has increasing thickness and a larger radius at is lower-most end, where it establishes connection with the closure <NUM> described below.

In some embodiments, the body <NUM> may be connected to and covered by a protective and decorative shroud <NUM>, as shown in isolation in <FIG> (other drawings, including <FIG>, show some versions of the shroud as it would be attached to the body <NUM>). The shroud <NUM> is formed to have a shell-like appearance, with the top surface of the body <NUM> received along its lower opening <NUM>. The shroud allows for varying contours and/or decorative elements to be provided, without needing to substantially alter the functional components concealed underneath it.

A plurality of side snap keys <NUM> are provided along the inner surface of the shroud <NUM> where it mates with the body <NUM>, as seen in <FIG>. Additional support keys <NUM> may also be formed thereon. Keys <NUM>, <NUM> may be snap-fitting posts, tabs, or other structures that are received by or mate to corresponding portions of the body. For example, keys <NUM> may fit within gaps provided by the web of ribs <NUM>, while keys <NUM> may engage the closure <NUM> and/or the container itself (not shown). Thus, the shroud <NUM> is preferably formed from a semi-resilient material that can withstand flexing (as is expected between the flats 34a - 34d and 38a - 38d, as described above).

Claim 1:
A trigger sprayer selectively connectable to a fluid carrying container and comprising:
a body (<NUM>) including a flow passage for the fluid, the flow passage terminating at a proximal end of the body proximate to a first engagement member which is a post (<NUM>) having an outer surface with a plurality of flats (38a-d) distributed around a portion where the post (<NUM>) connects to the body (<NUM>); and
a nozzle (<NUM>) connected to the proximal end and including a second engagement member which is a sleeve (<NUM>) formed in the centre of an inner block (<NUM>) of the nozzle and having a generally cylindrical shape and an inner surface including a plurality of flats (34a-d);
wherein the first and second engagement members cooperate to allow movement of the nozzle (<NUM>) relative to the body (<NUM>) between a first position and a second position, with a region of increased resistance to movement provided by the shape of the first engagement member relative to the shape of the second engagement member.