Patent Grant
10077150
This application is a national stage filing based upon International PCT Application No. PCT/GB2014/000272, with an international filing date of Jul. 8, 2014, which claims the benefit of priority to Great Britain patent application Nos. GB1312362.5, filed Jul. 10, 2013; GB1314023.1, filed Aug. 6, 2013; GB1402413.7, filed Feb. 12, 2014; GB1406951.2, filed Apr. 17, 2014; and GB1409751.3, filed Jun. 2, 2014, all of which are fully incorporated herein by reference as though fully set forth herein.
This invention relates to dispensers having dividers or fluid reservoirs therein arranged to at least partially prevent gas or air in the dispensers from being ejected through dip tubes in the dispenser. The invention further relates to dividers for use in fluid dispensers, which dividers at least partially prevent mixing of gas/air and fluid in a dispenser, in use.
It is known to provide both pressurized fluid dispensers, and non-pressurized fluid dispensers which dispense fluid through a nozzle arrangement, and which may include a dip tube connected to the nozzle arrangement, through which fluid is dispensed.
Nozzle arrangements are commonly used to facilitate the dispensing of various fluids from containers or vessels. For instance, nozzle arrangements are commonly fitted to pressurized fluid filled vessels or containers, such as an aerosol canister, to provide a means by which fluid stored in the vessel or container can be dispensed. In addition, so called pump and trigger activated nozzle arrangements are also commonly used to enable the fluid contents of a non pressurized vessel or container to be conveniently dispensed in response to the operation of the pump or trigger by an operator. Another version that is much less commonly used uses a pump or trigger to pressurize the air and fluid inside the container and this pressure can be topped up as the fluid is used up. This effectively becomes the same as an aerosol canister in use.
A typical nozzle arrangement comprises an inlet through which fluid accesses the nozzle arrangement, an outlet through which the fluid is dispensed into the external environment, and an internal flow passageway through which fluid can flow from the inlet to the outlet. In addition, conventional nozzle arrangements comprise an actuator means, such as, for example, a manually operated pump or trigger or aerosol canister. The operation of the actuator means causes fluid to flow from the container to which the arrangement is attached into the inlet of the arrangement, where it flows along the fluid flow passageway to the outlet.
Many liquors, foams or pastes are delivered using manually operated aerosol cans, pumps or triggers and they often have a diptube reaching from the top or outlet of the container to the bottom so that the fluid is drawn from the bottom to the top and out through the outlet. Sometimes these diptubes are part of the container and can be in the centre of the container or along a wall of the container especially with plastic containers. A large number of commercial products can be dispensed this way, including, for example, tooth paste, antiperspirants, de-odorants, perfumes, air fresheners, antiseptics, paints, insecticides, polish, hair care products, pharmaceuticals, shaving gels and foams, water and lubricants.
Most fluids are simply held in the container with air taking up the remainder of the container with pumps or triggers and air or a propellant taking up the remainder of the container for aerosols or pressurized containers. This is no problem for most fluids but some need to be kept separate from the air or in the case of aerosol canisters from the pressurized propellant which may be air or butane or other alternatives like CO2. Some products like foods can go off and others like shaving gel can expand and become either unusable or unstable. This also prevents accidental loss of the air or propellant when the device is used and this can be a problem.
The problem of separating the fluid from the air or propellant has been generally approached in two different ways. In aerosol cans deformable bags are used in can or via bags attached to valves. The fluid is kept in a bag inside the canister and the bag is either sealed around part of the can itself or around the valve in the can and the propellant gas is inside the can and around the bag. When the outlet valve is opened by depressing the actuator, the gas pressure acting on the bag forces out the fluid through the valve and actuator and the bag is compressed. The bags are often made of up to 4 different layers of material so as to keep the propellant and fluid apart and they are relatively expensive and the assembly process is generally expensive and complicated. The bags often never completely empty the contents and 5-10% of the fluid tends to remain in the bag.
With pumps and triggers bags are also sometimes used and another approach has been to use a shaped plate between the fluid and air called “follower plates” as they follow the fluid as the container empties. These plates seal against the side walls of the container and are upstream of the fluid in the container usually towards the base. As the fluid is discharged, the plate moves downstream keeping the fluid chamber filled. For this to work the walls of the container have to be parallel and the vessel is usually tubular or oval in shape. The plate is usually shaped to match the shape of the downstream end or top of the container so as to be able to drive most or substantially all of the fluid out of the container. If the top of the container is shaped like a standard bottle or container with a reduced neck on the shoulder then the bottom of the chamber has to be open so the follower plate can be inserted through the bottom. Alternatively, with a closed bottom the top of the container has to be the same size and shape as the rest of the container so the follower plate can be inserted from the top.
Advantages of follower plates include that they are relatively cheaper to make and assemble than other means described hereinabove. One disadvantage is that they cannot be used with diptubes or inside aerosol cans or with bottles or containers with smaller necks and a closed base.
Bags are widely used in pump or trigger containers and they can be a separate bag that is inserted after the container is made or they can be moulded into the container. The fluid is put inside the bag and is delivered by being sucked out of the bag by the pump or trigger collapsing the bag. Air is drawn into the container through a hole or aperture in the container wall or top and then around the bag as the bag is collapsed and the air is at atmospheric pressure. Sometimes the bag is made of one plastic or rubber and other times it is made of layers of different materials depending upon the barrier properties required to protect the fluid. These systems are generally more expensive than follower plates although they may be more versatile and standard containers can be used. Bags tend to be made of layers because they are thin whereas a follower plate tends to be thicker and made of a stronger, more chemically resistant plastic creating robust barrier.
There are two general types of aerosol cans with one having a seam along the length of the can and a separate top and bottom joined to the body and the other being seamless and made from one part which is drawn into shape and a separate top joined to the body. Known follower plates would not work with seamed containers as there would be no seal because of the seam. In seamless cans with reduced neck diameters it is not possible to use a follower plate because of the reduced neck preventing insertion of the plate and another problem with aerosol cans comprising diptubes is that any diptube present would be in the way of the follower plate.
It is therefore an aim of embodiments of the invention to provide fluid dispensers which enable separation of at least some of the air/gas or propellant in a dispenser from the dispensing liquid and which prevent or reduce leakage of the air/gas or propellant into a diptube or out of the dispenser. It is also an aim of embodiments of the invention to provide divider or fluid reservoirs for us in fluid dispensers which can be used in a wide variety of dispensers and which are robust, relatively inexpensive to make an insert, and which can be inserted into a wide variety of fluid dispensers including seamed dispensers, dispensers with reduced diameter necks and aerosols or other pressurized containers.
It is also an aim of embodiments of the invention to overcome or mitigate at least one problem of the prior art described herein above.
According to a first aspect of the invention there is provided a pressurized dispenser comprising a base around which surrounds a peripheral wall having an open end sealed by a dispensing element comprising a dip-tube, a fluid reservoir in contact with the dip-tube for reducing the compressed gas lost from the pressurized dispenser, a compressed gas and a dispensing liquid, wherein a majority of said fluid reservoir being located outside of the diptube and the fluid reservoir comprises a porous material, arranged in use to hold a volume of the dispensing liquid, the porous material being configured so that in use at least a portion of any compressed gas in the reservoir can be displaced by the liquid, ejecting said portion of the compressed gas into the dispenser, and wherein the dispensing element is configured to dispense the dispensing liquid continuously for at least 0.5 seconds, upon actuation of the dispensing element.
According to a second aspect of the invention there is provided a pressurized dispenser comprising a base around which surrounds a peripheral wall having an open end sealed by a dispensing element comprising a dip-tube or an outlet, a fluid reservoir in contact with the dip-tube or outlet for reducing the compressed gas lost from the pressurized dispenser, a compressed gas and a dispensing liquid, wherein the fluid reservoir comprises a porous material, arranged in use to hold a volume of the dispensing liquid, and wherein the porous material is configured so that in use at least a portion of any compressed gas in the reservoir can be displaced by the liquid, ejecting said portion of the compressed gas into the dispenser.
According to a third aspect of the invention there is provided a method of forming a pressurized dispenser of the first or second aspects of the invention, the method comprising the steps of:
According to a fourth aspect of the invention there is a fluid dispenser comprising a base around which surrounds a peripheral wall having an open end closed by a dispensing element comprising a dip-tube, the fluid dispenser comprising a divider.
According to a fifth aspect of the invention there is provided pressurized dispenser comprising a base around which surrounds a peripheral wall having an open end sealed by a dispensing element comprising a dip-tube, a fluid reservoir in contact with the dip-tube for reducing the compressed gas lost from the pressurized dispenser, a compressed gas and a dispensing liquid, wherein the fluid reservoir comprises a porous material, arranged in use to hold a volume of the dispensing liquid, the porous material comprising a porous or cellular material having a pore or cell density of at least 10 ppi (pores/cells per inch), at least 20 ppi or at least 30 ppi, and no more than 100 ppi or no more than 80 ppi.
According to a sixth aspect of the invention there is a method of forming a dispenser of any one of the first, second, fourth or fifth aspects of the invention, the method comprising the steps of:
According to a seventh aspect of the invention there is a method of dispensing a fluid from a fluid dispenser of the sixth aspect of the invention comprising forming a dispenser, partially filling the dispenser with a dispensing liquid such that at least some of the liquid enters the porous divider material, partially filling the dispenser with a gas, or air, and actuating the dispensing element to dispense at least a portion of the dispensing liquid.
According to a eighth aspect of the invention there is a divider for at least partially separating a dispensing fluid from a propellant, gas or air in a dispenser, the divider comprising a resiliently deformable member arranged to be inserted into a dispenser through one end thereof and move from a first configuration, in which the divider can be inserted into a dispenser, and a second configuration in which the divider is able to form at least a partial barrier within the dispenser.
According to a ninth aspect of the invention there is a method of separating a fluid dispenser into two chambers, the method comprising the steps of:
According to a tenth aspect of the invention there is a fluid dispenser comprising a base around which surrounds a peripheral wall having an open end, and further comprising a divider of the eighth aspect of the invention, the divider forming two chambers within the dispenser and being movable up and down the dispenser wall to vary the size of the chambers, in use.
According to an eleventh aspect of the invention there is a method of dispensing a fluid from a fluid dispenser of the tenth aspect of the invention comprising:
Further aspects of the invention, and features of the various aspects of the invention are defined in the appended claims.
The eighth to eleventh aspects of the invention provide resiliently deformable divider or follower plate that will be deformed to enable it to fit through a reduced neck and reform to function as a standard follower. In some embodiments, the dividers may have an aperture substantially in the centre that the diptube extends through in such a way that there is at least one seal between the diptube and divider and this seal is usually an integral part of the divider. In both cases there may be a seal around the outside of the divider that seals between the divider and the dispenser, and this seal is usually an integral part of the divider. The inner and outer seal may both be air tight but loose enough to enable the divider to move up and down the can as required. The divider may be resiliently deformable only in certain parts of it or it may all be resiliently deformable. The divider may be made from a polymeric or natural or synthetic rubber and may be one component and made of one material but two or more materials or two or more parts of one or more materials may be used if certain barrier properties are required or part of the divider could be coated in some way to enhance the barrier properties. For example it may be painted, coated or even coated or plated with metal on one or more sides.
The divider may be a follower plate.
Two chambers may be created inside the dispenser with one upstream of the divider and the other downstream of it. The air or compressed gas is normally upstream of the divider and the fluid downstream of the divider. If no diptube is used then the downstream chamber may use the outlet as a wall and if a diptube is used the non-outlet end or the base may used as a wall. With no diptube the divider may moves towards the outlet end or the top of the dispenser and with a diptube the divider moves towards the closed end or the base. The divider may be shaped so that it is substantially the same shape as the end of the dispenser that it moves towards so that all or substantially all of the fluid may be emptied.
In some embodiments, suitable for fluid dispensers in the form of aerosols the divider may be positioned on the downstream or closed end of the dispenser (usually the base), the diptube extends through the central hole in the divider and the or each seal may touch the downstream end of the dispenser. The upstream end of the diptube may be shaped so there is a gap around the end of the diptube so the fluid may flow through it. There may be a top on the dispenser which, in the case of an aerosol, may be located on a valve in a valve cup, and the diptube may be connected to the valve inlet. Any air between the downstream wall and the divider may be substantially sucked out. Fluid may be pumped through the diptube via the valve which is lifted to open it, into the downstream chamber and the divider may be pushed upstream by the fluid and may continue to move until all of the required fluid had been added to the chamber. The diptube may not move and the downstream end of the diptube may then be closed by releasing the valve so the valve automatically closes.
Air in the upstream chamber may be allowed to evacuate around the valve cup which would only be fixed in place but not sealed as the downstream chamber is filled with fluid and the divider moved upstream. Once the fluid chamber is filled there may be half to two thirds of the dispenser containing air and the fluid chamber may be used for the pressurized air or propellant or gas. If the dispenser contains air, pressurized air may be added to the gas chamber by pumping pressurized air under the valve cup and once the required pressure is achieved the valve may be crimped in place sealing it. If a propellant such as butane is used instead of air, any remaining air in the upstream chamber may be removed and then replaced with the required propellant subsequently followed be sealing the valve cup by crimping as before.
As the fluid is dispensed, the divider may move downstream towards the base keeping in contact with the fluid, and the valve of gas chamber increases causing a reduction in pressure of the gas. This process may continue until substantially all of the fluid has been ejected but there may still be air or gas in the gas chamber and the pressure of it will depend on the pressure required to eject the fluid. It may normally be between 1 and 3 bars. The action would be the same with a propellant such as butane for example, while other propellants may maintain a more consistent pressure throughout the working life of the dispenser.
In alternative embodiments of fluid dispensers of the invention, which comprise aerosol canisters the fluid may be in the chamber with the outlet wall or valve (now the downstream chamber) and the air or propellant in the chamber with the base (now the upstream chamber). With a closed wall or base the divider may start at the outlet end of the dispenser and there may be no diptube. Any residual air may be sucked out of the downstream chamber and then the fluid may be added into the downstream chamber through the valve which pushes the divider upstream towards the base wall of the dispenser leaving around half to one third of the dispenser inner volume for the propellant of compressed gas or air. There may be a hole in the upstream container wall or base and a one way input valve to allow the air or propellant to be pumped into the upstream chamber. As the fluid is dispensed, the divider may move downstream and the pressure in the upstream chamber may reduce. One advantage of this embodiment is that there is no diptube.
In embodiments comprising a pump or trigger the fluid would normally be put in the upper chamber with the outlet or downstream chamber with the air in the lower chamber with the base or the upstream chamber. The divider may start at the downstream end of the dispenser and there may be no diptube. Any residual air may be sucked out of the downstream chamber and then the fluid may be added into the downstream chamber to push the divider upstream usually towards the upstream wall of the dispenser. There may be a hole in the upstream container wall to allow the air or gas to escape so the remaining air is always at atmospheric pressure. As the fluid is dispensed, the divider may move downstream and air may be drawn into the air chamber through the same hole in the chamber wall to maintain atmospheric pressure.
For embodiments comprising a pump or trigger device, the open end of the dispenser top may be closed with the pump or trigger. As the fluid is dispensed a vacuum may be created in the fluid chamber causing the divider to move downstream so the fluid chamber stays full of fluid. This creates negative pressure in the air chamber so air may enter from outside the dispenser to keep it at atmospheric pressure. This action may continue until the divider meets the upstream wall having evacuated substantially all of the fluid.
In embodiments comprising a pump or trigger, the fluid may be put in the chamber with the base or closed wall (now the downstream chamber) and the air in the chamber with the opening (now the upstream chamber). The divider may start at the downstream or base end of the container and there may be a diptube. Initially any residual air may be drawn out of the downstream chamber and then the fluid added into the downstream chamber through the diptube and which pushes the divider upstream towards the upstream wall of the container or open end. There may be a hole or aperture in the upstream dispenser wall or the top to allow the air to escape so the remaining air or gas is always at substantially atmospheric pressure. As the fluid is dispensed, the divider may follow the fluid and air is pulled into the air chamber through the same hole in the chamber wall to maintain substantially atmospheric pressure.
Suitable material for the divider may be plastics, such as polyethylene or polypropylene for example, as these are very resistant to many fluids and propellants.
One way of achieving a deformable divider is to use areas or lines of weakness such as very thin sections, such as annular “V” shaped grooves which enables relatively easy deformation. Another way would be to use a mixture of porous foaming agent such as a closed cell material in the divider in combination with a relatively rigid material like polyethylene or polypropylene so it is both resiliently deformable and chemically resistant. An alternative would be to use two materials with the first material having a weakness in the area needed to deform and either over moulding or attaching a more resiliently deformable material such as a flexible version of the first material or an elastomer, in this way the chemical barrier may be maintained whilst the mechanical properties are added with the second material.
In embodiments comprising diptubes in the dispenser may be made from a rigid plastic material, or from a hard flexible plastics material. Some dispensers may have an integral diptube in the body of the dispenser and these could be used instead of the diptube in the follower plate.
One problem with known aerosol canisters particularly with compressed air and with pumps or triggers is inability to use such aerosols through 360 degrees where rotation of the canisters may cause the upstream end of a diptube can sometimes be in contact with the air or propellant instead of the fluid. For aerosols, this can be a major problem as the gas or air can be lost very quickly resulting in fluid being left in the canister or very low pressures near the end of the can life and a consequent reduction in performance. The dividers and dispensers of the invention described above overcome or mitigate this problem. In the embodiments there may be no need to keep the fluid separate from the air or propellant but instead is to keep the upstream end of the diptube always immersed in the fluid regardless of how the dispenser is shaken, tilted or inverted. Some gas or air can be lost but should be minimized. The divider and diptube arrangement described above can be used in these applications. It is not essential that any seals are always maintained as the divider may act as barrier that prevents or reduces a rapid movement of the fluid away from the upstream end of the diptube when the dispenser is tilted or shaken and it may be configured so that one or both seals are able to leak because once the dispenser is left upright the air or propellant and fluid will tend to return to the uppermost chamber and the fluid to the lower chamber especially in dispensers where the propellant is pressurized. There may be small holes in the divider to allow the fluid to return to the downstream chamber. Any gaps in the seal or holes in the divider should be small enough to ensure that the divider is pushed towards the fluid by the gas or propellant. This means that the divider may be relatively thin like packaging used in the food industry or it could be a closed cell foamed divider or even an open cell foam divider with an impermeable layer or skin on the surface that prevents any fluid passing through the divider.
The divider may not need to move, and thus the divider may be immovable within the dispenser. It may be fixed in position, preferably near to the downstream end of the dispenser with a small chamber formed between the divider and base of the dispenser. A diptube may pass through the divider and into the chamber which would contain the fluid to be dispensed. Fluid would be able to pass through or around the divider to replace any fluid dispensed. The rate that the fluid could enter the chamber would be comparable but greater than the flow at which it is dispensed as there is always fluid available to be dispensed. If the dispenser is tilted or shaken the loss of the fluid from the chamber may be reduced and the amount of air or gas that replaces it is also reduced. Any air or gas in the small chamber lost whilst the fluid was being dispensed is substantially reduced compared to the loss with no divider. In addition, once the dispenser is left upright, any air or gas would move upwards past or through the divider and would be replaced by the fluid.
In some embodiments the divider is made of a porous material such as foam and the upstream end of the diptube is located inside the foam. The fluid can now pass around the divider but would normally pass through it as it is either drawn or pushed into and through it. There may be no need to seal the divider against the dispenser walls or even the need to create a chamber between the divider and the base of the dispenser as the porous material may hold enough of the fluid itself. In some embodiments the dispenser may have one or more shaped bases or a peak in the base, and comprise a substantially flat porous divider which contacts the or each peak such that at least one chamber is formed in each recess extending from the peak. Fluid may be drawn through the diptube from inside of the porous divider and this causes more fluid to replace it. If the dispenser is upright then more fluid from above porous divider will be absorbed into it and the chamber below the divider may be full of fluid and any air or propellant may go around or through the divider into the chamber above it. If the dispenser is inverted then fluid will still go from the divider through the diptube and outlet and the fluid inside the small chamber now above the divider may be absorbed into the foam with air or propellant replacing it by going through or around the divider. When the container is angled somewhere between the two extremes of upright and inverted, the fluid will be touching at least some of the divider and will be absorbed. This may continue until the small chamber is empty and the fluid has been extracted from the divider but the dispensers tend to be moved through many angles as they are used so the fluid can quickly replenish the small chamber. The reservoir of fluid in the chamber and divider is generally more than enough for the likely usage at any one time which means there is generally no need to lose much, if any, air or propellant. There is also no need to have a smaller chamber for many applications and the foam divider may be made large enough to hold a sufficient volume of fluid. The divider may touch the base or walls of the dispenser and may be held around the diptube or may be any shape with the diptube pushed inside it. Generally it may be positioned on or around the upstream end of the diptube and touching the downstream wall and base of the dispenser. These embodiments are generally for small dispensers used with products like perfume as the foam divider can be very small such as a plug or rod on the end of the diptube for example. For large dispensers a divider in the form of a plug or rod is also useful. In some embodiments an open cell rod such as a backer rod, used in sealing applications, may be used.
A porous plug or rod is one solution to a problem because the foam is relatively cheap; it is easily pushed through a reduced neck in a dispenser and if it is larger than the neck, it readily reforms. It can be made from many materials including plastics, synthetic or natural rubber, paper or any other materials that will form a stable porous material and the porous material can even be made inside the dispenser by spraying or mixing materials inside the dispenser. Fluid and gas or propellants are able to rapidly flow into it yet may retain most of that fluid as the dispenser is moved around or shaken. The porous material naturally absorbs liquid in preference to gas or air and may replace gases with liquid so there may be very little gas or air lost in practice. Some closed cell foams can be converted into open cell foams by making holes in the material or the outer layer and these materials may also be used.
Any suitable absorbent or porous material may be used instead of the open cell foam described above provided the absorbent material is stable in the dispenser and fluid environment and that the fluid flows readily through it. Any material that has the required properties will suffice. Various foam and absorbents may be combined together for some applications.
Some foams or absorbents are designed to only allow liquids through and to prevent gas or air and these may also be connected to the end of the diptube or around the outlet.
Further aspects and features of the invention will be understood from the following description of a number of embodiments of the invention, which are provided by way of example only, with reference to the accompanying drawings, in which:
The propellant or air would then be pumped under pressure into an upper chamber 104 formed between the neck 105 of the canister and the dividing plate 120. Once filled the valve cup 106 and canister neck 105 would be crimped together at 108 forming a permanent seal. The contents of the two chambers cannot mix because of the seals 124, 125, 122 and 121 around the dividing plate 120.
As the fluid is dispensed through an outlet 116 in the valve 115 by depressing an actuator on the valve stem 118 the dividing plate moves downstream staying substantially in contact with the fluid. This increases the size of the upstream chamber 104. Eventually the divider plate 120 contacts the base 101 and by then virtually all of the fluid in chamber 103 has been evacuated.
The propellant in chamber 104 will often be air or gas and consequently the pressure in the chamber will reduce as the fluid is dispensed. Sometimes it will be a voc like butane and will exist in liquid and gas and will maintain a similar pressure as the fluid is expelled by more liquid turning into gas.
The dividing plate 120 is normally a solid and relatively thin plate but it could be made in a wide range of materials as required and it could for example, be a closed cell foam plate which would give it the flexibility to the deformed and pushed through the reduced opening. Some products made of open cell foam have an impermeable layer or skin around the outside or are coated so nothing will pass through and these could also be used.
In
This is true for all of the embodiments of
When the dispenser of
The embodiment shown in
It is often an advantage to deliver additional air or gas to the dispensing liquids when the canister is emptying and the pressure reducing to improve the quality of the spray and ideally the lower the pressure and the more empty the canister, the greater the volume of air or gas added. One way to achieve this in conventional dispensers is to add more holes in the diptube or a hole further upstream from the end 111 of the diptube. But this normally causes other problems as when the canister isn't being used and the level of the liquor is below the hole, the gas or air gets into the diptube through the hole and displaces much of the liquor in the diptube which is driven out of the bottom of the diptube. This can represent a substantial loss of air for a compressed air canister and isn't desirable. The holes are also tiny and are easily blocked especially with the liquor flowing through them. If the holes are too far away from the end of the diptube then air or gas is lost sooner than required. The air or gas lost is proportional to the pressure in the canister yet you actually want more air or gas to be delivered through the hole as the canister empties. The air or gas can escape through the hole 406 when the canister is tilted, shaken or inverted if the liquor no longer covers the hole. These are all serious problems with compressed air aerosols in particular as it is essential to keep the canister pressure as high as possible. By adding the foam part 401 on the end of the diptube 110 as shown in the embodiment of
It has been found that an O-ring is a good shape for the band because it seals the hole more efficiently than a band and it deforms more around the hole as the canister pressures increases. It also gives a more consistent flow increase with the reducing pressure in the canister.
In
In general for aerosol canisters and especially those producing an atomised spray particularly with compressed air or gas propellants, the pressure in the canister when it is nearly empty is often very low, resulting in a poor spray. It is known that adding some of this gas or air into the fluid at this time greatly improves the spray quality. Careful positioning of the diptube in combination with the correct foam size can be used to enhance the spray quality then because the fluid from the foam will be mixed with the air or gas in the foam and delivered together. Also, shaping the end of the diptube and its diameter will also alter the amount of propellant or gas drawn into the fluid. As the fluid level in the canister reduces so it reduces in the foam and the gas or air will replace it so when the diptube is exposed to the gas or air, it has a free run from the chamber above and it will be readily drawn through the diptube along with the fluid. By varying the foam cell size and the height of the angle of the end of the diptube air or gas that is added to the fluid can be controlled, enhancing the spray quality. As already described a simple and effective improvement is to add a hole or holes in the side of the diptube away from the upstream end of the diptube but still covered by the foamed part as shown in the
The type of porous or cellular material is important both interiors of material and what the average cell size is as well as the free space available and the actual size of the part and the density. A very fine cell structure with small chambers is little use with big flows of liquor or even with viscous liquids. Equally a coarse cell structure is not practical for tiny flows such as for perfume pumps. The foam also needs to be able to retain the fluid when inverted or out of the fluid or when the container is shaken and many coarse foams don't retain much fluid in those circumstances whereas fine foam may. Some foams absorb up to 15 times their size whereas others only absorb small volumes. Since it can be used for a wide variety of fluids, delivery systems, flows and discharge volumes, many types of foam will be used from fine to coarse and with a wide range of properties and materials. Also, many shapes and sizes of the divider part itself will be used. The divider part is essentially a reservoir of the fluid so if there is a small discharge then the fluid reservoir does not need to hold much fluid whereas if there is a large discharge it does. Also, if the dispenser is used upright for most of the time then the fluid will keep flowing through the divider and consequently a smaller divider is required whereas if the divider is often out of the fluid because of the dispenser being tilted and turned upside down a greater reservoir will be needed and the foamed part will need to be larger. Open cell foamed dividers may have an impermeable surface and one or more of the sides of the foamed divider could retain this so that fluid and air or propellant could only be drawn though the other sides, or part of the surface could be opened up with fine holes. Some closed cell foams may function like open cell foams if the surface has holes.
In some embodiments the porous or cellular material comprises pores having an average pore size of at least 50 microns, at least 100 microns or at least 200 microns, and may have a pore size of no more than 1000 microns, no more than 750 microns or no more than 500 microns.
In some embodiments the fluid reservoir, such as the porous material, may comprise a material having at least 10 ppi (pores per inch), at least 20 ppi and at least 30 ppi, and may have no more than 100 ppi, 80 ppi, 70 ppi or 60 ppi.
In some embodiments the fluid reservoir may hold at least 0.5 ml of fluid, or at least 1 ml or at least 2 ml.
In some embodiments the fluid reservoir holds at least 0.5 ml of liquid and has at least 10 ppi or at least 20 ppi.
One of the problems associated with dispensers with diptubes may be retaining the divider on the diptube during transportation and assembly so the divider may need to be permanently fastened to the diptube. This can be done in a variety of ways including heat welding, ultrasonic welding, fixing with a clip or wire, or fixing part of the skin of a foam divider instead of the foam itself. For porous foamed dividers preferred method is to push a pin through the foam divider and the diptube and bending the pin so as to trap the foam onto the diptube. This is usually done near to the input of the diptube. A staple or fastener could be used instead of the pin and one or both of the legs could be shaped to leak around them and this could also be arranged for the pin. Simply shaping or roughening the surface of the legs would cause such a leak and this could be used instead of making holes in the diptube under the foam. The staple or pin could be positioned so as to allow gas or air to escape into the diptube when the dispenser has been used to a set level such as 80 or 90% to improve the spray quality by fixing it to the appropriate position on the diptube.
Some absorbents like some foams can be made inside the dispenser and the diptube pushed into it during assembly and in some cases this may be the better option.
For foam dividers the foam should generally let any air or gas trapped in it to escape quickly and should and able to tolerate a range of different chemistry.
The volume of the foam may be important as it has to hold enough dispensing liquid to enable the dispenser to keep discharging liquid when the device is tilted or inverted or shaken. If the foam is partially immersed in the liquor then it will tend to draw on that liquor and that will go to the inlet of the diptube in preference to the gas or air but as the liquor in the foam is used up so air or gas will be lost along with the new liquor entering the foam. If the foam does not touch the liquor then as the liquor in the foam is expelled so the gas or air is lost through the foam. Aerosols deliver liquor at varying rates between 0.3-4 mls per second with 1 ml per second being common. So if there is only a small volume of foam and therefore a small volume of liquid that the foam can hold then the liquid can quickly be used up and the air or gas will rapidly escape and it takes a very short amount of time before it become critical. The greater the volume of foam the better, and generally 1 ml foam would be the minimum needed but it may be between 3-20 mls. In terms of the liquid the foam can hold, this may be at least 0.5 mls and preferably 1-3 mls and even more preferably 3-20 mls.
Foam is measured in pores per inch or “ppi” and the smaller the number the coarser the foam and the higher the number the finer the foam. The more the pores per inch and the finer they are the denser the foam. With higher ppi foams such as 90 ppi and over, the pore size is very small and that makes them suitable for filters but it also reduces the volume of liquid that they can hold. Conversely, coarser foams below 20 ppi have very low density foam with large sell sizes that could potentially hold far more liquid and it flows easily through it but the foam may not be able to retain the liquid if it isn't immersed in it. A pore size that enables the foam to retain the liquid if the dispenser is inverted or shaken but that also holds as much liquor as possible should be used. This also depends on the viscosity of the liquid as higher viscosities can be retained in larger pore sizes than lower viscosities and the greater the viscosity the greater the cell size needs to be in order to allow the liquid through. The porous material preferably comprises more than 10 ppi and most preferably greater than 20 ppi but the average pore size is preferably less than 120 microns and most preferably less than 90 microns.
Foam materials have been exemplified but any absorbent, cellular or porous material that allows fluid to flow through freely could be used instead, and the pore sizes, capacities and ppi described above apply thereto.
With an upright pressurized dispenser the air or gas tends to settle on top of the liquid present and consequently when the porous material is immersed the pressure of the air or gas causes the liquid to drive any air or gas out of the material and into the dispenser replacing the gas with liquid and ensuring that the foam is always full of liquid. This is also true if the dispenser is tilted anywhere above the horizontal provided the dispenser isn't substantially empty. Since pressurized canisters are generally always left standing upright after use this means that the foam will be recharged with liquid after use, but as this is a very quick action it tends to be recharged during use as well. If the level of the liquid goes below the top of the porous material then the gas will go to the same position in the porous material as the top of the liquid, the porous material may also absorb some liquid moving the air higher. The gas won't tend to go into the diptube because it is full of liquid and the gas takes the easiest route. In addition to the force of the gas or air pushing the liquid into the foam and the gas or air out, there is also a natural tendency for a porous material to absorb the liquid again replacing at least some of the gas or air. The larger the cell size the easier it is for the liquid to replace the gas or air.
The invention described can be used to produce a spray, foam or bolus of liquid from pressurized dispenser, or pump or trigger dispensers.
Whereas the invention has been described in relation to what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not limited to the disclosed arrangements but rather is intended to cover various modifications and equivalent constructions included within the spirit and scope of the invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 1312362.5 | Jul 2013 | GB | national |
| 1314023.1 | Aug 2013 | GB | national |
| 1402413.7 | Feb 2014 | GB | national |
| 1406951.2 | Apr 2014 | GB | national |
| 1409751.3 | Jun 2014 | GB | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/GB2014/000272 | 7/8/2014 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2015/004410 | 1/15/2015 | WO | A |
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| Entry |
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| European Patent Office; International Search Report and Written Opinion issued in corresponding International Application No. PCT/GB2014/000272. dated Dec. 12, 2014. |
| Number | Date | Country | |
|---|---|---|---|
| 20160145034 A1 | May 2016 | US |
