Patent Grant
12186771
Field of the Invention: Embodiments of the invention relate to a foam pump, or pump that generates a foamed liquid output, including some embodiments utilizing a compression spring assembly.
Description of Related Art: Foam pumps, or pumps used to generate a foamed liquid product through the combination of air and a liquid product in a fluid flow path disrupted by one or more mesh features, are well known and are commonly used with hand soaps, dish soaps, disinfectants, and other cleaning products. Such foam pumps typically include a fluid piston or pump as well as an air piston or pump in which fluid and air pushed by the pumps is mixed in a single flow path and subject to one or more disruptive features, such as a mesh, before exiting an orifice in communication with the fluid and air flow paths. The resulting product produced by the foam pump is a foamed liquid.
Foam pumps may have different configurations and the specifications, or physical characteristics, of such pumps are altered to better generate a foam product based on the intended use, the fluid characteristics, and properties of the formulation being foamed. For example, different mesh sizes may be used or the ratio of air to fluid product being mixed can be altered by the configuration of the pump to create a desired foam product. In many instances, the need for different configurations and requirement to mix the fluid and air products to generate a foam results in many more components being used in the manufacture of a foam pump compared to a regular fluid pump.
While the pump characteristics may be altered to generate alternative foaming qualities and characteristics, further improvements are desired and required to produce better foam consistency and characteristics with fewer parts or parts that can be more easily assembled.
Furthermore, foam pumps are bigger than there fluid pump counterparts, and they use more plastic or material for the same quantity of output as compared to standard fluid pumps. This is in part due to the larger size needed for an air piston or pump to be included with the fluid pump. Such air piston or pump often adds a significant amount of additional material and size to the pump because the ratios of air to liquid are high. Further, the increased number of parts required to mix the air and liquid adds to the total material of the foam pump. While not limiting, the additional material is not necessarily desirable, especially if the foam pump cannot be easily recycled. Many foam pumps cannot be recycled because of the mixture of plastic grades used to form the liquid pump and air pump and the inclusion of metal springs, metal or glass balls for valves, and other materials that cannot be easily recycled in the customary recycle streams. Reducing or limiting the number of different plastic grades and types used in a foam pump—and the elimination of other materials such as glass and metal—is therefore desirable.
Some steps have been taken to reduce the number of different plastic grades and types used in liquid pump manufacturing. In addition, steps have been taken to reduce the use of metal in such pumps. For example, U.S. Pat. No. 10,473,176 discloses, in part, a compression spring assembly and methods of using the same with pumps. The use of such a compression spring assembly in place of a metal spring may be beneficial in that the plastic compression spring may be recycled with the other components of the pump in a single recycle stream. However, further improvements and the reduction of parts is desirable to reduce the variance of materials, lightweight such pumps, and improve the recyclability of foam pumps and foam pump systems.
According to certain embodiments of the invention, a foam pump utilizes a compression spring assembly in place of a metal spring to provide a foam pump that may be easily recycled.
In other embodiments of the invention, a foam pump is formed with a reduced number of parts to minimize the amount of plastic utilized to manufacture the foam pump. In addition, a compression spring assembly is included in place of a metal spring to facilitate recycling of the foam pump in current recycling streams.
According to some embodiments of the invention, a foam pump may include an accumulator defining both a liquid chamber and an air chamber of the foam pump. The accumulator may also include a first cone upon which a compression spring assembly may rest in a non-actuated state and upon which the compression spring assembly may flex during actuation of the foam pump. A piston rod including a second cone sits within an interior space of the accumulator and a liquid piston is attached to the piston rod adjacent the liquid chamber and is seated in an upper portion of the liquid chamber. A fluid flow path is formed in the piston rod and is in communication with a fluid opening that is sealed by the liquid piston when at rest and which is open to an interior of the liquid chamber during actuation of the foam pump. A restrictor is attached to the piston rod at the end opposite the liquid piston. The fluid flow path opens into an interior portion of the restrictor. In some embodiments, the interior portion of the restrictor has a reduced cross-sectional area as compared to the cross-sectional area of the fluid flow path through the liquid piston. The restrictor is also connected to an air piston. The air piston includes an air piston seal seated in the air chamber. Adjacent the connection to the restrictor, the air piston includes a stepped constriction through which liquid flows when exiting the restrictor and into which air is injected from the air chamber as the air piston is moved therein. The stepped constriction decreases in cross-sectional area along the liquid and air fluid flow path. A head connection extending away from the stepped constriction of the air piston connects to a dispenser head having a head fluid flow path therein. Fluid and air passing through the stepped constriction flows into the head fluid flow path. A mesh holder seated in the head fluid flow path further mixes the air and fluid, creating a foam, that flows through the pump head and out an exit orifice therein. The mesh holder may include one or more mesh sections. As an alternative to, or in addition to, one or more mesh sections, other disruptive features and extensions may be present in the mesh holder to create a disruptive mixing of the air and fluid passing therein.
A dispenser head may be attached to the head connection. Actuation of the dispenser head actuates the air piston which in turn actuates the fluid piston. Air flows out of the air chamber through one or more openings in the fluid actuator and into an air valve chamber in which an air valve sits. The air valve includes an inlet air valve which allows air to flow into the air chamber on a return stroke following actuation of the foam dispenser and an outlet air valve that allows air to pass from the air valve chamber into the restrictor and into the stepped constriction during an actuation stroke of the foam dispenser. A compression spring seated between the first cone and second cone is compressed during actuation and returns the pump head, air piston, and fluid piston to the rest state following actuation of the foam dispenser.
The components of embodiments of foam dispensers according to the invention may be made of plastic materials. In some embodiments, the components are all made of a singular plastic material. In other embodiments, the components are made of similar materials that may be placed in the same recycle stream.
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:
A foam dispenser 100 according to various embodiments of the invention is illustrated in
As illustrated in
The foam dispenser 100 may also include an air piston 200, a piston rod 300, a restrictor 400, a mesh holder 420, a spring 430, and a liquid piston 500. The accumulator 120 may also include a liquid feed valve 122 such as a ball valve, flap valve, spider valve, or other such valve configuration. A dip tube 124 may be connected to an end of the accumulator 120 to facilitate flow of fluid from a container 900 into a portion of the foam dispenser 100.
According to various embodiments of the invention, an accumulator 120 includes a liquid chamber 126 and an air chamber 128. An accumulator spring cone 130 is formed in a bottom portion of the air chamber 128 and is positioned between the air chamber 128 and the liquid chamber 126. An opening through the accumulator spring cone 130 extends into the liquid chamber 126. A fluid intake end 310 of the piston rod 300 is attached to the liquid piston 500 which is seated in the opening in the accumulator spring cone 130. The piston rod 300 includes a piston rod spring cone 330 opposite the fluid intake end 310, which is positioned on an interior of the air piston 200. A spring 430 sits between the accumulator spring cone 130 and the piston rod spring cone 330. According to various embodiments of the invention, the spring 430 may be a plastic spring shaped as a cylindrical tube having a longitudinal opening through the wall of the spring. The spring 430 may also be a compression spring having a cylindrical tube shape. In still other embodiments, a spring 430 may be a traditional coil spring. In the case of a compression spring or plastic spring shaped as a cylinder, compression of the piston rod spring cone 330 towards the accumulator spring cone 130 spreads or opens the spring 430, creating a rebound or expansion force that acts on the piston rod spring cone 330 when the actuation force is released, moving the piston rod spring cone 330, and those parts of the foam dispenser 100 attached thereto, away from the accumulator spring cone 130.
A piston rod spring cone 330 may be defined generally adjacent the liquid output end 320 of the piston rod 300 as illustrated in
According to various embodiments of the invention, the piston rod 300 is connected to the air piston 200 by engagement of the flange 335 with an interior wall of the air piston 200. Movement of the air piston 200 thereby moves the piston rod 300 as well.
The liquid output end 320 of the piston rod 300 includes an opening in communication with the liquid flow path 340. Liquid entering the liquid opening 312 and flowing through the liquid flow path 340 of the piston rod 300 exits the piston rod 300 adjacent the liquid output end 320. According to various embodiments of the invention, a restrictor 400 can be seated in the liquid output end 320 such that the restrictor 400 makes a fluid tight seal with the liquid flow path 340 through the piston rod 300 such that liquid flowing through the piston rod 300 flows into openings in the restrictor 400. A restrictor 400 may be seated in the air piston 200 and one or more restrictor ribs 411 may assist in maintaining the positioning of the restrictor 400.
A piston rod 300 may also include one or more air outlets 328. As illustrated in
A restrictor 400 according to various embodiments of the invention is illustrated in
An alternate view of the assembly illustrated in
As the liquid and air mixture is formed in the air piston constriction area 280, the air and liquid are further mixed and forced through one or more openings in the air piston 200 adjacent the air piston constriction area 280 and into an interior space defined by the head connection 245 of the air piston 200.
A mesh holder 420 holding or defining one or more mesh pieces or other foam generating features capable of mixing and causing turbulence in the air/liquid mixture can be positioned in the dispenser head 110. Flow of the air/liquid mixture through the mesh holder 420 and exposure to the mesh or other features held therein helps to further mix the air/liquid stream and generate a foam that is pushed through the dispenser head 110 and out the dispenser opening 112 as a foam product.
A cross-sectional view of an air piston 200 according to various embodiments of the invention is illustrated in
An air piston 200 according to some embodiments of the invention also includes an air piston wall 205 having one or more air inlets 220 formed through the air piston wall 205 such that air may flow from an exterior side of the air piston wall 205 through the one or more air inlets 220 and into an interior side of the air piston wall 205. The one or more air inlets 205 allow air to flow back into the air chamber 128 following the actuation of the dispenser head 110. Upon release of a force on the dispenser head 110, the spring 430 acts on the piston rod 300, returning the piston rod 300 to a rest state. As the piston rod 300 moves back to the rest state, the piston rod 300 engages the air piston 200, moving the air piston 200 relative to the accumulator 120. The movement of the air piston 200 creates a vacuum, sucking air from atmosphere through gaps or space between the dispenser head 110 and the closure 160, past the air valve 600, through the one or more air inlets 220 and into the air chamber 128.
An air piston 200 according to embodiments of the invention may also include an air flow chamber space 228 which helps define the air flow chamber 628 of the assembled foam dispenser 100. An air piston 200 also includes a restrictor seat 240 into which a restrictor 400 may be assembled or seated in the final foam dispenser 100 assembly. The restrictor seat 240 may be adjacent to an air piston constriction 280. A head connection 245 may also be used to attach the air piston 200 to the dispenser head 110. The head connection 245 may include one or more connection features such as flanges, beads, snap connections, or other configurations used to friction fit or otherwise connect the air piston 200 to the dispenser head 110 such that movement of the dispenser head 110 translates to movement of the air piston 200. An air valve seat 260 may also be provided to hold an air valve 600 in an assembled configuration.
According to certain embodiments of the invention, an air flow chamber 628 may be defined by one or more surfaces of the piston rod 300, the restrictor 400 and the air piston 200. The air valve 600 may also assist or contribute to the definition of the space forming an air flow chamber 628. For example, as illustrated in
An air valve 600 according to various embodiments of the invention is illustrated in
The cross-sectional view of the air valve 600 illustrated in
A liquid piston 500 according to various embodiments of the invention is illustrated in
A liquid piston 500 according to some embodiments of the invention includes three different chevrons. An exterior chevron 510 forms the outer surface or wall of the liquid piston 500 as illustrated. A flange extending inward from an interior surface of the exterior chevron 510 forms a central seal 560 that may engage with a portion of the liquid intake 210 end of a piston rod 300. In a rest state—or non-actuated state—the central seal 560 prevents liquid from flowing into the liquid opening 312 in a piston rod 300. An upper chevron 530 extends upwardly and away from the central seal 560. A lower chevron 550 extends downwardly from the central seal 560 in a direction opposite that of the upper chevron 530 as illustrated in
When assembled to a piston rod 300 and the other components of a foam dispenser 100, an exterior surface of the exterior chevron 510 seals against the interior walls of the liquid chamber 126 of the foam dispenser 100. Actuation of the dispenser head 110 move the liquid piston within the liquid chamber 126 and portions of the exterior surface of the exterior chevron 510 maintain contact with the walls of the liquid chamber 126, preventing liquid from passing between the walls of the liquid chamber 126 and the exterior chevron 510.
The upper chevron 530 and lower chevron 550 engage surfaces of the piston rod 300 when assembled and during operation of the foam dispenser 100. In a rest state, the lower chevron 550 engages the walls of the liquid intake end 310 of the piston rod 300. The upper chevron 530 engages the piston rod 300. Upon actuation of the dispenser head 110, the lower chevron 550 moves and is unseated from the liquid intake end 310 of the piston rod 300. Such movement also unseats the central seal 560 from the liquid intake end 310, forming a liquid flow path from the liquid chamber 126, past the lower chevron 550, and into the liquid opening 312 of the piston rod 300. During movement of the liquid piston 500, the upper chevron 530 continues to engage the walls of the piston rod 300 such that fluid flowing from the liquid chamber 126 into the liquid opening 312 cannot also flow past the upper chevron 530 into the air chamber 128. In this manner, the liquid piston 500 allows liquid to flow from the liquid chamber 126 and into the liquid flow path 340 of the piston rod 300 during operation.
During the return stroke of the foam dispenser 100, or when the force on the dispenser head 110 is released and the sprint 430 acts to return the foam dispenser 100 to a rest state, the liquid piston 500 reseats itself, preventing liquid flow from the liquid chamber 126 into the liquid flow path 340 of the piston rod 300.
According to certain embodiments of the invention, a liquid piston 500 may also include one or more puller beads formed on portions of the liquid piston 500. For example, as illustrated in
According to certain embodiments of the invention, a foam dispenser 100 utilizing a plastic or resin c-spring style spring 430 includes an accumulator spring cone 130 and a piston rod spring cone 330 having the same slope angle. For example, according to some preferred embodiments of the invention, the angle of slope of the accumulator spring cone 130 and the piston rod spring cone 330 is between 10 degrees and 12 degrees. More preferably, both spring cones include a slope of 11 degrees. In other embodiments, the slope of the accumulator spring cone 130 and piston rod spring cone 330 may be different or may vary by one or two degrees. In still other embodiments, a spring cone may include a changing slope such that the slope engaged with the spring changes over the stroke of the foam dispenser 100 or over the actuation of the spring 430.
According to various embodiments of the invention, components of the foam dispenser 100 may be made of a single plastic material. In other embodiments, multiple plastic grades or materials may be used but those used are capable of being recycled in the same recycling stream or processes such that the entire foam dispenser 100 may be recycled in common recycling processes. In some embodiments, the container 900 used with the foam dispenser 100 may also be recycled in the same recycling stream or using the same recycling process as the other components of the foam dispenser 100 such that a user need not separate the container 900 from the foam dispenser 100 to facilitate recycling.
According to various embodiments of the invention, a foam dispenser 100 according to embodiments of the invention may be connected to a container 900 containing a liquid product to be foamed. For example, the liquid product may include a soap, a disinfectant, a cleaning solution, a disinfecting solution, a fragrance solution, or any other liquid which is desired to be foamed for use.
Having thus described certain 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.
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