Self-contained viscous liquid dispenser

Information

  • Patent Grant
  • 6729502
  • Patent Number
    6,729,502
  • Date Filed
    Wednesday, November 28, 2001
    22 years ago
  • Date Issued
    Tuesday, May 4, 2004
    20 years ago
Abstract
A self-contained viscous liquid dispenser includes a housing defining an internal liquid reservoir, and an opening defined through a front surface of the housing. An insert member is fitted through the opening, extends into the reservoir, and defines an internal pump chamber having a back end open to the reservoir and a front end open to the outside of the housing. A pump cylinder is slidably disposed and retained in the chamber. The pump cylinder is movable within the pump chamber from a rest position to a pressurizing position to pressurize and dispense liquid within the pump chamber through a delivery channel and out a dispensing orifice in the pump cylinder. The pump cylinder may be a multiple component device.
Description




FIELD OF THE INVENTION




The present invention relates to the field of viscous liquid dispensers, for example soap dispensers.




BACKGROUND OF THE INVENTION




Various configurations and models of liquid dispensers, particularly liquid soap dispensers, are well known in the art. Conventional dispensers typically employed in public restrooms and the like are wall mounted units that typically include a house or structure that is permanently affixed to a wall. These dispensers typically include an access door or member so that the dispenser can be opened by a maintenance person for refilling or servicing. With certain types of dispensers, separate refill cartridges are inserted into the housing structure. With other types of dispensers, the maintenance technician must directly refill a reservoir provided in the housing structure. The dispensers typically include a delivery device, such as a dosing pump, and a device such as a lever or button for actuating the dosing pump. The dispensers may be vented or unvented.




The conventional dispensers depend on the continued maintenance and operability of the housing structure that is permanently affixed to the wall. In other words, if the housing structure, and particularly the dosing pump, is damaged or vandalized, the dispenser becomes inoperable and must be replaced. The conventional dispensers also depend on a supply system wherein additional liquid soap must be separately stored, transported, and loaded into the dispensers. This process entails unnecessary logistic and man power resources.




The present invention is an improvement over existing systems in that it provides a disposable self-contained dispenser with a significantly increased capacity as compared to standard dispensers, is relatively inexpensive, and does not depend on the separate storage and delivery of refill cartridges or bulk volumes of liquid soap.




OBJECTS AND SUMMARY OF THE INVENTION




Objects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.




The present invention provides a self-contained viscous liquid dispenser. Although having particular usefulness as a liquid soap dispenser, the dispenser according to the invention is not limited to a liquid soap dispenser and may be utilized in any application wherein it is desired to dispense metered doses of a viscous liquid. The liquid dispenser will be described herein with reference to a soap dispenser for ease of explanation.




The viscous liquid dispenser includes a housing that may be formed of any suitable material. For example, the housing may be molded from relatively inexpensive plastic materials and may have any desired aesthetic shape. The housing also defines an integral sealed internal liquid reservoir. In other words, the liquid reservoir is not a separate component from the housing, such as a cartridge or the like. The housing may be comprised of wall members that give the dispenser its outward appearance and also define the internal liquid reservoir.




A dispensing pump mechanism is disposed at least partially within the reservoir. The pump mechanism has a delivery end that extends out of the reservoir which is actuated by a user to dispense the viscous liquid.




The dispenser also includes a mounting mechanism that is configured as an integral component of the housing. The mounting mechanism allows the dispenser to be detachably connected to complimentary mounting structure on a wall surface. In this way, the dispenser may be easily removed from the wall surface for disposal or recycling once the liquid has been depleted. A new liquid dispenser according to the invention is then attached to the wall surface.




In one embodiment of the invention, the housing comprises a substantially vertical back side that is configured to be placed adjacent to the wall surface. The mounting mechanism is configured in the back side. For example, if the housing is a molded component, the mounting mechanism is molded integral with the back side. The mounting mechanism may comprise a recess that is defined in the back side. The recess may be defined by side walls that have engaging structures defined thereon. These engaging structures interlockingly engage with complimentary structure provided on the wall mounting structure. The wall mounting structure may be, for example, a plate member or similar device that is relatively permanently affixed to the wall. In one embodiment of the engaging structure, the vertical side walls of the recess include at least one angled surface on each vertical side wall. These angled surfaces engage against complimentary angled surfaces on the mounting wall structure similar to a conventional dove-tail configuration. The housing is slidable in a generally vertical direction onto the wall mounting structure so that the angled surfaces of the mounting mechanism slide into engagement against the angled surfaces of the wall mounting structure. Once engaged, the angled surfaces prevent the dispenser from being pulled away from the wall mounting structure. A securing device may be provided on the back side of the housing to prevent relative sliding movement between the housing and the wall mounting structure upon engagement of the angled surfaces. This securing device may be, for example, a simple protrusion disposed on the back side of the housing that engages in a complimentary recess or divot defined in the wall mounting structure.




In one particularly useful embodiment, at least two spaced apart angled surfaces are provided on each vertical wall of the recess that engage against complimentary spaced apart angled surfaces on the wall structure. The spaced apart configuration of the angled surfaces maximizes the surface contact area between the housing and the wall mounting structure without significantly increasing the relative sliding distance between the members.




As mentioned, the housing structure is preferably formed from a relatively inexpensive molded plastic and may comprise separately molded components that are permanently affixed or adhered to each other. For example, the housing may include a front component that is formed separately from and adhered to a back component. It may be desired that the front and back components have different characteristics. For example, it may be desired that the back component is more rigid than the front component to provide enhanced structural support and rigidity to the dispenser mounted on the wall structure. This may be accomplished by simply making the back component thicker than the front component.




It may also be desired to make at least a portion of the housing translucent or clear so that a maintenance technician can easily determine the remaining level of liquid within the reservoir. For example, a window may be provided in the housing. In one particularly useful embodiment, the housing includes a back component that is formed from a translucent material so that the entire volume of the reservoir is visible from the outside.




Any manner of actuator may be provided with the dispenser to allow the user to operate the pump mechanism. For example, in one embodiment, the actuator may comprise a panel member that contributes to the aesthetic appearance of the housing. The panel member may be hinged or otherwise movably connected to the housing member and lie in contact against a delivery end of the pumping mechanism. Upon the user depressing or moving the panel, the pumping mechanism is actuated so that a metered dose of the liquid is dispensed. In an alternate embodiment, the actuator may comprise a member, such as a decorative cap or the like, directly attached to the delivery end of the pump mechanism. In other words, the actuator need not be connected directly to the housing. Various embodiments of aesthetically pleasing actuators may be used in this regard.




The pump mechanism may include a pump chamber that is formed integral with the housing within the reservoir. For example, the housing may comprise a molded plastic component wherein a pump chamber is integrally molded on the interior of the housing. The pump chamber has a back end that is open to the reservoir section of the housing and a front end that is open to the outside of the housing. A pump cylinder is slidably disposed and retained in the chamber. The pump cylinder has a channel defined therethrough and a delivery end extending out of the front end of the chamber. The pump cylinder is retained within the chamber so that it cannot be pulled therefrom. An actuator is configured with the delivery end of the pump cylinder so that the device may be actuated by a user from outside of the housing. A valve mechanism is disposed in the delivery end of the pump cylinder and is configured to close upon the user releasing the actuator to prevent leakage or dripping of liquid from the pump cylinder.




In one embodiment, the pump cylinder is insertable into the pump chamber from its back end. The chamber includes retaining structure, such as a flange member or the like, at its front end to prevent withdrawal of the pump cylinder from the pump chamber through the front end. A cap member or like device is attached to the back end of the pump chamber once the cylinder has been inserted into the chamber. The cap member has an orifice defined therethrough for drawing liquid into the pump chamber. A check valve device, such as a shuttle valve, is disposed in the orifice to close the orifice upon actuation of the pump cylinder.




The valve mechanism disposed in the delivery end of the pump cylinder may comprise a flexible flap member that is movable to an open position by the pressure of the liquid being dispensed. Upon release of the actuator, the flap member automatically returns to a closed position and thus prevents undesired leakage or drippage of the liquid out of the delivery end of the pump cylinder. In one particularly useful embodiment, the valve mechanism comprises a plurality of flap members that define an opening therethrough in their open position, and seal against each other in their closed position.




A vent path is defined into the reservoir to prevent drawing a vacuum therein. In a particularly desired embodiment, the vent is provided in a top surface of the housing structure. Since the housing structure is mounted in use upon a wall surface, there is little concern of the liquid leaking from the vent in the top surface. In other embodiments, the reservoir may be vented through the pump mechanism. However, venting through the pump mechanism may result in undesired leakage through the mechanism, particularly if the pump mechanism is disposed in the lower portion of the housing. Venting may also be accomplished through the valve mechanism in the delivery end of the pump cylinder.




It should be appreciated that the configuration and appearance of the housing is not a limiting feature of the invention. Also, the invention is not limited to the use of any particular type of materials or manufacturing process. Various embodiments of interlocking engagement structure between the back side of the housing and the wall mounting member are also within the scope and spirit of the invention. For example, the engaging structure may include bayonet type fasteners, or the like.




In an alternate embodiment of a pump mechanism that may be used in a dispenser according to the invention, an insert member is inserted through an opening defined in a front surface of the housing. The insert member extends into the reservoir and defines an internal pump chamber having a back end open to the reservoir and a front end open to the outside of the housing. The insert member is attached to the housing at the opening by any suitable mechanism. In one particular embodiment, the housing comprises a plurality of protrusions extending from the front surface and disposed around the opening. The insert member comprises a front flange having a plurality of counter-bored holes defined therethrough into which the protrusions extend upon mounting the insert member into the housing. The protrusions are then heated to a molten state wherein the protrusion material flows into the counter-bored holes and permanently affixes the insert member to the housing upon re-solidifying. If it is desired to recycle or reuse the pump mechanism, a less permanent or temporary type of attachment mechanism may be used to affix the insert member to the housing, such as a releasable adhesive, mechanical connection (i.e., threaded engagement), etc.




At least one seal is disposed between an outer surface of the insert member and the housing to ensure that liquid within the reservoir does not leak out from around the insert member. In one particular embodiment, this seal is a radially inward extending seal disposed around the opening in the housing that engages and seals against an outer surface of the insert member. This seal may be provided on a cylindrical extension of the housing that extends from the front surface into the reservoir. In an alternate embodiment, the seal may be a radially outward extending seal disposed at a forward end of the insert member that engages and seals against a portion of the housing defining the opening. It may be desired to use both types of seals in the same embodiment.




An alternative embodiment of a pump cylinder that may be used with an integrally formed pump chamber or pump chamber insert is also provided. This pump cylinder may include multiple components. For example, in one embodiment, the pump cylinder includes a first component and a second component inserted into a chamber defined in the first component. Longitudinally extending channels in the components align to define a delivery channel through the pump cylinder. This channel terminates at a delivery orifice defined in a delivery end of the pump cylinder. Once combined, the components define a complete pump cylinder that is slidable within the pump chamber from a rest position to a pressurizing position wherein liquid drawn into the pump chamber is pressurized and dispensed through the delivery channel and out the dispensing orifice.




In order to seal the pump cylinder relative to the pump chamber, a first radially extending seal, such as a flange seal, may be provided on the first component of the pump cylinder that slidably engages along a wall defining the pump chamber. A second similar seal may be provided on the second component that also slidably engages along the pump chamber wall.











The invention will be described in greater detail below with reference to particular embodiments illustrated in the figures.




BRIEF DESCRIPTION OF THE DRAWINGS





FIG. 1

is a perspective view of a dispenser according to the present invention;





FIG. 2

is a perspective view of the back side of the dispenser illustrated in

FIG. 1

;





FIG. 3

is an alternative perspective view of the dispenser according to FIG.


1


and complimentary wall mounting structure;





FIG. 4

is a cross-sectional view of the dispenser taken along the lines indicated in

FIG. 3

;





FIG. 5

is a cross-sectional view of the pump mechanism of the dispenser taken along the lines indicated in

FIG. 3

;





FIG. 6

is a cross-sectional operational view of the pump mechanism;





FIG. 7

is a cross-sectional operational view of the pump mechanism;





FIG. 8



a


is partial perspective and cut-away view of the pump mechanism particularly illustrating the check valve device;





FIG. 8



b


is a partial perspective and cut-away view of the pump mechanism particularly illustrating the locking feature thereof;





FIG. 9



a


is a perspective view of a valve mechanism incorporated in the pump cylinder.

FIG. 9



b


is an operational perspective view of the valve mechanism of

FIG. 9



a;







FIG. 10

is a perspective view of a back component of the dispenser housing;





FIG. 11

is a perspective partial operational view of a wall mounting bracket for mounting the dispenser;





FIG. 12

is a cross-sectional view of the wall mounting bracket taken along the lines indicated in

FIG. 11

;





FIG. 13

is a cross-sectional view of the vent valve taken along the lines indicated in

FIG. 2

;





FIG. 14

is a an enlarged perspective view of the panel member actuator attached to the pump housing;





FIG. 15

is a perspective view of an alternative embodiment of the dispenser;





FIG. 16

is an enlarged component view of the actuator used with the dispenser illustrated in

FIG. 15

;





FIG. 17

is a perspective view of an alternative embodiment of the dispenser particularly illustrating a window feature for determining the level of liquid within the dispenser;





FIG. 18

is a cross-sectional view of an alternate embodiment of a pump mechanism according to the invention;





FIG. 19

is a perspective partial component view of the pump mechanism embodiment of

FIG. 18

;





FIG. 20

is perspective partial assembled view of the components shown in

FIG. 19

;





FIG. 21

is a perspective view of the pump chamber insert of the embodiment of

FIG. 18

; and





FIG. 22

is a perspective view of a component of the pump cylinder of the embodiment of FIG.


18


.











DETAILED DESCRIPTION




Reference will now be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment, may be used with another embodiment, to yield still a further embodiment. It is intended that the present invention include modifications and variations to the embodiments described herein.




A viscous liquid dispenser


10


according to the invention is illustrated generally in the figures. The dispenser


10


is illustrated and described herein as a liquid soap dispenser, which is a particularly useful embodiment of the present invention. However, it should be appreciated that the present invention is not limited to a dispenser for liquid soap, but has application in any environment wherein it is desired to dispense a metered amount of a viscous liquid from a dispensing unit.




The dispenser


10


includes a housing, generally


14


. The housing


14


may contain side walls or members


16


, a back side


18


, and a front side


20


. The housing


14


can take on any desired configuration and be formed from any number of components. In the illustrated embodiment, the housing


14


includes a front component


24


and a back component


22


. The front and back components are separately manufactured and are permanently joined. It should be appreciated that the components may be manufactured from any desired material. In a preferred embodiment, the dispenser


10


is a disposable item and the housing


14


is molded from a relatively inexpensive plastic material. Referring particularly to

FIG. 10

, the back component


22


may be molded from a clear or translucent plastic and includes side edges


26


and alignment tabs


48


. The tabs


48


align the back component


22


relative to the front component


24


and the side edges


26


fit into correspondingly sized recesses


28


(

FIG. 4

) defined in the side walls


16


of the front component


24


. The back component


22


is permanently joined to the front component


24


by adhesives, welding, or any other relatively permanent attaching means.




The housing


14


defines an internal liquid reservoir


68


within the internal volume thereof. In the illustrated embodiment, the liquid reservoir


68


includes essentially the entire volume defined by the front component


24


and back component


22


. Although not illustrated, it should be understood that any number of internal structural members, such as baffles or the like, may be included within the reservoir


68


. It should be understood that the housing


14


thus also serves as a closed or sealed reservoir and the dispenser


10


cannot be opened by the maintenance technician. A desired amount of viscous liquid, for example soap, is preloaded into the dispenser


10


prior to the dispenser being delivered to its point of use.




Applicants have found that it may be desired for the back component


22


of the housing


24


to be more rigid than the front component


24


. One way of achieving this feature is to simply mold the back component


22


with a thickness greater than that of the front component


24


. As will be explained in greater detail below, the dispenser


10


is mounted onto a supporting wall surface by means of an internal mounting mechanism configured on the back side


18


of the housing


14


. A more rigid back component


22


aids in mounting the dispenser


10


. It has also been found that, if the front and back components are molded from a resilient plastic material, once the dispenser is empty, the back component


22


has enough “give” to enable the dispenser


10


to be easily removed from the supporting wall structure.




A dispensing pump mechanism, generally


88


, is disposed at least partially within the reservoir


68


. The pump mechanism


88


has a delivery end


90


that extends out of the housing or reservoir


68


. The pump mechanism


88


is configured to dispense a metered amount of the viscous fluid upon a user actuating the pump mechanism. It should be appreciated that any number of conventional and well known pump devices may be utilized in the dispenser


10


. The pump mechanism


88


illustrated in the drawings is one embodiment of a particularly well suited mechanism.




Referring to

FIGS. 5 through 7

, the pump mechanism


88


includes a cylinder


92


that is slidable within a chamber


70


. The volume of chamber


70


determines the metered dose of liquid dispensed upon each actuation of the pump. The chamber


70


may be formed by any internal structure of the housing


14


. It may be preferred that the chamber is defined by structure integrally molded with the front component


24


of the housing


14


. In the illustrated embodiment, the chamber


70


is defined by chamber walls


72


as a generally cylindrical chamber. The cylinder


92


includes a channel


94


defined longitudinally therethrough. The channel


94


is in communication with the interior of the pump chamber


70


through an end wall of the cylinder. The delivery channel


94


terminates at a dispensing orifice


96


defined in the front end of the cylinder


92


.




The cylinder


92


sealingly engages against the chamber walls


72


by any conventional means. For example, a flange or piston


101


may be disposed at the rear end of the cylinder


92


for sealing engagement against chamber wall


72


. In an alternative embodiment, O-rings


116


(

FIG. 8



a


) may be provided around the piston


101


. The piston


101


pressurizes the chamber


70


and ensures that the viscous liquid contained within the chamber is dispensed through the delivery channel


94


upon actuation of the cylinder


92


and does not simply move from one end of the pump chamber


70


to the other upon movement of the cylinder.




The pump cylinder


92


is biased within the chamber


70


by way of, for example, a spring


98


. Other resilient devices, including a leaf spring, spring washer, and the like, may be utilized for this purpose. In the illustrated embodiment, the spring


92


is seated within a recess


102


defined by a flared flange


100


, as particularly illustrated in

FIGS. 5

through


7


. The opposite end of the spring


98


is fitted around a cylindrical extension


76


of an end cap


74


. The end cap


74


is permanently fixed to the structure defining the pump chamber


70


after the cylinder


92


has been inserted into the pump chamber.




Structure is also provided to ensure that the cylinder


92


cannot be pulled from the front end of the chamber


70


. In the illustrated embodiment, this structure corresponds to a flange portion of the front wall


86


of the chamber


70


. As illustrated in

FIG. 5

, the flange portion


86


of the wall engages against the piston


101


of the pump cylinder


92


.




A check valve device


104


is configured with the pump mechanism


88


to ensure that the viscous liquid within the pump chamber


70


is not pushed out of the chamber


70


upon movement of the cylinder


92


within the chamber


70


. In the illustrated embodiment, the check valve device


104


is a shuttle type check valve having radially extending arms


106


. The shuttle valve is slidably disposed within an opening defined through the end cap


74


. The space between the radial arms


106


is open to the reservoir


68


so that the liquid can flow from the reservoir


68


into the pump chamber


70


upon movement of the cylinder to the forward end of the pump chamber


70


, as illustrated in

FIG. 7. A

cap


108


is provided on the forward end of the shuttle valve


104


disposed within the pump chamber


70


to ensure that the opening in the end cap


74


is sealed upon actuation of the pump. The cap


108


seals against the end face of the end cap


74


.




Operation of the pump mechanism


88


is particularly illustrated in

FIGS. 6 and 7

. To dispense a metered amount of the viscous liquid contained within the reservoir


68


, a user actuates the pump mechanism


88


by way of an actuator


30


. The actuator


30


will be described in greater detail below. Upon depressing the actuator


30


, the pump cylinder


92


is moved rearward within the pump chamber


70


. Pressure of the viscous liquid within the chamber


70


forces the shuttle valve


104


to close and the viscous liquid contained within the chamber


70


is directed into the delivery channel


94


defined longitudinally within the pump cylinder


92


. The viscous liquid is expelled through the dispensing orifice


96


, as particularly illustrated in FIG.


6


. Upon release of the actuator


30


, the spring


98


forces the pump cylinder to return to the position illustrated in FIG.


7


. This action unseats the shuttle valve


104


and draws viscous liquid back into the pump chamber


70


, as particularly illustrated in FIG.


7


.




So as not to draw a vacuum within the reservoir


68


, the reservoir is vented. This venting may be accomplished by various means. For example, the reservoir


68


could be vented directly through or around the cylinder


92


. However, this may not be a desired embodiment since fluid would tend to leak out from around the cylinder. One preferred venting method as illustrated in the figures is to vent the top of the housing


14


, for example by way of a conventional vent valve


130


disposed through the top surface of the housing


14


. The vent valve


130


is particularly illustrated in FIG.


13


and utilizes a ball


132


seated within a ball cage


134


. The ball


132


seats against and seals an opening provided in a top member


133


upon an overfill condition of the viscous liquid, as illustrated in

FIG. 13

, or upon the housing


14


being overturned during shipment or the like. Once the dispenser is hung on a wall surface for subsequent use, the ball


132


falls within the ball cage


134


to open the vent valve


130


. Sealing of the ball


132


may further be assisted by a spring.




As mentioned, the pump mechanism


88


is operated by a user depressing an actuator


30


. The actuator


30


may be any member configured to move the pump cylinder


92


. In one embodiment illustrated in the figures, the actuator


30


is defined by a panel member


32


that adds a distinctive aesthetically pleasing look to the housing


14


. The panel member


32


includes side walls


34


having inwardly disposed protrusions


36


(

FIG. 14

) that engage within correspondingly sized divots or recesses


38


provided in the sides


16


of the housing


14


. A channel member


40


(

FIG. 3

) may be provided on the inner face of panel member


32


to positively engage against the front end of the pump cylinder


92


. A depression


33


may be defined in the front face of panel member


32


to indicate to a user the proper location for depressing the actuator.




It should be appreciated that the actuator may take on any configuration or aesthetically pleasing shape. In an alternate embodiment illustrated particularly in

FIGS. 15 and 16

, the actuator


30


is defined by a cap


42


that is attached directly to the front face


93


of the pump cylinder


92


. This attachment may be provided by adhesives, mechanical interlocking devices, or the like. Arms


44


may slidably engage within recesses


46


defined in the pump housing


14


to ensure proper alignment and to provide rigidity to the structure.





FIGS. 8



a


and


8




b


illustrate a locking characteristic of the pump cylinder


92


that is particularly useful during shipment of the dispensers


10


. The pump cylinder


92


may include a longitudinal channel


118


defined in the top thereof.




A tab portion


87


of the pump chamber front wall member


86


is disposed within the longitudinal channel


118


. In this way, the pump cylinder


92


is prevented from rotating upon actuation and release thereof. A partial circumferential channel


120


is defined in the pump cylinder


92


, as particularly illustrated in

FIG. 8



a


. The circumferential channel


120


is defined along the pump cylinder


92


at a location corresponding to the completely depressed or actuated position of the cylinder


92


within the chamber


70


, as illustrated in FIG.


6


. For shipment of the dispensers


10


, the pump cylinder


92


may be depressed and then rotated so that the tab


87


is engaged within the circumferential channel


120


, as particularly illustrated in

FIG. 8



b


. In this configuration, the pump cylinder


92


is locked in position and cannot move within the chamber


70


until the pump cylinder is rotated back into the position illustrated in

FIG. 8



a


. This procedure would be accomplished by the maintenance technician prior to attaching the actuator


30


and mounting the dispenser


10


onto a supporting wall surface.




It may be desired to include a valve mechanism within the dispensing orifice


96


of the pump cylinder


92


to prevent leakage of viscous liquid or soap from the dispenser. Any manner of sealing valve may be utilized in this regard. Applicants have found that a particularly useful valve mechanism


110


is the type of valve illustrated in

FIGS. 9



a


and


9




b


. This valve


110


includes a flange member


113


used to seat the valve


110


within the delivery and of the pump cylinder


92


, as particularly illustrated in

FIGS. 5 through 7

. The valve includes at least one, and preferably a plurality, of resilient flaps


112


defining an opening


114


therethrough. The flaps


112


seal against themselves when the valve


110


is positioned within the pump cylinder


92


in the orientation illustrated in

FIGS. 5 through 7

. Upon actuation of the pump cylinder


92


, liquid pressure forces the resilient flaps


112


to open to dispense the liquid from the pump cylinder


92


, as particularly illustrated in

FIG. 6. A

separate cap member


122


may be used to secure the valve


110


in position with respect to the dispensing orifice


96


, the cap member


122


includes its own opening aligned with the dispensing orifice. The cap member


122


may comprise a press fit element or may be permanently adhered, welded, etc., to the pump cylinder


92


.




The valve


110


also tends to vent the pump chamber


70


as the cylinder


92


moves back to its rest position after being actuated. As a vacuum is drawn in the chamber


70


, the resilient flaps separate slightly and are drawn towards the chamber


70


thus defining a vent path. Once the chamber is vented, the flaps close and seal against each other.




The valve


110


illustrated in

FIGS. 9



a


and


9




b


is conventionally known in the art as a bifurcating valve and may be obtained from LMS Corporation of Michigan.




The dispenser


10


according to the invention also includes an integrally formed mounting mechanism configured as an integral component of the housing


14


. This mounting mechanism allows the dispenser


10


to be detachably connected with complimentary mounting structure, generally


58


, provided on a wall surface


12


(FIG.


3


). In one embodiment according to the invention, the mounting mechanism is defined as an integrally molded feature of the back side


18


of the dispenser


10


. In the illustrated embodiment, a recess


50


is molded into the back side


18


. The recess


50


is defined by generally vertical side walls


52


. Engaging structure is provided along the side walls


52


for engaging against or with complimentary structure provided on the wall mounting structure


58


, as discussed in greater detail below. In the illustrated embodiment, the engaging structure is defined by angled surfaces


56


defined along the vertical walls


52


. The angled surfaces


56


engage against complimentary angled surfaces


62


defined on the wall mounting structure


58


, as can be particularly seen in

FIGS. 3 and 12

. In the illustrated embodiment, at least two angled surfaces


56


are provided and are separated by a section of vertical wall


52


. The two angled surfaces


56


engage against angled surfaces


62


of the wall mounting structure


58


. In order to attach the dispenser


10


to the wall mounting structure


58


, the maintenance technician simply positions the dispenser


10


against the wall mounting structure


58


such that the angled surfaces


56


are vertically disposed between the corresponding angled surfaces


62


of the wall mounting structure. Then, the maintenance technician simply slides the dispenser


10


in a vertical direction so that the angled surfaces


56


,


62


engage, as particularly illustrated in FIG.


12


. In this interlocking configuration, the dispenser cannot be pulled away from the wall mounting structure


58


. The double angled surface


56


configuration provided on each vertical wall


52


is particularly useful in that it provides an increased interlocking surface area of angled surfaces with relatively little vertical movement required between the dispenser


10


and the wall mounting structure


58


as compared to a single angled surface


56


having the same longitudinal surface area.




Once the dispenser


10


has been properly located on the wall mounting structure


58


, it is desirable to include a securing device to indicate to the technician that the dispenser


10


has been properly positioned and to prevent removal of the dispenser


10


without a concerted effort. In the embodiment illustrated, the securing device comprises a protrusion


126


extending from the back side


18


of the housing within the recess


50


. The protrusion


126


slides up a ramp surface


129


defined in the mounting structure


58


and snaps into a correspondingly sized divot


128


disposed adjacent to the ramp surface


129


. The wall mounting structure


58


may comprise any manner of suitable attaching structure. In the illustrated embodiment, the wall mounting structure


58


is defined by a plate member


64


that is attached to the wall surface


12


, for example by screws, adhesives, or the like. The wall mounting structure


58


serves simply to provide an interlocking engagement device for the dispenser


10


. It should be appreciated that any manner of interlocking engaging configurations may be provided for detachably connecting the dispenser


10


to complimentary wall structure provided on a supporting wall. For example, relatively simple bayonet type fasteners, spring loaded latches, and the like, may be provided in this regard. A desirable feature of the invention is that the entire dispenser


10


is disposable and, thus, relatively simple yet reliable engagement devices preferred. It has been found that the double angled surface configuration as illustrated and described herein is particularly useful in this regard.




It may also be desired to provide means for the maintenance technician to determine the level of viscous liquid within the dispenser. In this regard, as discussed above, a portion of the housing


14


may be formed from a translucent or clear material. In the embodiment illustrated particularly in

FIG. 1

, the entire back component


22


is formed from a translucent or clear material so that the service or maintenance technician can view the remaining liquid level from the side of the dispenser. In an alternative embodiment illustrated in

FIG. 19

, a window


136


of clear or translucent material may be provide anywhere in the housing


14


, preferably near the bottom portion of the housing, to provide the maintenance technician with the capability of viewing inside the reservoir to determine the remaining amount of liquid therein.




As previously mentioned, a suitable pump mechanism for use in a dispenser according to the invention may include a self-contained device having a pump chamber housing that is fitted into a bore defined through a front wall surface of the housing so as to be in communication with the internal reservoir. Such an embodiment is illustrated in

FIGS. 18 through 22

. This embodiment is similar in many aspects to the embodiment of

FIGS. 5 through 9

and, thus, the common features need not be described in detail.




Referring to

FIGS. 18 through 22

, in this embodiment the housing


300


includes a bore


302


defined through a front surface


304


. A generally cylindrical extension


312


may extend rearwardly from the front surface


304


into the reservoir. The extreme end of the cylinder extension


312


has a radially inward extending seal


310


. As will be described in greater detail below, seal


310


seals against a chamber insert member. A circumferential recess or groove


319


may also be defined in the extension


312


. A plurality of nubs or protrusions


308


extend from the front surface


304


and surround the bore


302


. The cylindrical extension


312


, ring seal


310


, groove


319


, and protrusions


308


may all be molded integrally with housing


300


.




A chamber insert


314


is designed to fit through the bore


302


. The insert


314


is shown particularly in

FIGS. 19 and 21

and may be a generally cylindrical member having an interior wall


325


defining an internal pump chamber


322


. An opening


323


is defined through the forward end of the insert


314


through which a pump cylinder slides, as described below. The insert


314


includes a front outer flange


316


having a plurality of counter-bored holes


317


defined therethrough. The holes


317


align with the protrusions


308


. The insert


314


is fitted through the bore


302


from the front side of the housing


300


. The back side of the flange


316


is pressed against the front surface


304


of the housing


300


and the protrusions


308


extend through the holes


317


. The insert is permanently attached to the housing


300


by melting the protrusions


308


in a “heat stake” process so that the molten material flows into the counter-bored holes


317


and thus anchors the insert


314


upon hardening, as particularly shown by the right-hand protrusions in FIG.


20


. It should be appreciated that many other suitable devices and methods could be used to anchor or secure the insert


314


relative to the housing


300


, including adhesives, welding, etc.




The insert


314


has an outer circumferential surface


318


that, when slid through the bore


302


and cylindrical extension


312


, is tightly engaged by the seal


310


at the end of the extension


312


. Thus, a first seal between the insert


314


and housing


24


is formed in this way. A ring-like protrusion


321


may be formed or otherwise provided around the surface


318


which engages in the groove


319


to give a positive indication that the insert


314


has been properly inserted. The ring


321


may be an O-ring and thus also provide a sealing capacity.




The insert


314


includes a radially outward extending portion


320


defined rearward of the back side of the outer flange


316


. This portion


320


acts as a seal against the cylindrical extension


312


, as particularly seen in FIG.


18


. Thus, a second seal between the insert


314


and housing


24


is formed in this way.




The insert


314


includes an inner flange


326


defining the diameter of the opening


323


, and an alignment tab


324


formed in the chamber


322


. This tab


324


cooperates with a longitudinally extending channel or groove defined in the pump cylinder, as described below.




An alternate embodiment of pump cylinder is disclosed in

FIGS. 18 and 22

. This pump cylinder embodiment may be used in the integrally molded pump chamber illustrated in

FIGS. 5 through 9

or with the pump chamber insert


314


. This embodiment includes a two-part pump cylinder


340


. The first component


342


is a generally cylindrical member having a channel


344


defined therethrough that terminates at a dispensing orifice


96


defined in the front end of the first component


342


. The front end of the first component


342


thus corresponds to the delivery end of the pump cylinder


340


. A flange


354


is provided at the rearward end of the first component


342


to prevent the pump cylinder


340


from being pulled out of the pump chamber


322


. This flange


354


engages against the inner flange


326


of the insert


314


in the fully extended position of the pump cylinder


340


, as illustrated in FIG.


18


.




As with the embodiment of

FIGS. 5 through 9

, a locking feature is provided for the pump cylinder


349


. A longitudinal groove or channel (not visible in

FIG. 18

) is defined along the top outer surface of the first component


342


and is engaged by the alignment tab


324


of the insert


314


as the cylinder is slid longitudinally within the pump chamber


322


. In this way, the pump cylinder


340


is prevented from rotating upon actuation and release thereof. A partial circumferential groove


352


is defined in the outer surface of the first component


342


, as particularly illustrated in FIG.


18


. The circumferential groove


352


is defined at a location corresponding to the pressurization position of the pump cylinder


340


within the pump chamber


322


. For shipment of the dispenser, the pump cylinder


340


may be depressed and then rotated so that the tab


324


is engaged within the circumferential groove


352


. In this configuration, the pump cylinder


340


is locked in the pressurization position and cannot move within the pump chamber


322


until the pump cylinder is rotated back into position so that the tab


324


is engaged within the longitudinal groove


350


.




The first component


342


of the pump cylinder


340


also includes a flange seal


356


defined at the rearward end thereof. The flange seal


356


engages against the interior wall


325


of the insert


314


and ensures that the viscous liquid contained within the chamber


322


is pressurized and dispensed through the pump cylinder


340


upon movement of the cylinder from its rest position to the pressurization position and does not simply move from one end of the pump chamber to the other upon movement of the cylinder.




The second component of the pump cylinder


340


may be a plug member


346


having a generally cylindrical extension


347


that is fitted into a chamber


341


defined in the rearward end of the first component


342


. The plug member


346


has a channel


348


defined therethrough that axially aligns with the channel


344


defined in the first component


342


. The aligned channels


344


and


348


thus define the delivery channel through the pump cylinder


340


. As shown in

FIG. 22

, the channel


348


may be open along the top thereof wherein a closed channel is formed by cooperation of the first component wall defining the chamber


341


and the open channel


348


. A cup-shaped flange member


358


is defined at the rearward end of the plug member


346


. The side wall of the flange member


358


engages against the interior wall


325


of the insert


314


and thus defines a second flange seal between the pump cylinder


340


and the pump chamber


322


. The interior of the cup-shaped flange member


358


defines a recess or seat


362


against which a spring sits, as described below.




As with the embodiment of

FIGS. 5 through 9

, a check valve is provided with the pump chamber


322


to ensure that the viscous liquid within the chamber


322


is not pushed out of the chamber upon movement of the pump cylinder


340


within the chamber. The check valve in this embodiment is a shuttle valve


392


having radially extending and spaced apart arms


336


. The shuttle valve


392


is slidably disposed within an opening defined through an end cap


328


. The space between the radial arms


336


is open to the reservoir so that liquid can flow from the reservoir into the pump chamber


322


upon movement of the pump cylinder


340


to the forward end of the pump chamber


322


. A sealing cap


334


, such as an elastomeric cap, is provided on the forward end of the shuttle valve


392


to ensure that the opening in the end cap


328


is sealed upon actuation of the pump and rearward movement of the pump cylinder


340


within the chamber


322


to its pressurization position. The cap


334


seals against the forward end of a cylindrical extension


338


of the end cap


328


. An open cage member


330


extends from the end cap


328


into the reservoir and surrounds the radial arms


336


.




The pump cylinder


340


is biased with the pump chamber


322


to its rest position by way of a spring


360


. Other types of resilient devices, such as a leaf spring, spring washer, and the like, may be utilized for this purpose. The spring


360


has a forward end seated in the recess


362


of the cup-shaped flange member


357


of the plug member


346


. The opposite end of the spring


360


is fitted around the cylindrical extension


338


of the end cap


328


.




The end cap


328


is permanently fixed (i.e., by welding, adhesive, etc.) to the rearward end of the chamber insert


314


after the pump cylinder


340


and spring


360


are inserted into the insert from its rearward end.




As with the embodiment of

FIGS. 5 through 9

, it may be desired to include a valve mechanism within the delivery end of the pump cylinder


340


to prevent leakage of viscous liquid from the dispenser. A particularly useful sealing valve is the type of valve illustrated and described with respect to

FIGS. 9



a


and


9




b.






Operation of the embodiment depicted in

FIGS. 18 through 22

is substantially the same as described above with respect to the embodiment of

FIGS. 5 through 9

and thus need not be set forth again in detail.




The pump mechanism of

FIGS. 18 through 22

may be desirable from a manufacturing and assembly standpoint. It may also be desirable to be able to remove the pump mechanism from the housing and recycle or reuse all or part of the pump mechanism. In this case, it might be preferred to provide a more readily “breakable” or disconnectable attachment between the chamber insert


314


and the housing


24


, such as a releasable adhesive, mechanical fastener (i.e., threaded connection), etc. Although within the scope and spirit of the invention, with the embodiment of

FIGS. 18 through 22

it might prove prohibitive to break the heat stake welds between the chamber insert


314


and front surface


304


of the housing


300


to remove the insert


314


.




It should be appreciated that the invention includes modifications and variations to the embodiments of the invention described herein.



Claims
  • 1. A self contained viscous liquid dispenser, comprising:a housing defining an internal liquid reservoir, said housing including a front surface having an opening therethrough adjacent a bottom surface of said reservoir; an insert member fitted through said opening, said insert extending into said reservoir and defining an internal pump chamber having a back end open to said reservoir and a front end open to the outside of said housing, said front end of said insert member attached to said housing at said front surface such that said pump chamber is disposed substantially rearwardly of said front surface of said housing; a pump cylinder slidably disposed and retained in said pump chamber, said pump cylinder having a delivery end extending out of said pump chamber and a delivery channel defined therethrough terminating at a dispensing orifice in said delivery end, said pump cylinder movable within said pump chamber from a rest position to a pressurizing position to pressurize and dispense liquid within said pump chamber through said delivery channel and out said dispensing orifice; and an actuator configured with said delivery end of said pump cylinder to move said pump cylinder from said rest position to said pressurizing position from outside of said housing.
  • 2. The dispenser as in claim 1, further comprising a valve mechanism disposed in said delivery end of said pump cylinder, said valve mechanism opening upon an operator actuating said actuator and closing upon release of said actuator to prevent leakage or dripping of liquid from said pump cylinder.
  • 3. The dispenser as in claim 2, wherein said valve mechanism comprises at least one flexible flap member that is movable to an open position upon actuation of said actuator and automatically returns to a closed position upon release of said actuator.
  • 4. The dispenser as in claim 3, further comprising a plurality of said flap members that define an opening therethrough in said open position and seal against each other in said closed position.
  • 5. The dispenser as in claim 1, wherein said pump cylinder is insertable into said pump chamber from said back end, said chamber further comprising retaining structure at said front end to prevent withdrawal of said pump cylinder from said pump chamber through said front end.
  • 6. The dispenser as in claim 5, further comprising an end cap attachable to said back end of said pump chamber upon insertion of said pump cylinder within said pump chamber.
  • 7. The dispenser as in claim 6, further comprising an orifice defined through said cap member for drawing viscous liquid into said pump chamber, and a check valve device disposed in said orifice to close said orifice upon movement of said pump cylinder to said pressurization position.
  • 8. The dispenser as in claim 7, wherein said check valve device further comprises a sealing cap disposed to seal said orifice upon movement of said pump cylinder to said pressurization position.
  • 9. The dispenser as in claim 1, wherein said actuator comprises a panel member pivotally connected to said housing and in contact against said delivery end of said pump cylinder.
  • 10. The dispenser as in claim 1, wherein said actuator is attached directly to said delivery end of said pump cylinder.
  • 11. The dispenser as in claim 1, wherein said pump cylinder comprises a first component having a first channel defined therethrough, and a second component fitted into said first component and having a second channel defined therethrough that is axially aligned with said first channel, said first and second channels defining said delivery channel through said pump cylinder.
  • 12. The dispenser as in claim 11, wherein said first component further comprises a first radially extending seal that slidably engages along an inner wall of said insert member defining said pump chamber, and said second component further comprises a second radially extending seal that also slidably engages along said inner wall of said insert member.
  • 13. The dispenser as in claim 1, further comprising a biasing element disposed within said pump chamber to bias said pump cylinder to said rest position.
  • 14. The dispenser as in claim 1, further comprising at least one seal disposed between an outer surface of said insert member and said housing.
  • 15. The dispenser as in claim 14, wherein said at least one seal comprises a radially inward extending seal disposed around said opening in said housing that engages and seals against said outer surface of said insert member.
  • 16. The dispenser as in claim 15, wherein said opening in said housing is defined by a cylindrical extension that extends from said front surface into said reservoir, said radially extending seal disposed on said cylindrical extension.
  • 17. The dispenser as in claim 14, wherein said insert member comprises a radially outward extending seal disposed at a forward end thereof that engages and seals against a portion of said housing defining said opening.
  • 18. The dispenser as in claim 1, further comprising a first and a second seal between an outer surface of said insert member and said housing, said first seal comprising a radially inward extending seal disposed around said opening in said housing that engages and seals against said outer surface of said insert member, and said second seal comprising a radially outward extending seal disposed at a forward end of said insert member that engages and seals against a portion of said housing defining said opening.
  • 19. A self contained viscous liquid dispenser, comprising:a housing defining an internal liquid reservoir, said housing including a front surface having an opening therethrough adjacent a bottom surface of said reservoir; an insert member fitted through said opening, said insert extending into said reservoir and defining an internal pump chamber having a back end open to said reservoir and a front end open to the outside of said housing, said insert attached to said housing at said front surface; a pump cylinder slidably disposed and retained in said pump chamber, said pump cylinder having a delivery end extending out of said pump chamber and a delivery channel defined therethrough terminating at a dispensing orifice in said delivery end, said pump cylinder movable within said pump chamber from a rest position to a pressurizing position to pressurize and dispense liquid within said pump chamber through said delivery channel and out said dispensing orifice; an actuator configured with said delivery end of said pump cylinder to move said pump cylinder from said rest position to said pressurizing position from outside of said housing; and further comprising a locking mechanism disposed between said pump cylinder and said pump chamber to retain said pump cylinder locked in said pressurization position during storage and transit of said dispenser.
  • 20. The dispenser as in claim 19, wherein said locking mechanism comprises a circumferentially extending groove defined in an exterior surface of said pump cylinder at a position corresponding to said pressurization position, and a radially extending tab configured on said insert member that engages in said groove.
  • 21. A self contained viscous liquid dispenser, comprising:a housing defining an internal liquid reservoir, said housing including a front surface having an opening therethrough adjacent a bottom surface of said reservoir; an insert member fitted through said opening, said insert extending into said reservoir and defining an internal pump chamber having a back end open to said reservoir and a front end open to the outside of said housing, said insert attached to said housing at said front surface; a pump cylinder slidably disposed and retained in said pump chamber, said pump cylinder having a delivery end extending out of said pump chamber and a delivery channel defined therethrough terminating at a dispensing orifice in said delivery end, said pump cylinder movable within said pump chamber from a rest position to a pressurizing position to pressurize and dispense liquid within said pump chamber through said delivery channel and out said dispensing orifice; an actuator configured with said delivery end of said pump cylinder to move said pump cylinder from said rest position to said pressurizing position from outside of said housing; and wherein said housing comprises a plurality of protrusions extending from said front surface and disposed around said opening, and insert member comprises a front flange having a plurality of holes defined therethrough into which said protrusions extend upon mounting said insert member into said housing.
  • 22. The dispenser as in claim 21, wherein said holes are counter-bored and said protrusions have been melted so as to flow into said holes to permanently retain said insert member relative to said housing.
  • 23. A self contained viscous liquid dispenser, comprising:a housing defining an internal liquid reservoir, said housing further comprising a back side configured for securement against a supporting wall surface; a pump chamber defined in said reservoir, said pump chamber having a back end open to said reservoir and a front end open to the outside of said housing; a pump cylinder slidably disposed and retained in said chamber, said pump cylinder having a delivery end extending out of said pump chamber and a delivery channel defined therethrough terminating at a dispensing orifice in said delivery end, said pump cylinder movable within said pump chamber from a rest position to a pressurizing position to pressurize and dispense liquid within said pump chamber through said delivery channel and out said dispensing orifice; said pump cylinder further comprising a first component having a first channel defined therethrough, and a second component fitted into said first component and having a second channel defined therethrough that is axially aligned with said first channel, said first and second channels defining said delivery channel; and an actuator configured with said delivery end of said pump cylinder to move said pump cylinder from said rest position to said pressurizing position.
  • 24. The dispenser as in claim 23, wherein said first component further comprises a first radially extending seal that slidably engages along a wall defining said pump chamber, and said second component further comprises a second radially extending seal that also slidably engages along said wall defining said pump chamber.
  • 25. The dispenser as in claim 23, further comprising a valve mechanism disposed in said delivery end of said pump cylinder, said valve mechanism opening upon an operator actuating said actuator and closing upon release of said actuator to prevent leakage or dripping of liquid from said pump cylinder.
  • 26. The dispenser as in claim 25, wherein said valve mechanism comprises at least one flexible flap member that is movable to an open position upon actuation of said actuator and automatically returns to a closed position upon release of said actuator.
  • 27. The dispenser as in claim 23, further comprising an end cap attachable to said back end of said pump chamber subsequent to insertion of said pump cylinder within said pump chamber.
  • 28. The dispenser as in claim 27, further comprising an orifice defined through said cap member for drawing viscous liquid into said pump chamber, and a check valve device disposed in said orifice to close said orifice upon movement of said pump cylinder to said pressurization position.
  • 29. The dispenser as in claim 28, wherein said check valve device further comprises a sealing cap disposed to seal said orifice upon movement of said pump cylinder to said pressurization position.
  • 30. The dispenser as in claim 23, wherein said actuator comprises a panel member pivotally connected to said housing and in contact against said delivery end of said pump cylinder.
  • 31. The dispenser as in claim 23, wherein said actuator is attached directly to said delivery end of said pump cylinder.
RELATED APPLICATIONS

The present application is a Continuation-In-Part (CIP) application of U.S. Ser. No. 09/741,570 filed on Dec. 19, 2000.

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Continuation in Parts (1)
Number Date Country
Parent 09/741570 Dec 2000 US
Child 09/997278 US