Patent Application
20110272494
The present invention relates to pump sprayers and more particularly to pump sprayers which can provide a preferred particle size distribution under real world operating conditions.
Trigger sprayers are well-known in the art. Trigger sprayers utilize a handheld reservoir, typically depending from a manual pump. The reservoir may hold any liquid desired to be sprayed in a stream, fine droplets, foam or mist. The liquid may comprise an air freshener, fabric refresher, hair spray, cleanser, etc.
The pump is activated by an articulating trigger. The user squeezes the trigger with his or her hand, typically retracting the trigger from a forward resting position to a rearward dispensing position. The motion of the trigger causes pumping of the liquid from the reservoir and ultimate spraying thereof.
The characteristics of the spray, e.g. stream, droplets, mist, are determined by several parameters and operating characteristics of the pump. For example, the nozzle geometry, piston bore, piston stroke and pump efficiency will all affect the spray characteristics.
The situation is complicated if a pump designed for one particular liquid is used with a different liquid. The liquid rheology, surface tension, etc. also affect the spray characteristics.
The situation is further complicated by user operation. The pump may be designed and intended to be used with full trigger strokes, each stroke dispensing a full volume of the piston displacement at a particular stroke speed. However, the user may not always, or ever, operate the trigger in the intended manner.
If the piston bore is too large, the force necessary to achieve proper trigger stroke may be too great for a particular user. If the piston stroke is too long or if the trigger articulation is too long, the user may not pull the trigger for the entire intended path length. If the user's hand is too small or too large, the user may not operate the trigger as intended. The user may operate the trigger slower or faster than intended. The user's hand may fatigue and operation may change in the middle of a particular usage and even mid-stroke.
Thus, there is a need in the art to accommodate not only intended use conditions for a particular liquid, but real-world conditions as well.
U.S. Pat. No. 3,768,734 to Anderson Jr. et. al. (Arrowhead Products); U.S. Pat. No. 4,503,998 to Martin (Universal dispensing Systems); U.S. Pat. No. 4,691,849 to Tada; U.S. Pat. No. 4,819,835 to Tasaki (Yoshino); U.S. Pat. No. 4,940,186 to Tada; U.S. Pat. No. 5,156,304 to Battegazzore (Guala) teaching a spraying device having a rocker lever for converting angular trigger motion to pump displacement; U.S. Pat. No. 5,299,717 to Geier (CoCoster Tecnologie Speciali) teaching a manual spray device having the axis of the piston generally parallel to the motion of the trigger; U.S. Pat. No. 5,318,206 to Maas et al. (AFA Products); U.S. Pat. No. 5,385,302 to Foster et al. (Contico Int'l) teaching a trigger sprayer having a pump assembly parallel to the discharge path; U.S. Pat. No. 5,570,840 to Gettinger (Fourth and Long) teaching a spraying device having first and second pumps; U.S. Pat. No. 5,575,407 Foster et al. (Contico Int'l); U.S. Pat. No. 5,593,093 to Foster et al. (Contico Int'l); U.S. Pat. No. 5,645,221 to Foster (Contico Int'l); U.S. Pat. No. 5,628,434 to Foster et al. (Contico Int'l); U.S. Pat. No. 5,628,461 to Foster et al. (Contico Int'l); U.S. Pat. No. 5,884,845 to Nelson (Continental Sprayers) U.S. Pat. No. 6,244,473 to Keung et al. (Owens Illinois Closure); 2009/0008415 A1 to Ohshima (Mitani Valve); Re. 35,744, reissued Mar. 17, 1998 of U.S. Pat. No. 5,234,166 to Foster et al. (Contico Intl); U.S. Pat. No. 5,228,602 to Maas et al. (AFA Products); U.S. Pat. No. 5,341,965 to Maas et al. (AFA Products); U.S. Pat. No. 5,425,482 to Foster et al. (Contico Int'l); U.S. Pat. No. 5,467,900 to Maas et al. (AFA Products); U.S. Pat. No. 5,507,437 to Foster et al. (Contico Int'l); U.S. Pat. No. 5,509,608 Reexamination Certificate B1 (4195) to Foster et al. (Continental Sprayers); U.S. Pat. No. 5,513,800 to Foster et al. (Contico Int'l); U.S. Pat. No. 5,549,249 to Foster et al. (Contico Int'l); U.S. Pat. No. 5,551,636 to Foster et al. (Contico Int'l); U.S. Pat. No. 5,553,752, Reexamination Certificate C1 (4343), to Foster et al. (Contico et al); U.S. Pat. No. 5,566,885 to Foster et al. (Contico Int'l); U.S. Pat. No. 5,615,835 to Nelson (Contico Int'l); U.S. Pat. No. 5,730,335 issued to Maas et al. (AFA products); U.S. Pat. No. 5,984,149 to Thanisch et al. (Spraysol); U.S. Pat. No. 6,116,472 to Wanbaugh et al. (Calimar); U.S. Pat. No. 6,131,820 to Dodd (Calimar); U.S. Pat. No. 6,234,361 to Bloom (Owens Illinois Closure) U.S. Pat. No. 6,364,175 to Bloom (Owens Illinois Closure); U.S. Pat. No. 6,378,786 to Beeston et al. (Reckitt Benkiser); U.S. Pat. No. 6,425,501 to Keung et al. (Owens Illinois Closure); U.S. Pat. No. 6,910,605 to Schuckmann et al. (Schuckmann); U.S. Pat. No. 7,017,833 to Foster (Continental AFA Dispensing); U.S. Pat. No. 7,175,056 to Buti (Spray Plast); U.S. Pat. No. 7,219,848 to Sweeton (Meadwestvaco Calimar); U.S. Pat. No. 7,413,134 to Tsuchida (Yoshino Kogyosho); U.S. Pat. No. 7,410,079 to Kuwahara et al. (Yoshino Kogyosho); U.S. Pat. No. 7,467,752 to Sweeton (Meadwestvaco Calimar); U.S. Pat. No. 7,497,358 to Clynes et al. (Meadwestvaco Calimar); EP 7 757 984; WO 2009/078303; JP 2003-230854; EP 1317963; JP 2503986; and JP 2003-200087 show various attempts in the art.
The invention comprises a trigger sprayer suitable for dispensing liquid from a reservoir, through a nozzle into particles. The trigger sprayer advantageously delivers a particle size distribution suitable for liquids having particular rheological properties.
In
All figures are drawn to scale unless specifically stated otherwise.
Referring to
Referring to
Manual actuation of the trigger 24 through its stroke causes corresponding vertical movement of a piston 40. Vertical movement of the piston 40 pumps liquid from the reservoir 22, through a flow path and out the nozzle 28. This embodiment of the pump sprayer 20 utilizes an articulating, top-pivoting trigger 24, although it is recognized that vertical push button type sprayers, as commonly used for hair spray, could be utilized as well.
A return spring 42 provides bias to urge the trigger 24 back to the forward position at the end of the stroke. Two curved parallel springs 42 may be utilized. The springs 42 may be connected at each end and may be disposed outside the piston 40/pump chamber 44. The vertically upwards flow path may be disposed between the springs 42.
The trigger 24 motion creates hydraulic pressure in the pump, causing the liquid to be dispensed. The liquid in the reservoir 22 is drawn vertically through a dip tube 30, and into the pump chamber 44. The return stroke creates a vacuum, drawing the liquid from the reservoir 22 to refill the pump chamber 44. A reciprocating piston 40 pressurizes the pump cylinder, and liquid drawn therein. This pressure causes the liquid to be sprayed out of the sprayer nozzle 28. A return spring 42 automatically alternates the trigger 24 to the forward rest position.
Referring to
Referring to
The reciprocating piston 40 may have an upper seal 150U and a lower seal 150L, both of which fit within the body 48. Actuation of the trigger 24 causes corresponding downward vertical movement of the piston 40. Liquid is drawn upwardly through the dip tube 30 and forced into the liquid chamber 44, where it remains until displaced upwardly into an annular chamber 44 intermediate the piston 40 and body 48.
A valve 55 disposed within the piston 40 may have vertical movement thereof resisted by a spring (not shown). As force from the trigger 24 motion increases the force applied to the piston 40 the valve 55 may move downwardly, pressurizing liquid in the chamber 44 to be later dispensed.
Referring back to
Liquid flowing through the tube 58 passes through the spinner 27. The spinner 27 imparts a tangential rotation to the liquid before the liquid reaches the nozzle 28. The spinner 27 is inserted into the nozzle 28, up to the shoulder of the spinner 27. The spinner 27 and nozzle 28 are stationary. The spinner 27 may comprise a constant diameter pin with two longitudinal grooves disposed 180 degrees out on the downstream half of the axial length. The grooves terminate in a swirl chamber. The swirl chamber is disposed on the face of the spinner 27.
The spinner 27 may have two longitudinally opposed ends, an upstream end into which the aforementioned bent tube 58 is fitted and a downstream end which fits into the nozzle 28. The spinner 27 may have a length of about 11 mm and a stepped diameter of about 4-5 mm. The spinner 27 may have two longitudinally oriented slots equally circumferentially spaced around the downstream portion thereof.
Upon exiting the spinner 27 the liquid passes through the nozzle 28 for dispensing into the atmosphere or onto a target surface. The nozzle 28 may have a diameter of 0.5-6 mm, and be radiused on the outside face. The liquid is dispensed from the nozzle 28 in a predetermined spray pattern, which may vary according with the stroke speed, stroke length, etc. of the trigger 24 operation. Optionally, provision may be made for adjusting the spray pattern.
The entire pump assembly 26 may be encased in a multi-part polypropylene housing 70. There may be no direct opening from the pump to the outside of the housing 70, except for the nozzle 28.
Referring to
The embodiment of
A suitable pump sprayer 20 may be made according to the teachings of WO 2009/078303, published Jun. 25, 2009 (Canyon Co. Ltd). However, the sprayer 20 in this publication must be adjusted to provide the work, otherwise the consumer may not properly dispense the liquid therefrom. If the trigger 24 force is too great, stroke length too long or too short,
One of ordinary skill may desire different particle size distributions of liquid dispensed using the sprayer 20 of the present invention. If the particles are too large, the liquid may simply fall onto the floor or form a wet spot, puddling on the target surface. If the particles are too small, they may not have enough surface area to be efficacious. For example, spray particles less than 50 microns in diameter may remain suspended indefinitely or until evaporation occurs.
The particle size diameter is determined using a Spraytec 2000 particle size analyzer, using Malvern RT Sizer 3.03 software. Both are available from Malvern Instruments, Ltd, UK.
A 300 mm lens is used, having minimum and maximum particle size detections of 0.10 and 900.00 microns, respectively. The spray nozzle is positioned 140 mm from the laser beam, using a 100 mm path length. A particulate refractive index of 1.33 and dispersant refractive index of 1.00 are selected. A residual of 0.41 is selected, with the extinction analysis Off and multiple scatter set to On. The Scatter start is set to 1, scatter end is set to 36, and scattering threshold is set to 1.
A linear servo-drive motor may be used to provide the desired trigger speed/stroke rate. The servo-drive motor is connected a sled, which, in turn, is connected to a load cell. The load cell captures the peak force. The load cell is connected to the proximal ends of an articulating link comprising two parallel arms. The distal end of the articulating parallel arms are joined by a cross bar. The cross bar, in turn, engages the trigger 24 of the sprayer to be tested. The sprayer 20 may be held rigidly, and the trigger 24 pulled from behind. The cross bar rides on the trigger to provide actuation force.
One of skill will consider the Dv(50) measurement, meaning that 50 percent of the particles have a mean particle diameter less than the value indicated. Likewise one of skill will consider the Dv(90) measurement, meaning that 90 percent of the particles have a mean particle diameter less than the value indicated.
One of skill may also consider the D[4,3] measurement. This measurement sums the individual particle diameters raised to the 4th power, divided by the sum of the individual particle diameters raised to the 3rd power. This measurement is independent of the actual number of particles under consideration in the measurement.
The measurements discussed relative to
Table 3 provides certain operating parameters for the aforementioned sprayers 20, including stroke length, stroke output, the number of strokes necessary to achieve 5 mL of output from the sprayer 20. The volume of 5 mL was chosen as this volume approximates the least volume typically sprayed during a single usage.
As used herein, all references to tests and data at 30 strokes per minute were run with the trigger 24 traveling from the forward resting position to only one third of the articulation to full stroke position. The term strokes per minute and acronym SPM are used interchangeably.
Ideally, the 90 SPM test and 30 SPM test would have coincident particle size distributions. The coincidence would indicate no loss of performance when ideal conditions are adjusted for real world usage. However, in every case tested the particle size distribution increased when the 30 SPM one-third stroke condition was utilized. The stroke force was applied to the trigger 24 at a position 40 mm from the hinge about which the trigger 24 articulates.
The trigger sprayer 20 described and claimed herein is suitable for use with liquids having certain rheological properties ranging from those of distilled water to those of an air/fabric refreshing liquid. Particularly, the liquids suitable for use with the present invention may have a dynamic viscosity ranging from about 0.85 to about 1.1 centipoises at 25 degrees C. and a kinematic viscosity ranging from about 8.9 E-4 to about 0.001 Pascal*seconds. The liquids may have a surface tension ranging from about 20 to about 75 milliNewtons/meter at 25 degrees C.
Referring to
The error bands on the left and right sides of the bar graph indicate the widths of the particle size distributions about the respective peak values, between the lowest value measured and the highest value measured. The peak value is determined by the average value of the particle size distribution for that test, i.e. either 90 SPM or 30 SPM.
The number inside the bar graph indicates the difference between the 30 SPM one-third stroke peak particle size distribution and the 90 SPM particle size distribution. Perfect coincidence would be indicated by a value of zero inside the bar.
The values in parenthesis, to the right of the designated sprayer 20, indicates the volume dispensed in a full stroke of the trigger 24 of the respective sprayer 20. Volumes dispensed per stroke range from 0.5 to 1.4 mL. If the volume dispensed per stroke is too small, the user will have to engage in more trigger 24 actuations per use, potentially increasing time and frustration with each usage. If the volume dispensed per stroke is too large, the user will may potentially dispense too much product with each usage, and be unable to prevent undue wetting or overpowering perfume aromas.
Referring to
It is noted that the Yoshino sprayer had even less difference between the two tests than the sprayer 20 according to the invention. However, this sprayer 20 has the significant disadvantage that it only sprays out half of the volume, per stroke, of the present invention. Thus, the user may become more likely to experience fatigue of the hand when using the invention or not properly dispense enough liquid to be efficacious.
Referring to
It is noted that the Yoshino sprayer 20 again had less difference between the two tests than the sprayer 20 according to the invention. However, again it is noted, this sprayer 20 has the significant disadvantage that it only sprays out half the volume, per stroke, of the present invention. Thus, the user may become more likely to experience fatigue of the hand when using the invention or not properly dispense enough liquid to be efficacious.
Referring to
Again the Yoshino sprayer 20 had less difference between the two tests than the sprayer 20 according to the invention, but again at the sacrifice of spray volume. However, this sprayer 20 has the significant disadvantage that it only sprays out half the volume, per stroke, of the present invention. Thus, the user may become more likely to experience fatigue of the hand when using the invention or not properly dispense enough liquid to be efficacious.
Referring to
Referring to
The work was measured by tallying the cumulative distance of the trigger 24 strokes, measured in a straight line, at a distance of 40 mm from the trigger 24 pivot, for the cumulative number of trigger 24 strokes necessary to provide a total spray volume of 5 ml. This cumulative distance is then multiplied by the force applied, to yield the work.
The Yoshino sprayer 20 consistently required the greatest work of all sprayers tested, despite having the lowest dispensing volume. For the present invention, the work ranged from 1.3 to 1.5 Newton meters for the test liquid and increased to about 3.4 to about 3.5 Newton meters with distilled water.
Referring to
As discussed below a particle size distribution difference refers to the difference obtained testing for the respective particle size distribution at 90 SPM and 30 SPM. The test may include a sampling of n=1, or may include a sampling of n=3.
Thus the invention described and claimed hereunder, when used with distilled water, may have a Dv(50) particle size distribution difference less than 70, 60 or 50 microns but greater than 25 or 30 microns; a Dv(90) particle size distribution difference less than 200, 190, 180, 170, 160, 150 or 140 microns but greater than 60, 70, 80, 90 or 100 microns; and a D[4,3] particle size distribution difference less than 100, 90, 80, 70, or 60 microns but greater than 20, 30 or 40 microns.
The invention described and claimed hereunder, when used with the aforementioned test liquid, may have a Dv(50) particle size distribution difference less than 60, 50, 40 or 30 microns but greater than 15, 20 or 25 microns; a Dv(90) particle size distribution difference less than 175, 150 or 75 microns but greater than 625 or 50 microns; and a D[4,3] particle size distribution difference less than 90, 80, 70, 60 or 50 microns but greater than 20, 25 or 30 microns.
The invention described and claimed hereunder, when used with distilled water, may have a peak actuation force at a distance of 40 mm from the trigger 24 pivot of less than less than 70 or 65 Newtons, but greater than 35, 40 or 50 Newtons at 90 SPM; and less than 30, 25 or 20 Newtons, but greater than 10 or 15 Newtons at 30 SPM.
The invention may be used with a liquid having a surface tension of at least 20, 21, 22, 23, 24 or 25 and less than 75, 74, 73, 72, 71, or 70 mNewtons/meters; a kinematic viscosity of at least 8.7 E-4, 8.8 E-4, 8.9 E-4 or 9E-4 and/or less than 0.0015, 0.0014, 0.0013, 0.0012, 0.0011 or 0.0010 Pascal seconds at 25 C; and/or a dynamic viscosity less of at least 0.87, 0.88, 0.89, 0.9 and less than 1.15, 1.14, 1.13, 1.12, 1.11 or 1.10 centipoises at 25 C.
The invention described and claimed hereunder, when used with the aforementioned test liquid, may have a peak actuation force at a distance of 40 mm from the trigger 24 pivot of less than less than 75, 70 or 65 Newtons, but greater than 35, 40 or 50 Newtons at 90 SPM; and less than 30, 25 or 20 Newtons, but greater than 10 or 15 Newtons at 30 SPM.
The invention described and claimed hereunder, when used with distilled water or the aforementioned test liquid, may have work to dispense 5 mL of distilled water or test liquid, respectively, less than 8, 7.5, 7.0, 6.5, 6.0, 5.5, 5.0, 4.5 or 4.0, but greater than 3.0 or 3.5 Newton meters at 90 SPM and less than 5, 4.5, 4.0, 3.5, 3.0, 2.5, 2.0 or 1.5, but greater than 0.5, 1 or 1.25 Newton meters at 30 SPM.
The trigger sprayer of the present invention may dispense at least 0.6, 0.7, 0.8, 0.9, 1.0, 1.1 or 1.2, but less than 2.0, 1.9, 1.8, 1.7 1.6 or 1.5 ml of a liquid contained in the reservoir 22 per full stroke of the trigger 24 at 90 SPM. The trigger sprayer of the present invention may dispense at least 0.20, 0.25, 0.30, but less than 0.60, 0.55, or 0.5 ml of a liquid contained in the reservoir 22 per one-third stroke of the trigger 24 at 30 SPM.
All percentages stated herein are by weight unless otherwise specified. It should be understood that every maximum numerical limitation given throughout this specification will include every lower numerical limitation, as if such lower numerical limitations were expressly written herein. Every minimum numerical limitation given throughout this specification will include every higher numerical limitation, as if such higher numerical limitations were expressly written herein. Every numerical range given throughout this specification will include every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein.
The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”
Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern. While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
