WO2025061899A1

WO2025061899A1 - All plastic fine misting dispenser with pre-compression functionality

Info

Publication number: WO2025061899A1
Application number: PCT/EP2024/076353
Authority: WO
Inventors: Gaurang Mittal; Raj Kamal SINGHAL; Ajeet Singh; Phillipe BASTOS
Original assignee: Rieke Packaging Systems Limited
Priority date: 2023-09-19
Filing date: 2024-09-19
Publication date: 2025-03-27

Abstract

Various aspects of a fine mist dispensing sprayer and pump are contemplated. The pump is constructed from all plastic components and, more preferably, from the same grade of polymeric material. The pump exhibits pre-compression utility while relying on only a single biasing member, in combination with a pair of pumping chambers that includes a lower chamber with a cylindrical sealing cylinder that engages an inner set of wiper elements on a moving pin or piston. The pump may be configured to dispense axially or at an angle to the axis of reciprocation without necessarily changing the piston, the lower housing, or the biasing member.

Description

TITLE

ALL PLASTIC FINE MISTING DISPENSER WITH PRE-COMPRESSION FUNCTIONALITY

TECHNICAL FIELD

[0001] The present invention relates generally to sprayer dispensers and, more specifically, to a spray dispenser capable of delivering a fine mist with pre-compression functionality to insure immediate and complete discharge of intended/desired dose.

BACKGROUND

[0002] Pump dispenses can be configured to provide a convenient means for dispensing fluids as a mist of atomized and/or finely dispersed droplets. The reciprocating plunger may dispense this mist at an angle relative to the axis of reciprocation, making it useful for dispensing perfumes, fragrances, and other airborne products, or in-line with that axis to enable for one-handed operation, making it useful for delivering medications such as nasal sprayers. In either arrangement, the plunger is operatively connected to pump engine including biasing means to drive reciprocation. In turn, that engine draws fluid from a container and is connected to or formed integrally as part of a closure that attaches to the neck of the container.

[0003] At the outlet of many fine misting sprayers, one or more dispensing channels and/or swirl chambers are provided, often times with interstices between a cup-shaped nozzle element and a post defining these flow paths. The nozzle serves to mix and atomize the fluids prior to being expelled from the outlet positioned downstream from the swirl chamber, with the outlet formed as a through-hole formed in the cup. [0004] United States patents 8,690,081; 9,364,838; and 9,370,786 provide examples of nozzle elements that can be employed in some misting sprayers. One or more dispensing channels are between the interface of the post attached to the sprayer head and a separate cup mounted onto the post. A recess within the cup defines a swirl chamber that is fluidically connected to the orifice outlet in the cup. Swirl channels create outlets in a vertical y-axis to deliver fluid into the chamber. These nozzle elements are specifically designed to dispense low viscosity liquids as a fine mist, such as those found in Patent Cooperation Treaty publication W02020/103701 and United States patent 7,201,296, as well as many others.

[0005] The need for high pressure output, ease of actuation, and comparatively small doses and container sizes all distinguish fine misting dispensers from larger reciprocating pumps that dispense flowable liquid doses, such as those seen in Patent Cooperation Treaty publication WO2022/052464, United States patent 5,819,990, and United States patent publication 2022/0048058, as well as many others.

[0006] As noted above, misting dispensers can be designed for operation using only one hand (e.g., by squeezing axially down on the dispenser between a user’s fingers and palm or thumb). Often, these dispensers must deliver precise volumes of fluids that are directed onto or into an specific target (e.g., the user’s nose, throat, eyes, etc.), such as those found in United States patent publications 2003/0155377 and 2022/0409833 and United States patents 5,195,665; 6,824,020; 9,186471; and 11,559,821.

[0007] Another critical requirement for many fine mist sprayers is “pre-compression” functionality, meaning the pump will immediately deliver the desired amount of liquid as atomized droplets and/or a fine mist. Many pre-compression dispensers rely upon a pair of separate springs to insure sufficient suction is achieved on the initial downstroke so as to move fluid through the pump body and into the swirl chamber or dispensing duct/outlet with sufficient force to atomize the fluid. United States patent 8,016,164 provides an example of such designs.

[0008] Trigger sprayers may incorporate alternative pre-compression designs, possibly by employing a reservoir that is charged the first time the pump is first actuated. Thereafter, a an actuating stroke will deliver a portion of the charged liquid from the this chamber (while simultaneously recharging it). Advantageously, these designs require only one spring, but the comparatively large dose and container sizes for trigger sprayers allow for the use of such large and bulky configurations. Examples can be found in United States patent publications 2008/0230563 and 2022/02410193.

[0009] To that end, the need for multiple springs, metallic springs, and/or separate precompression reservoirs all add complexity, components, and costs. As such they tend to be ill- suited for incorporation into compact misting dispensers.

[0010] Additionally, it is becoming increasingly important for businesses to design sustainable products made from recyclable/reusable, polymeric materials. In this manner, such “all-polymer” pumps can be recycled without the need to disassemble and/or separate out components made from difficult to recycle materials (e.g., metallic or foil parts, thermosetting resins, specialized elastomers, and other materials that either cannot be recovered or that require temperatures and conditions for recycling that are incompatible with the materials used in the other parts within the design).

[0011] This increasing need for all-polymer or — more preferably — a single polymer dispensers with reciprocating components to suction, move, and/or dispense fluids means that partially or completely metallic biasing members are no longer acceptable. Accordingly, examples of plastic biasing members and/or mostly plastic dispensers can be found in Patent Cooperation Treaty publication WO 1994/020221; WO2018/126397; WO2022/038194; WO 2022/038199; and, as well as United States Patents 5,924,603; 9,016,527; 10,549,299; and 10,773,269 and United

States Patent Publications 2012/0000943; 2018/0318861 and 2021/0310469.

[0012] Of course, some of these publications contemplate large, conventional lotion pumps (i.e., reciprocating dispensers in which pre-compression and/or fine misting capabilities are not required). Given that these pumps deliver liquids or foams in a single, discrete dose (or “shot”), the wholesale adoption of teachings from these references is not always feasible for smaller fine mist dispensers. In particular and as just one non-limiting example, the size (diameter and/or height) and stiffness and spring constant (based on the selection of plastic material) required for replacing metallic coiled springs will necessarily be different, and plastic springs of similar/identical proportions cannot be substituted similarly sized metallic springs. The need to deliver consistent and complete fine mist doses on the first stroke only exacerbates that problem, and the tendency for plastics to degrade and lose stiffness over repeated uses makes the problem even worse. As yet another exemplary issue, fine mist sprayers are often associated with small container necks (in comparison to lotion and larger volume reciprocating pumps), which introduces additional design complications and necessitates the use of biasing members with comparatively small diameters.

[0013] An all-plastic and, more preferably, single-polymer design for dispenser capable of producing a fine mist is needed. More specifically, a fine misting dispenser with pre-compression functionality is of particular import. Further, a design with a compact footprint, in terms of its diameter being significantly smaller than its axial height, and a pump engine that dispenses mist along an axial or orthogonal orientations (relative to the axis of reciprocation) with minimal alterations to the housing/ actuator head and virtually no changes to the pump engine itself (i.e., the piston, biasing member, and closure) would enable broader adoption.

SUMMARY OF INVENTION

[0014] In its most fundamental form, the invention contemplates a fine mist-producing dispenser characterized primarily by its absence of metallic and thermoset polymeric components and, separately, the absence of any ball or flap valves. Instead, the inventors rely upon a plurality of strategically positioned wipers or sliding surfaces, provided on multiple different components, each of which is selected and positioned relative to the plastic spring so as to create a “dead stroke” during the very initial stages of actuation. This dead stroke minimizes or eliminates any perception of non-responsiveness because the dispensing event still occurs in the remainder of that initial downstroke.

[0015] The various inventive reciprocating dispensers contemplated herein produce precompression functionality while using only one single plastic biasing member, preferably constructed from the same non -thermosetting resin as the other major components of the pump (and without relying on elastomers or other materials that tend to be incompatible with recycling operations). Upper and lower pumping chambers are configured to have at least one upper and two or three lower wiper elements, all moving during the actuation stroke within their respective chambers. Significantly, an inner lower wiper element may be provided on or coupled to a “floating” piston or pin that seals and releases from cylindrical sealing formation on the lower housing. This lower housing defines a lower pumping chamber. While the upper wiper and piston move in concert during the downward actuation stroke, the movement of the upper wiper will temporarily fall out of synchronization in comparison to the piston (i.e., the piston will be temporarily displaced owing to pressure created in the dispensing channel) so as to produce precompression functionality. Notably, this configuration enables the use of a conventional sprayer head, in which dispensing is at an angle (preferably perpendicular) relative to the axis of reciprocation, or a nasal sprayer, in which dispensing is in line with that axis. In either instance, the fine misting dispensers herein do not require any valve elements other than the pin/piston and wiper surfaces.

DESCRIPTION OF THE DRAWINGS

[0016] Operation of the invention may be better understood by reference to the detailed description taken in connection with the following illustrations. These appended drawings form part of this specification, and any information on/in the drawings is both literally encompassed (i.e., the actual stated values) and relatively encompassed (e.g., ratios for respective dimensions of parts). In the same manner, the relative positioning and relationship of the components as shown in these drawings, as well as their function, shape, dimensions, and appearance, may all further inform certain aspects of the invention as if fully rewritten herein. Unless otherwise stated, all dimensions in the drawings are with reference to inches, and any printed information on/in the drawings form part of this written disclosure.

[0017] In the drawings and attachments, all of which are incorporated as part of this disclosure: [0018] Figure 1 is an isometric perspective view of a fine mist dispensing pump according to a first aspect of the invention.

[0019] Figure 2A is a cross sectional side view taken along a diameter of Fig. 1, while Figure 2B is an exploded view of the components contained in Fig. 2A. [0020] Figures 3 A through 3D are comparative, cross sectional side views of the sequence of actuation of the fine mist dispensing pump in Fig. 2A, with Fig. 3 A showing the pump in the rest position (i.e., fully extended), Fig. 3B showing the initial “dead stroke,” Fig. 3C illustrates the beginning of dispensing as sufficient pressure has accumulated to displace the sealing pin, and Fig. 3D shows the final downstroke (i.e., fully depressed) so as to engage decompression ribs and initiate the return stroke so that the biasing member fully extends the pump back to its original, rest position.

[0021] Figure 4 is a cross-sectional schematic view of a fine mist sprayer utilizing a single plastic bellows spring in combination with a dead stroke arrangement/positioning of the lower inner wiper in order to create an all-plastic, pre-compression fine mist pump.

[0022] Figure 5 is a perspective cross sectional view of isolated components of the pump engine and actuator head of the fine mist dispensing pump of Fig. 2A, with a darkened arrow highlighting the fluid flow path therethrough.

[0023] Figure 6 is a cross-sectional perspective view of the pump from Fig. 5, but with the plastic bellows spring omitted.

[0024] Figures 7A and 7B are cross sectional side views of alternative means of accommodating fluid flow through the “dead stroke” region, with the arrow in Fig. 7A indicating fluid flow during the return travel for the plunger and Fig. 7B indicating the sealed configuration

[0025] Figures 8 A, 8B, and 8C are cross sectional side views taken along a diameter of the pump, as shown in Fig. 1, each showing an alternative configuration and positioning for the multiple sliding seal surfaces, provided on a variety of different components (in comparison to the configuration shown in Fig. 2A and elsewhere herein), that may be used in combination with the “dead stroke” feature described herein. [0026] Figure 9A is an isolated cross sectional perspective view of the “dead stroke” region of the lower piston that is common to the pumps of Figs. 2A, 8A, 8B, and 8C, including the decompression ribs and return or make up air venting port, while Figures 9B and 98C show isolated cross sectional side views with the lower piston in the fully extended (Fig. 9B) and fully depressed (Fig. 9C) positions.

DETAILED DESCRIPTION OF EMBODIMENTS

[0027] Specific reference is made to the appended embodiments, drawings, and description, all of which disclose elements of the invention. While specific embodiments are identified, it will be understood that elements from one described aspect may be combined with those from a separately identified aspect. In the same manner, a person of ordinary skill will have the requisite understanding of common processes, components, and methods, and this description is intended to encompass and disclose such common aspects even if they are not expressly identified herein.

[0028] As used herein, the words “example” and “exemplary” mean an instance or illustration and, as such, are not intended to indicate a key or preferred aspect or embodiment. The word “or” should be construed as inclusive rather an exclusive, unless context suggests otherwise. For example, the phrase “A employs B or C,” includes any combination or permutation (e.g., A employs B; A employs C; or A employs both B and C). As another matter, the articles “a” and “an” are generally intended to mean “one or more” unless context suggest otherwise.

[0029] Similarly, “fine mist” means the liquid being dispensed is sufficiently broken up, by way of a nozzle or other known implements, so as to exit through the outlet only as small droplets (i.e., without any discernible stream or jet of liquid). Such fine mist may be widely dispersed as a large enveloping cloud, or it can be delivered in a more localized and directed cone or pattern (e.g., spray angles of at least 20° and approaching 170° and having exiting pressures well in excess of ambient conditions and sufficient to insure the droplets separate and disperse so as to fully break up any contiguous flow of liquid). More ideally, a user spraying a fine mist will perceive the output merely as increased moisture or humidity, without any immediate puddling. [0030] Understanding that the invention is particularly useful with elongated containers having a plunger that reciprocates along an axis, it will be understood that “axial” and “longitudinal” may be used synonymously, with both referring to a direction on or parallel to that axis (in some drawings, axial may also correspond to vertical or up/down directions). In contrast, “radial” or “transverse” are with reference to the axial direction, meaning an orthogonal relationship (in some drawings, radial may correspond to horizontal or left/right directions). Fluid enters the pump through an inlet oriented at one end of the pump, while flowing downstream from the inlet to an outlet positioned at a distal end of the plunger.

[0031] The small container neck sizes and inherent difficulties in the material properties, manufacturing limitations, and costs of recyclable polymeric resins make the development of a single polymer fine mist dispenser with pre-compression functionality incredibly difficult. Such fine mist sprayers require a low spring rate and a small package size (in comparison to lotion pumps, where the container neck diameter can be twice as large as those used for fine mist sprayers). Also, plastic springs are highly prone fatigue/ permanent set, meaning that stressors on the springs should be kept well below the yield strength so as to avoid permanent fatigue/damage/deleterious impacts on spring performance.

[0032] In fact, the inventors have discovered numerous issues that make it challenging to simply substitute a plastic spring for the metallic coil springs used in many prior art applications, including some of those noted in the background above. First and foremost, metals commonly used in compression or tension springs is sufficient resilient and durable to allow spring rates and dimensions that simply cannot be matched by conventional plastic materials. As a result, an identically proportioned plastic spring usually cannot match the performance of the metallic item it is intended to replace. In fact, most plastic springs tend to have a larger footprint, in terms of height and/or diameter so as to make it impractical, if not impossible, to accommodate the plastic spring within the space occupied by metallic springs. Designs that require two separate springs only exacerbate that problem.

[0033] Further, plastic materials tend to wear and degrade over time. The inventors have observed that plastic bellows springs, similar to the ones illustrated in the drawings, tend to lose their stiffness as they cycle through compression and extension and, within a comparatively small number of uses, a plastic spring having ideal characteristics for pre-compression will degrade to the point where it is not capable of producing the force required to sustain and fulfill the desired pre-compression function for which a misting dispenser might be designed.

[0034] “Effort to operate” (ETO) is another way of quantifying stiffness and the user experience in actuating a spring. Generally, it is desirable to minimize variation in the ETO, especially in mist sprayers where actuation travel lengths are short (in comparison to trigger or conventional reciprocating pumps). Specifically, this short travel means that even small variations in dimensions of a plastic spring can lead to large changes in ETO if spring rate is high (i.e., ETO = Kx, if K is big, small change in x will impact ETO).

[0035] In view of these challenges, the inventors realized, in order to create viable all -plastic fine mist dispensing pumps with pre-compression capabilities, it was necessary to reconfigure and move away from many of the components found in conventional fine mist pumps that rely on multiple springs and one or more ball valves (e.g., see United States patent publication 2012/0000943). In particular, they discovered that a sealing cylinder provided within the lower pump chamber is spaced apart from — but capable of eventually engaging and sealing to an inner lower wiper on or moving with the piston — will create a dead stroke at the beginning of each actuation event. This dead stroke is perceived as part of the normal, one-time actuation needed to produce a fine mist, so the user will not necessarily notice any difference (as compared to pumps that do not have pre-compression functionality, in which case several actuation strokes are needed to “prime” the various chambers before a fine mist can be dispensed).

[0036] In combination with this dead stroke, the dispenser requires a series of “wiper elements.” These elements are configured to slide axially along a selected portion of the inner surface(s) of the pump engine, thereby creating a hermetic seal. In turn, the volume of pumping chambers and/or the ability for liquid to be suctioned through the engine and propelled toward the outlet. Notably, in order to maintain the seal, the wipers will trace the outer circumference (usually circular/annular) around the element on which they are disposed, with the inner surface that is seal having a corresponding shape and diameter. The wipers may also be engineered to flex and/or create a known amount of friction, which in turn influences the characteristics of the actuation, spring force, and ultimately dispensing characteristics of the fine mist itself. By way of example and as will be described in greater detail below, the plunger attached to the actuation head may include upper wipers engaging the surface of the upper chamber and lower wipers on the upper element and/or the piston (or a component affixed to the piston). Notably, the upper element, the piston, and/or the plunger can and will move independently from during various stroke portions of the actuation cycle.

[0037] Also, it must be emphasized that the stiffness of the plastic spring, as well as the anticipated degradation of its stiffness as it is used over time, are important to the dead stroke. In essence, the dead stroke allows for pressure build up in the lower chamber so that, when the inner lower wiper seals the inlet defined by the sealing cylinder, sufficient pressure is achieved both to displace the piston relative to the plunger and to project fluid with sufficient force through the channel and outlet so as to reliably and repeatably produce the same quality and quantity of fine mist.

[0038] With reference to Figs. 1 through 9C, various aspects and embodiments of fine mist dispensing and nasal sprayers are disclosed. Importantly, all of these are made from all plastic parts and, more preferably, from a single grade of polymer (e.g., polyethylene) in order to comply with impending or existing regulatory requirements. It will be understood some components, features, and functions are common to all disclosed embodiments, while others may be substituted or eliminated. Any combination or permutation of these possibilities is expressly disclosed and encompassed, even if it is not yet expressly identified in a claim.

[0039] A fine mist dispenser 1 includes a plunger or actuator head 10 that travels along an axis of reciprocation A-A. Usually, axis A-A will be vertical and/or intersect the plane defined by the container neck (not shown, but to which the dispenser 1 is detachably coupled) at a perpendicular angle. All of the components of the dispenser are envisioned to be made from sustainable or recyclable polymeric materials and, more preferably, all should be made from the same grade and composition of material. Non-thermosetting resins, preferably selected from homopolymers and copolymers of polypropylene and/or polyethylene (including combinations thereof), should be particularly useful.

[0040] Also, as noted herein, the dimensions of the fine misting pump are particularly relevant. More specifically, fine misting and nasal sprayers tend to require much smaller container sizes (including the diameter of the neck) and axial or actuation travel ranges as compared to large lotion pumps and trigger sprayers. As such, a distinguishing characteristic of the inventive fine misting dispensers contemplated herein are a travel range for the reciprocating actuator that is less than 1.00 cm. Another distinguishing characteristic is that these dispensers will draw liquid through the inlet while outputting only a fine mist, preferably at a predetermined and repeatable dosing volume. When fine mist is projected along an axis that coincides with axis A-A, the dispenser may be referred to as a nasal sprayer. In contrast, when mist projected at an angle to that axis (and particularly at or close to a right angle), those dispenser designs may be referred to as a fine misting pump.

[0041] The dispenser 1 includes a reciprocating actuator head 10, an upper element or floating/main piston 20, an upper or top wiper element 30, an all-plastic (i.e., made only from nonthermosetting polymer(s)) bellow or biasing member 40, a cap or closure element 50, a bottom wiper element 60, and a lower element or housing 70. Each of these components will be described in greater detail below, although reference should be made to the drawings and other portions of the disclosure in order to fully appreciate the arrangement, operation, and potential alternatives for each of these elements. Also, when so configured, it will be understood these components impart the benefits and advantages of the invention, as identified herein. The system may also rely on optional elements, such as a snap-fitting overcap 2, a nozzle insert 111 (which cooperates with formations on the head to create swirl chamber and/or mi sting/ atomizing features), a sealing gasket 701, and/or a dip tube 702.

[0042] Actuating head 10 will reciprocate along axis A-A in response to downward force exerted by a user and upward force exerted by the biasing member 40. The reciprocal actuation cycle includes a down stroke (which itself is initiated with a dead stroke and finishes during a dispensing stroke), while the upward movement is the return stroke. Owing to the biasing member 40, the rest position causes the head 10 to be fully extended away from the closure 50.

[0043] The head 10 presents at the top of the dispenser 1. It defines an inner flow channel 13 that terminates at outlet 11. The channel 13 may be integrally formed only in the head 10 or, as shown, a plunger extension 101 may be snap-fitted to the head to extend the channel 13 in the axial direction. The outlet 11 is configured to dispense liquid as a fine mist, usually through the positioning of one or a plurality of swirl elements or formations in nozzle insert 111. In some aspects, the outlet 11 includes a nozzle or cup fitted onto a post, with the interstices between these elements defining flow channels that serve the same purposes as the swirl elements similar to those described in some of the documents noted in the background above, all of which are incorporated by reference. Generally speaking, the swirl elements are configured to cause the liquid to mix intimately and under pressure so that, when the mixture is expelled through the orifice defining the outlet 11, the liquid is broken into small droplets that effectively atomized and disperse the liquid as a fine mist.

[0044] The upper element or “floating” piston 20 defines an upper pump chamber 21. In some aspects, that chamber 21 may be surrounded by the axially-aligned sidewalls and bottom panel of the floating piston 20 (as may be the case for nasal sprayers), or the adjacent components may full enclose upper pump chamber 21. In either instance, chamber 21 is fluidically connected to the channel 13, meaning it is disposed between the outlet 11 and the inlet. The configuration of the chamber 21 allows it to coaxially receive the wiper element 30, so that its upper wiper elements 35 seal to and slide axially along the inner surfaces of the upper pump chamber 21.

[0045] In one aspect useful for fine mist dispensing pumps, the piston 20 can be formed from a hollow tubular body 22 characterized by a lower portion 23 and an upper engagement flange 24 that can cooperate with the upper end of the biasing member 40. An outer wiper element 25 is integrally formed or coupled to the lower portion 23. Wiper 25 can actually include two or more radially projecting formations, such as upper radial flange 25a and lower radial flanges 25b. The spacing of flanges 25a, 25b is such so that, when the actuator 10 is in the rest position, the vent aperture 56 will be positioned therebetween to prevent make-up air from entering the container. As will be described below, the vent 56 will do so during the actuating stroke because the upper flange 25a will travel below the elevation of the vent 56, thereby exposing it to ambient pressure/air through the interstices of the elements above it, although in some aspects (see Figs. 8A and 8C), only one of the wipers 25a or 25b needs to be provided, while other aspects can omit the vent 56 altogether (in these aspects, an “airless” system is created, in which the container volume shrinks, either through the use of a flexible/crushable container such as a bag or by way of providing a sliding piston element as the container bottom).

[0046] Vent apertures 56 penetrate the sidewall of the lower element 70 and cooperate with the wipers on the upper element 20 and/or piston 30 to insure that make up air is admitted during actuation. This arrangement avoids pressure differentials between the sealed container and the ambient environment.

[0047] The middle portion of the piston 20 has a hollow interior defining the chamber 21, possibly including a radial ledge 26 that serves as the floor and lower-most stopper for movement of the upper wiper 35 and/or other features on the top wiper 30/plunger extension 101. In this regard, it must be noted that the plunger extension 101 can be formed integrally as the top wiper 30 itself, so long as the sealing wiper 35 in the upper chamber 21 move in concert with the top wiper element 30 and, more importantly, independently from the piston 20.

[0048] In aspects of the fine mist nasal pump, the chamber 21 is defined by the walls 22, and radial groove is disposed at the midsection of the main piston 20 between the walls 22, the ledge 26, and a coaxial cylinder 27. The coaxial cylinder 27 only extends partially upward into the chamber 21, and groove 27 is sized to accommodate the wings 35 on the top element 30. Cylinder 27 is a hollow tube whose inner diameter receives and allows for the bottom wiper element 60 to slide axially therein.

[0049] The upper wiper element 30 is configured to move in concert with the plunger 10 throughout the actuation stroke. In some aspects, this top wiper 30 is snap-fitted or otherwise coupled into/along the interface where it meets the head 10 and defines the channel 13.

[0050] The biasing member 40 is made from polymeric resin(s) that is compatible with or identical those used to make other portions of the dispenser 1. In one form, it may take the shape of a bellows or helical coiled solid or perforated conical spring. The top end of the member 40 abuts the underside of flange 24 so as to urge the main piston 20 and the actuator 10 into an exended position; however, because the piston 20 and actuator 10 are not coupled together, these components may move in or out of synchronization, depending upon the stage of the actuation cycle. The bottom end of the member 40 abuts or is coupled to the lower housing 50, possibly by way of coupling formations 52 projecting radially inward on or as part/extension of the ledge 54. Examples of appropriate bellows 40 can be found in United States patent 5,924,603, United States patent publications 2017/0326567, and Patent Cooperation Treaty patent publications 2022/038194 and 2022/038199, all of which are incorporated by reference herein. However, it will be understood that the materials, dimensions (height, wall thickness, diameter, etc.), and other features of the bellows may need to be adjusted to obtain the ideal range of spring force for the pre-compression functionality described herein.

[0051] The closure element 50 couples to the container (not shown), which may be a convention hard-sided container with a narrow, threaded neck or collapsible soft-side vessel or bag. The lower closure cup 51 has a threaded skirt 55 configured to couple to the container. An optional cylinder 53 may extend above the annular panel or ledge 54 (which, along with the skirt 55, defines the cup 51) to conceal portions of the actuator head 10. Gasket 701 is positioned beneath the ledge 54 so that, as the closure 50 is tightened/affixed to the container, a good seal is formed and maintained.

[0052] In some aspects as seen in Figs. 7A and 7B, the lower housing 50 could be further characterized by a hollow tubular extension 58. Extension 58 includes an optional annular coupling groove that could receive portions of the lower element 70, while its hollow interior accommodates the lower wiper 60. More significantly, Fig. 7A illustrates an alternative fluid path F2 by which liquid enters the lower pre-compression pump chamber and the passes through an aperture 60a in the lower wiper to gain passage to the upper pump chamber (not shown in these views), whereas Fig. 7B demonstrates the point during the dispensing stroke (i.e., immediately after the dead stroke) when the inner wiper elements 61 contact the sealing cylinder 72. However, as noted above, this arrangement is merely indicated as an alternative, and the preferred arrangements are found in Figs. 2A, 4, 8A, 8B, and 8C.

[0053] A lower pump or pre-compression chamber 73 is defined by the inner facings of the sidewalls 76 on element 70. The chamber 73 is fluidically connected to the channel 13 and, by extension, the outlet 11 by way of an inlet defined by dip tube coupling skirt 75 and sealing cylinder 72.

[0054] A sealing cylinder 72 extends upward into the chamber 73. Preferably, the top edge of the cylinder 72a is tapered and terminates beneath (i.e., at an axial elevation equal to or less than) the vent aperture 56. As such, the cylinder 72 is coaxially aligned within the housing 70 on the axis A-A. The inner diameter of the cylinder 72 is radially inset from walls 76 by ledge/floor 74. The sizing of the cylinder 72 selected to receive the inner wiper element 61, which helps to create the desired pre-compression functionality by creating and then releasing pressure within the flow path as the actuation cycle proceeds. Notably, this arrangement eliminates the need for either a second biasing member or a ball or flap valve, thereby eliminating the costs and risks associated with these moving parts.

[0055] One or more decompression ribs 78 may protrude radially inward from the inner surfaces of the cylinder 54. Ribs 78 can be spaced even apart and terminate at the same elevation. In this manner, the lower end of the inner wiper 61 will engage the top edge of the ribs 78 to transition from down to upstroke (with upward movement induced when the user relaxes the downward/actuation force being exerted on the head 10). Ribs 78 release pressure and reset the head 10 for another actuation cycle.

[0056] A sealing pin portion 63 is provided as the inner most coaxial element traveling on axis A-A. The pin 63 may be integrally formed or coupled atop the bottom wiper element 60. As previously noted, element 60 moves independently from the upper element 30 during selected portions of the actuation cycle, so as to allow for the selective release of pressurized fluid into the channel 11 and out of the outlet 13.

[0057] The pin includes a stepped shoulder 64 traveling within the upper or pump chamber 21. Shoulder 64 sealingly engages the sides of the channel 11, although sufficient clearance is provides between the sidewalls of the pin and the upper element 30 and/or plunger 10 to allow for axial fluid flow therebetween.

[0058] The lower end element 60 includes an inner wiper element 61. This inner wiper 61 has similar characteristics as the other wipers 25a, 25b, 35 in terms of sealing to the inner surface (here, on the cylinder 72). In some of the aspects shown in Figs. 8 A and 8C, the inner wiper 61 may be surrounded by an integral outer wiper (Fig. 8A) in the lower pump chamber 73, or the wiper can be formed as a separate component coupled to the upper element 20 (Fig. 8C). In this regard, Fig. 8A is somewhat analogous to the concepts shown and discussed in Figs. 7A and 7B.

[0059] In terms of operation, the plunger 10 urges the upper wiper element 30 and the element/floating piston 20 downward during the actuation stroke, so as to build pressure in the lower pre-compression chamber 73. The top surface 64 is temporarily displaced by and when sufficient pressure is created so as to unseal the channel 13 and release fine mist through the outlet 11. While the elements 20, 30, 60 will move axially in comparison to the housing 50 (which remains fixed to the container), these movements may vary between elements and at various times during the actuation and return strokes. In this manner, these moving parts serve as de facto valves without the need for ball valves, flaps, or independent, spring-loaded mechanisms.

[0060] With particular reference to Figs. 3A to 3D, the four sequential stages of actuation or operation are shown. Fig. 3A illustrates a rest position, during which the pump is not operating and the biasing member fully extends the floating piston away from the closure and lower housing. Because the top wiper element can “bottom out” (i.e., come into contact with) a radial step inside the hollow surface of the piston, the upper surface of the pin blocks and seals the dispensing channel in the rest or fully extended position. Actuation occurs as the user presses and releases the actuator head, so that the biasing member compresses and the most of the components travel axially downward (i.e., toward the container). Upon release of the actuator head (or the pressure being exerted on it), the biasing member urges the components to travel axially upward (i.e., away from the container).

[0061] Fig. 3B represents the dead stroke phase of downward axial travel. Here, the user begins depressing the actuator head, which initially travels less than 3.0 mm and, more preferably, about 2.0 to 1.5 mm during this phase. This dead stroke increases pre-compression before opening the channel, thereby compensating for the preload decrease of the biasing member may natural experience over the course of extended actuations and/or at higher than normal temperature conditions. As implied by the name, no dispensing occurs during this phase. However, the lower wiper element seals the compression chamber to build pressure inside the system as actuation continues.

[0062] Fig. 3C shows the dynamic phase, including the dispensing stroke prior to/during which fine mist is ejected from the outlet, which also coincides with downward axial travel. Here, pressure continues to build within the compression chamber and the pump chamber until the pin becomes displaced (i.e., moves down, thereby opening the channel and releasing pressurized fluid out toward the outlet). The actuator head can travel about 7.0 mm, about 6. 0 mm, or preferably 5.6 mm during this dynamic phase. It will be understood that the biasing member is being compressed during this phase, which means the actuator head, the floating piston, and — at least until dosing/release — the sealing pin are all moving downward at the same time. Because dosing and dispensing occurs within the end stage of this dynamic phase, this can be referred to as the dispensing stroke.

[0063] Fig. 3D represents the release phase. Here, the pump continues its downward axial travel for a nominal distance, usually less than 1.0 mm and preferably about 0.8 mm. At that lowermost point of actuation (i.e., depression or axial travel of the actuator head), the inner wiper element engages the decompression ribs so break the inner seal, thereby releasing internal pressure and allowing for the pump to reset by virtue of the biasing member urging the plunger and its associated components upward. Thus, when the user ceases to press down on the actuator head, the biasing member will urge the piston upward through its return stroke, although here the top wiper element will not begin moving upward at the exact same time as the piston. [0064] In view of the foregoing, the invention generally contemplates a fine mist dispensing pump or nasal sprayer, either of which will exhibit pre-compression function by dispensing a dose at a predetermined volume and pressure. The dispenser does not contain any metllaic , elastomeric, or thermoset components, and it operates on an actuation cycle that includes a dead stroke, a dispensing stroke, and a return stroke. Notably, the dead and dispensing strokes occur as the actuator travels downward, while the return stroke is driven by a biasing member that urges the actuator upward. In this aspect, the invention includes an upper element defining an upper pump chamber; a plunger, coaxially received within the upper pump chamber, traveling along an axis of reciprocation and defining an outlet configured to dispense liquid as a fine mist during a dispensing stroke; an upper wiper element in contact with an inner surface of the upper pump chamber and configured to move: i) during a return stroke of actuation, and ii) in concert with the plunger; a lower housing, configured to coaxially receive portions of the upper element and the plunger, defining a lower pump chamber with an integral, coaxially aligned sealing cylinder extending upwardly into the lower pump chamber along the axis; a biasing member made from a polymeric material and configured to urge the plunger into an extended position relative to the lower housing during the return stroke; a piston, coaxially received the upper element, having a top end configured to seal a channel fluidically connecting the upper chamber to the outlet; a lower outer wiper element in contact an inner surface of the lower pump chamber; and a lower inner wiper element configured to selectively engage an inner surface of the sealing cylinder during portions of the dispensing stroke and during portions of the return stroke. This aspect may also include one or combination of the following, additional features: wherein the plunger urges the upper wiper element and the piston downward during a dead stroke; wherein the top end temporarily unseals the channel during the dispensing stroke to expel the fine mist from the outlet; wherein a plurality swirl elements are positioned around the outlet; wherein the swirl elements are formed on a nozzle element attached to the plunger at the outlet; wherein the plunger, the upper element, the upper wiper element, the biasing member, the lower housing, and the piston are all completely constructed from the same polymeric material; wherein the sealing cylinder includes one or more decompression ribs along an inner facing and wherein the inner lower wiper element comes into contact with at least one of the decompression ribs so as to transition from the actuation stroke to the return stroke; wherein the lower outer and lower inner wiper elements are integrally formed as part of the piston; further comprising a second lower outer wiper element in contact with the inner facing of the lower pump chamber, said second lower wiper element formed integrally on the upper element; wherein the lower outer wiper element is integrally formed as part of the upper element; wherein the lower inner wiper element is integrally formed as part of the piston; further comprising a second lower outer wiper element in contact with the inner facing of the lower pump chamber, said second lower wiper element formed integrally on the upper element; wherein the lower wiper element and the second lower wiper element are axially spaced apart; further comprising a make-up air aperture provided in lower pump chamber; and wherein the lower outer wiper element is positioned at an axial elevation so that the lower outer wiper element passes over the make-up air aperture twice during a single actuation cycle.

[0065] Another aspect encompasses a fine mist dispensing pump or nasal sprayer. The pump/sprayer comprises a reciprocating actuator head including a fine misting outlet; a top wiper element, defining an interior channel fluidically connected to the outlet, having a upper wiper element disposed at an opposing end from where the top wiper element is coupled to the actuator head; a floating piston having a hollow tubular body with an outer wiper element disposed at a lower portion and a pump chamber defined along a middle interior portion, wherein the pump chamber is: i) configured to coaxially and slidably receive the top wiper element and ii) fluidically connected to the channel; a pin coaxially and slidably received within the lower portion of the floating piston, the pin having a inner wiper element disposed at a lower surface and an upper surface that extends into the pump chamber and is configured to selectively seal the channel in the top wiper element; a lower housing having a hollow tubular extension defining a pre-compression chamber that is fluidically connects to: a) the channel and b) an inlet disposed at a lower end of the extension, and wherein a sealing cylinder extends upward into the pre-compression chamber from the lower end; and a biasing member made from a non-thermoset polymeric material and positioned to urge the lower housing away from the floating piston. The actuator head includes an abutting surface. When the pump is actuated, the abutting surface engages the floating piston and a lower most edge of the inner wiper temporarily seals to an inner surface of the sealing cylinder. This aspect may also include one or combination of the following, additional features: wherein the lower housing includes a vent aperture positioned through a sidewall at an elevation that is above a top edge of the sealing cylinder; wherein the outer wiper element comprises an upper radial flange and a lower radial flange, with the upper and lower radial are spaced apart so that the vent aperture is positioned therebetween when the pump is in a rest position; wherein components consisting of the biasing member, the lower housing, the pin, the floating piston, the top wiper element, and the reciprocating actuator head are all made from the non-thermoset polymeric material; wherein the non-thermoset polymeric material is any one or combination of: homopolymers and copolymers of polypropylene, homopolymers and copolymers of polyethylene, and any combination thereof; wherein the components are all made from the same composition and grade of nonthermoset polymeric material; wherein the lower housing includes or is formed integrally with a closure cap; wherein the sealing cylinder includes decompression ribs along the inner surface; wherein a nozzle insert having swirl formations is disposed at the outlet; wherein an axial range of travel for the reciprocating actuator head is less than 1.00 cm; and wherein the outlet is configured to project a fine mist spray along an axis that is at an angle in comparison to a travel axis for the reciprocating actuator head. [0066] As noted in the background above, United States Patents 5,819,990 and 5,924,603 Patent Cooperation Treaty Publications WO 2022/038194 and WO 2022/038199 disclose particularly useful and advantageous designs for the biasing member. Therefore, the illustration of a bellows-style biasing member in the appended drawings should not be construed as limiting the broadest aspects of the invention.

[0067] All components should be made of materials having sufficient flexibility and structural integrity, as well as a chemically inert nature. The materials should also be selected for workability, cost, and weight. Common polymers amenable to injection molding, extrusion, or other common forming processes should have particular utility. Polypropylene and polyethylene may be particularly advantageous, especially in providing single-polymer designs, although polypropylene is stiffer in comparison and provides for different aesthetic appearances (e.g., ability to make translucent components).

[0068] Critically, owing to legislative trends and consumer demands, the entirety of any dispenser is desirably made from recyclable materials and,, more ideally, all from a single grade of polymer, selected specifically for its low cost, durability, and non-toxicity. In this manner, the entirety of the dispenser can be recycled. As noted elsewhere herein, polypropylene (and more rigid grades of polyethylene) may be particularly well-suited. As used herein, single grade of polymer refers to the specific resin used in the molding or manufacturing process and, as such, should not be construed as limited to a single chemical species. Thus, to the extent some common injection-molding grades of resin may rely on copolymers or blends of materials, “single grade” is intended to cover such materials. In short, the emphasis is on selecting sustainable and easily recycled grades of resins, and then employing these resins in every component of the dispenser pump. Elastomers and other difficult-to-recylce grades of polymers, as well as pump designs that require metallic, glass, and other non-polymeric components must be avoided.

[0069] As documented in the references incorporated above, creation of specific components from the same grade of material is challenging. For example, the biasing member must be sufficiently strong but resilient to sustain thousands of actuation strokes. Conversely, the pump cylinder (and components coming into contact with it) must be strong but sufficiently low friction enough to minimize actuation force, achieve the desired ETO, and improve user experience. Still further, the actuator and closure must be non-reactive (relative to both the dispensed fluid and ambient environment) and capable of maintaining a water-tight seal, including valves and dispensing/fluid flow path channels. Thus, elastomers, low-density polyethylene, and other polymers and copolymers normally used in specific components for mixed-source pumps (i.e., pumps having a metallic spring and/or different grades and types of polymers/copolymers) may not be viable.

[0070] In one example, a conventional misting pump relying upon a ball valve and metallic spring was compared against two versions of the inventive pump according to the embodiment shown in Fig. 2A. The conventional pump had a comparatively smaller inner diameters within the pump chambers most analogous to the lower (3.05 mm vs. 3.75 to 4.00 mm) and (3.75 mm vs. 4.50 to 5.00 mm) chambers of the inventive designs, although all the pumps employed an axial travel/compression distance of about 0.5 mm. Also, the conventional pump had a smaller outlet valve diameter (0.7 mm vs. 0.9 mm) that required about 20% less force to open that port (16.1 N vs. 19.3 to 21.1 N) and overall ETO operation force (18.4 N vs 23.3 to 25.7 N). Nevertheless, the conventional pumps 30% less output pressure (27 Kpa for the conventional pump vs. 37 Kpa for the inventive pump), thereby suggesting excellent pre-compression performance that should produce high quality, consistent fine mist. According to some aspects, the inventive pump can achieve pressures of up to 45 to 60 Kpa during pre-compression (i.e., at the dead stroke and immediately before ejecting mist in the dispensing stroke).

[0071] For the sake of clarity, as used herein, dead stroke refers to that portion of the actuation in which some components are moving relative to one another without necessarily inducing movement in the valve immediately upstream from the outlet. As such, the dead stroke, when implemented in conjunction with the various sliding surfaces and pump chambers disclosed, enables and sustains prolonged pre-compression via a single plastic spring. Further, insofar as the dead stroke does not open or close a valve (whether adjacent to the outlet or at the inlet into a pump chamber), it must be distinguished from designs where a reservoir is initially filled, as is the case in some of the trigger sprayers noted in the background above.

[0072] All components of the pump dispenser should be made of materials having sufficient flexibility and structural integrity, as well as a chemically inert nature. Certain grades of polypropylene and polyethylene are particularly advantageous, especially in view of the absence of any thermosetting resins, elastomeric polymer blends, and other chemically distinct polymers or copolymers (in comparison to the other components of the dispensing pump). Notably, high density polyethylene (i.e., having a density of greater than 0.940 g/cm³) possesses certain advantages over lower density polyethylene types (e.g., medium density at 0.925 to 0.940 g/cm³ and/or lower density at 0.880 to 0.925 g/cm³), as well as allowing for consideration of other specialized, stiffer versions capable of cross-linking.

[0073] References to coupling in this disclosure are to be understood as encompassing any of the conventional means used in this field. This may take the form of snap- or force fitting of components, although threaded connections, bead-and-groove, and slot-and-flange assemblies could be employed. Adhesive and fasteners could also be used, although such components must be judiciously selected so as to retain the recyclable nature of the assembly.

[0074] In the same manner, engagement may involve coupling or an abutting relationship. These terms, as well as any implicit or explicit reference to coupling, will should be considered in the context in which it is used, and any perceived ambiguity can potentially be resolved by referring to the drawings.

[0075] References sealing or being in a sealed state means that interfacing components are in sufficient and intimate contact to prevent unwanted fluid flow across that interface. These fluids may be liquid (e.g., dispensed fluids) or gaseous (e.g., make-up air). These seals can be temporary, as is the case with sliding seals on the piston, so that the interfacing surfaces are capable of sliding over/across one another. In other instances, the seal is intended to be permanent, so that the aforementioned coupling arrangements or force fittings created by a “plug seal” arrangement (in which an edge or flange is forced fitted into a gap on the other component) are effective and appropriate. In the drawings, it will be understood that sealing features are or may need to be employed, particularly in those areas where a non-linear interface appears.

[0076] Although the present embodiments have been illustrated in the accompanying drawings and described in the foregoing detailed description, it is to be understood that the invention is not to be limited to just the embodiments disclosed, and numerous rearrangements, modifications and substitutions are also contemplated. Any patents identified in this document are incorporated by reference to provide further details informing aspects of the background and aspects of the invention itself. The exemplary embodiment has been described with reference to the preferred embodiments, but further modifications and alterations encompass the preceding detailed description. These modifications and alterations also fall within the scope of the appended embodiments or the equivalents thereof.

Claims

CLAIMS What is claimed is:

1. A pre-compression, fine mist dispenser containing no metallic or thermoset polymeric components and operating on an actuating cycle defined by a dead stroke, a dispensing stroke, and a return stroke, the dispenser comprising: an upper element defining an upper pump chamber; a plunger, coaxially received within the upper pump chamber, traveling along an axis of reciprocation and defining an outlet configured to dispense liquid as a fine mist during a dispensing stroke; an upper wiper element in contact with an inner surface of the upper pump chamber and configured to move: i) during a return stroke of actuation, and ii) in concert with the plunger; a lower housing, configured to coaxially receive portions of the upper element and the plunger, defining a lower pump chamber with an integral, coaxially aligned sealing cylinder extending upwardly into the lower pump chamber along the axis; a biasing member made from a polymeric material and configured to urge the plunger into an extended position relative to the lower housing during the return stroke; a piston, coaxially received the upper element, having a top end configured to seal a channel fluidically connecting the upper chamber to the outlet; a lower outer wiper element in contact an inner surface of the lower pump chamber; a lower inner wiper element configured to selectively engage an inner surface of the sealing cylinder during portions of the dispensing stroke and during portions of the return stroke; wherein the plunger urges the upper wiper element and the piston downward during a dead stroke; and wherein the top end temporarily unseals the channel during the dispensing stroke to expel the fine mist from the outlet.

2. The dispenser of claim 1 wherein a plurality swirl elements are positioned around the outlet.

3. The dispenser of claim 1 or 2 wherein the swirl elements are formed on a nozzle element attached to the plunger at the outlet.

4. The dispenser of any one of claims 1 to 3 wherein the plunger, the upper element, the upper wiper element, the biasing member, the lower housing, and the piston are all completely constructed from the same polymeric material.

5. The dispenser of any one of the preceding claims wherein the sealing cylinder includes one or more decompression ribs along an inner facing and wherein the inner lower wiper element comes into contact with at least one of the decompression ribs so as to transition from the actuation stroke to the return stroke.

6. The dispenser of any one of the preceding claims wherein the lower outer and lower inner wiper elements are integrally formed as part of the piston.

7. The dispenser of claim 6 further comprising a second lower outer wiper element in contact with the inner facing of the lower pump chamber, said second lower wiper element formed integrally on the upper element.

8. The dispenser of any one of the preceding claims wherein the lower outer wiper element is integrally formed as part of the upper element and wherein the lower inner wiper element is integrally formed as part of the piston.

9. The dispenser of claim 8 further comprising a second lower outer wiper element in contact with the inner facing of the lower pump chamber, said second lower wiper element formed integrally on the upper element, and wherein the lower wiper element and the second lower wiper element are axially spaced apart.

10. The dispenser of any one of the preceding claims further comprising a make-up air aperture provided in lower pump chamber and wherein the lower outer wiper element is positioned at an axial elevation so that the lower outer wiper element passes over the make-up air aperture twice during a single actuation cycle.

11. A fine mist dispensing pump comprising: a reciprocating actuator head including a fine misting outlet; a top wiper element, defining an interior channel fluidically connected to the outlet, having a upper wiper element disposed at an opposing end from where the top wiper element is coupled to the actuator head; a floating piston having a hollow tubular body with an outer wiper element disposed at a lower portion and a pump chamber defined along a middle interior portion, wherein the pump chamber is: i) configured to coaxially and slidably receive the top wiper element and ii) fluidically connected to the channel; a pin coaxially and slidably received within the lower portion of the floating piston, the pin having a inner wiper element disposed at a lower surface and an upper surface that extends into the pump chamber and is configured to selectively seal the channel in the top wiper element; a lower housing having a hollow tubular extension defining a pre-compression chamber that is fluidically connects to: a) the channel and b) an inlet disposed at a lower end of the extension, and wherein a sealing cylinder extends upward into the pre-compression chamber from the lower end; a biasing member made from a non-thermoset polymeric material and positioned to urge the lower housing away from the floating piston; and wherein the actuator head includes an abutting surface and, when the pump is actuated, the abutting surface engages the floating piston and a lower most edge of the inner wiper temporarily seals to an inner surface of the sealing cylinder.

12. The pump of claim 11 wherein the lower housing includes a vent aperture positioned through a sidewall at an elevation that is above a top edge of the sealing cylinder.

13. The pump of claim 12 wherein the outer wiper element comprises an upper radial flange and a lower radial flange, with the upper and lower radial are spaced apart so that the vent aperture is positioned therebetween when the pump is in a rest position.

14. The pump of any one of claims 11 to 13 wherein components consisting of the biasing member, the lower housing, the pin, the floating piston, the top wiper element, and the reciprocating actuator head are all made from the non-thermoset polymeric material.

15. The pump of claim 14 wherein the non-thermoset polymeric material is any one or combination of: homopolymers and copolymers of polypropylene, homopolymers and copolymers of polyethylene, and any combination thereof.

16. The pump of claim 14 or 15 wherein the components are all made from the same composition and grade of non-thermoset polymeric material.

17. The pump of any one of claims 11 to 16 wherein the lower housing includes or is formed integrally with a closure cap.

18. The pump of any one of claims 11 to 17 wherein the sealing cylinder includes decompression ribs along the inner surface.

19. The pump of any one of claims 11 to 18 wherein a nozzle insert having swirl formations is disposed at the outlet.

20. The pump of any one of claims 11 to 19 wherein an axial range of travel for the reciprocating actuator head is less than 1.00 cm.

21. The pump of any one of claims 11 to 20 wherein the outlet is configured to project a fine mist spray along an axis that is at an angle in comparison to a travel axis for the reciprocating actuator head.