DIAPHRAGM-STYLE BOTTLE PUMP

Abstract

A diaphragm bottle pump system for dispensing a personal care product includes a bottle, a pump body, and a plurality of valves. The bottle holds the product. Further, the pump body includes a lower pump body and an upper pump body that define a diaphragm chamber therebetween that is acted on by a diaphragm. A first valve allows the product to pass from the bottle to the diaphragm chamber and prevents the product from passing to the bottle from the diaphragm chamber. A second valve allows the product to pass from the diaphragm chamber to an outside of the system and prevents the product from passing to the diaphragm chamber from the outside of the system. Additionally, a third valve allows air to pass from the outside of the system to the bottle and prevents the air from passing to the outside of the system from the bottle.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a diaphragm-style bottle pump.

2. Description of the Related Art

Commercialized personal care products can be sold in a bottle having a pump attached thereto. Conventionally, such bottle pumps are vertically-oriented positive displacement pumps. These pumps must be actuated in a linear fashion along the vertical axis. Conventional vertical displacement pumps generally extend well above the top of a bottle to which they are attached. Additionally, such conventional pumps have many components, generally including a piston and a return spring. The conventional pumps can also include a closure, piston, piston seal, actuator, sometimes ball valves, and thus can be difficult and expensive to produce and assemble. Further, conventional pumps generally include metal components, which can become corroded and contaminate the product dispensed from the bottle.

SUMMARY OF THE INVENTION

The present invention relates to a diaphragm bottle pump system for dispensing a fluid personal care product. The system includes a bottle, a pump body, and a plurality of valves. The bottle holds the product. A lower pump body is attached to the bottle and has an air inlet. An upper pump body is attached to the lower pump body and has a flexible diaphragm positioned on a top part thereof. Further, the lower pump body and the upper pump body define a diaphragm chamber therebetween. A first valve allows the product to pass from the bottle to the diaphragm chamber and prevents the product from passing to the bottle from the diaphragm chamber. A second valve allows the product to pass from the diaphragm chamber to an outside of the system and prevents the product from passing to the diaphragm chamber from the outside of the system. Additionally, a third valve allows air to pass from the outside of the system to the bottle and prevents liquid from escaping the bottle.

A method of dispensing a personal care product according to the present invention comprises holding the product in a bottle attached to a diaphragm pump including a diaphragm in an original position on a top of the diaphragm pump. The diaphragm is pressed a first time such that the diaphragm is changed from the original position to a depressed position to expel air from a diaphragm chamber through a first valve. The expelled air is prevented from returning to the diaphragm chamber from the outside of the diaphragm pump through the first valve. Then, the diaphragm is released a first time such that the diaphragm returns to the original position from the depressed position to create a negative pressure in the diaphragm chamber. By releasing the diaphragm, the product is drawn from the bottle to the diaphragm chamber through a second valve. The drawn product is prevented from returning to the bottle from the diaphragm chamber through the second valve. During the uptake phase ambient air enters the bottle through a third valve to equalize pressure. Additionally, the drawn air and the product in the bottle are prevented from passing through the third valve to the outside of the bottle. Further, the diaphragm is pressed a second time such that the diaphragm is changed from the original position to the depressed position to expel the drawn product held in the diaphragm chamber to the outside of the diaphragm pump through the first valve.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:

FIG. 1 is a perspective view of an exemplary embodiment of the bottle pump;

FIG. 2 is a top view of an exemplary pump;

FIG. 3 is a bottom view of an exemplary pump;

FIG. 4 is a sectional side view of an exemplary pump;

FIG. 5 is a front view of an exemplary pump;

FIG. 6 is an exploded view of an exemplary pump;

FIG. 7 is an assembled view of the exemplary pump shown in FIG. 6;

FIG. 8 is an perspective view of an exemplary pump;

FIG. 9 is a sectional side view of an exemplary pump;

FIG. 10 is a sectional side view of an exemplary pump;

FIG. 11 is a sectional side view of an exemplary pump; and

FIG. 12 is a sectional side view of an exemplary pump.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Certain terminology may be used in the following description for convenience only and is not limiting. The words “top,” “bottom,” “above,” “below,” “lower,” and “upper” designate directions in the drawings to which reference is made. The terminology includes the words noted above as well as derivatives thereof and words of similar import. Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views.

FIG. 1 shows an exemplary embodiment of the diaphragm-style bottle pump 10 (hereinafter “pump 10”), which is a positive displacement pump. The pump 10 can be attached to a bottle 20 to form a system to dispense personal care products. The bottle 20 can contain a product to be dispensed, such as shampoo, conditioner, lotion, or other skin or facial care products. The bottle 20 could also be used to dispense soap, such as hand soap. The pump 10 can be engaged with the bottle 20 via male and female threads or the pump 10 can be snap fit on the bottle 20. Such a snap fit may be preferable as the orientation of the pump 10 with respect to the bottle 20 can be adjusted without compromising the seal formed between the pump 10 and the bottle 20. Thus, the connection of the pump 10 to the bottle 20 can create an atmospherically closed system such that the product does not escape the system other than in the intended manner through the outlet valve 62 described below. The pump 10 and the bottle 20 can be disposable. Alternatively, the pump 10 can be reusable either with the same bottle 20 or with a new bottle 20 attached thereto.

FIG. 2 shows an exemplary embodiment of the pump 10. The pump 10 includes a diaphragm 30 on a top portion thereof. The diaphragm can be made of, for example, a thermoplastic elastomer or a thermoset elastomer. An exemplary thermoplastic elastomer from which the diaphragm 30 can be made is DYNAFLEX® G2701-1000-02 produced by GLS Corporation. The diaphragm 30 can be non-transparent or at least a portion of the diaphragm 30 can be translucent such that the user can see the product through the translucent portion of the diaphragm 30. The diaphragm 30 can have an oval shape. Further, the minor axis of the oval can be approximately the width of a user's thumb. Thus, due to the size, shape, and material composition of the diaphragm 30, the diaphragm 30 can be easily pressed by the user.

FIG. 3 shows the bottom view of an exemplary embodiment of the pump 10. As will be discussed in greater detail below, the pump 10 includes an air valve 34 that allows air to enter the bottle 20. The air valve 34 is a one-way valve that can be, for example, an umbrella valve or a mushroom valve preferably made of silicone. The air valve 34 could also be a ball and spring valve. Because the air valve 34 is a one-way valve, air can be drawn into the bottle 20 but air cannot escape and the product cannot spill out of the bottle 20 through the air valve 34. The pump 10 also includes a dip tube 38 that serves as a passageway for the product to be dispensed to enter the diaphragm chamber 42 (see FIG. 4) from the bottle 20. Thus, the dip tube 38 can extend downward from the pump 10 into the bottle 20. The dip tube 38 can be made of a linear low-density polyethylene, for example. In another exemplary embodiment, the dip tube could also be injected with the body to reduce assembly. FIG. 3 also shows a product outlet 46 from which the product is ultimately dispensed from the pump 10 to the user.

FIG. 4 is a side section view of an exemplary embodiment of the pump 10. The grooves 50 in the pump 10 can be used to attach the pump 10 to the bottle 20. As discussed above, the grooves 50 could contain the male or female thread, or could have a lip or a groove that is used to snap fit the pump 10 and the bottle 20 together.

The pump 10 includes an air inlet 54 that is upstream of the air valve 34. The air inlet 54 communicates with an outside of the pump 10 such that air can be drawn in through the air inlet 54, pass through the air valve 34 positioned downstream of the air inlet 54, and then enter the bottle 20.

As can be seen in FIG. 4, a product valve 58 is positioned downstream of the dip tube 38. The product valve 58 is a one-way valve that allows the product to be dispensed to pass therethrough into the diaphragm chamber 42. Thus, the product valve 58 does not allow any air or product to pass from the diaphragm chamber 42 back into the dip tube 38 or the bottle 20. The product valve 58 can be a flapper valve as shown in FIG. 9 or a duck bill valve The product valve 58 can be made of, for example, an elastomer, such as the thermoplastic elastomer that comprises the diaphragm 30.

The diaphragm chamber 42 is a pump chamber that is formed downstream of the product valve 58. The diaphragm chamber 42 comprises the area under the diaphragm 30 and is bounded by the body of the pump 10. The diaphragm chamber 42 includes an entrance from the product valve 58 and an exit to the product outlet 46.

Downstream from the diaphragm chamber 42 is the product outlet 46. FIG. 9 shows the path the product takes from the diaphragm chamber 42 to the product outlet 46. An outlet valve 62 is housed in the product outlet 46. The outlet valve 62 is another one-way valve that allows the product to be dispensed from the product outlet 46 without drawing air or dispensed product from outside the pump 10 back into the pump 10. The outlet valve 62 can also be a flapper valve or a duck bill valve that is made of, for example, an elastomer. Further, the outlet valve 62 can be held in the product outlet 46 by an outlet cap such as a hinged fixture 66. The hinged fixture 66 can be positioned on an end of the product outlet 46 such that that outlet valve 62 is fixed by the outlet cap 66 with respect to the product outlet 46.

FIG. 5 is a front view of an exemplary embodiment of the pump 10. As discussed above, air can enter the pump 10 through the air inlet 54 and the product can be dispensed from the product outlet 46 by passing through the outlet valve 62 and the outlet cap 66.

Operation of the pump 10 will now be described with reference to FIG. 4.

As discussed above, the diaphragm 30 can be approximately the width of a user's thumb. Thus, a user can hold the bottle 20 in his or her hand and operate the pump 10 by pressing the diaphragm 30 with his or her thumb. Accordingly, the pump 10 is convenient to use with a single hand. Alternatively, the user can set the bottle 20 on a support, such as a table top, and press the diaphragm 30 with one or more of their fingers.

When the user presses the diaphragm 30, as shown in FIG. 1, in the downward direction, the diaphragm 30 is moved from the original position to a depressed position in which the diaphragm 30 decreases the size of the diaphragm chamber 42 such that the contents of the diaphragm chamber 42 are expelled through the product outlet 46 to an outside of the pump 10. Thus, pressing the diaphragm 30 exerts a force on the contents of the diaphragm chamber 42 that is sufficient to expel the contents through the outlet valve 62. The exerted force can be, for example, about four to eight pounds. As discussed above, the product valve 58 is a one-way valve that does not allow the contents of the diaphragm chamber 42 to pass through the product valve 58 back into the dip tube 38 and the bottle 20. Thus, the first time the diaphragm 30 is pressed, air in the diaphragm chamber 42 will pass through the outlet valve 62.

In the exemplary embodiment shown in FIG. 4, the diaphragm chamber 42 is angled such that it is raised on the outlet side. This helps evacuate air during the initial priming.

Once the user releases the diaphragm 30 from its depressed position, the elastic diaphragm 30 will attempt to return to its original shape. Additionally, the pump 10 may contain a semi-rigid support structure, such as the fingers 70 positioned under the diaphragm 30, that contacts the diaphragm 30 and are deflected when the diaphragm 30 is pressed. In one exemplary embodiment, the fingers 70 only come in contact with the diaphragm 30 after the diaphragm 30 is pressed. Then, when the diaphragm 30 is released, the elasticity of the fingers 70 produces an upward force on the diaphragm to help return the diaphragm 30 to its original position. Thus, a conventional metal spring is not required to return the diaphragm 30 to its original position. Accordingly, corrosion can be avoided in the pump 10.

Alternatively, the diaphragm 30 may be provided with a means for assisting return of the deformed diaphragm 30 to its original position such as by a spring. Exemplary embodiments of the spring include a helical spring 86 as shown in FIG. 10 or an eye-shaped spring 90 as shown in FIG. 11. In an exemplary embodiment, a cantilevered structure could be molded to the bottom half of the diaphragm cavity 42 and help return the deformed diaphragm 30 to its original position. Additionally, the thickness of the diaphragm 30 can be biased in certain regions to help return the deformed diaphragm 30 to its original position. For example, the diaphragm 30 could be thicker around the perimeter and thinner in the center.

As the diaphragm 30 returns to its original position, a reduced pressure is created in the diaphragm cavity 42. Because the outlet valve 62 is a one-way valve that prevents anything from entering the diaphragm cavity 42 through the outlet valve 62, the partial vacuum due to the negative pressure is filled by drawing in the contents of the dip tube 38 through the product valve 58 into the diaphragm cavity 42.

If the pump 10 has not been previously used, then one or more strokes will likely be required to prime the pump 10. These initial priming strokes of the diaphragm 30 draw the air out of the dip tube 38, such that a strong enough vacuum is created to draw the product to be created up through the dip tube 38 into the diaphragm cavity 42. For example, a vacuum of four pounds per square inch could draw the product into the diaphragm cavity 42.

Because the product is drawn up into the dip tube 38 and then passed through the product valve 58, a reduced pressure is created in the bottle 20. Thus, as the diaphragm 30 is released and returning to its original position, the vacuum due to the reduced pressure created in the bottle 20 causes air to be drawn into the bottle 20 through the air inlet 54 and the air valve 34 to equalize the internal pressure of the bottle 20 with the outside atmosphere.

Thus, repeated pressing and releasing of the diaphragm 30 will cause the product in the bottle 20 to pass into the diaphragm chamber 42 via the dip tube 38 and then be dispensed from the product outlet 46. Additionally, air will be drawn into the bottle 20 via the air inlet 54 to replace the dispensed product. Accordingly, because it can be automatically ventilated during use, the bottle 20 can be a solid bottle that can stand on its own and is not required to contract when the product is removed from the bottle 20. Thus, a pump 10 and bottle 20 that is convenient to use can be provided.

The diaphragm 30 can be pressed from many different angles in many different directions. Thus, the pump 10 can be actuated in a non-linear and off-axis fashion that deviates from the vertical actuation of conventional pumps and resulting in improved ergonomics.

In an exemplary embodiment, the pump 10 can include a lever 94 to shut off passage of the product from the dip tube 38 to the diaphragm chamber 42. As can be seen in FIG. 12, the lever 94 can fit between the upper half of the pump body 74 and the lower half of the pump body 78. Further, the lever 94 includes a portion that projects outside of the pump body 74, 78 to allow the lever 74 to be rotated between an open position and a closed position. In the open position, product can be dispensed as discussed above. In the closed position, the lever 94 blocks the dip tube 38 to prevent the product from passing from the dip tube 38 to the diaphragm chamber 42 when the diaphragm 30 is pressed. Thus, accidental discharge of the product can be prevented.

As discussed above, the pump 10 can be used with a personal care product. Accordingly, regulating the amount of each dose may be important. When the diaphragm 30 is the size of a thumb, the product dosage amount for every non-priming pump is approximately less than 3.6 milliliters and more than 1 milliliter. Preferably, the dosage amount is two milliliters. Other dosage amounts can be achieved depending on the size and shape of the diaphragm 30 and the diaphragm chamber 42. The size and shape of the pump 10 can be adjusted to achieve a target dosage that depends on the product to be dispensed.

FIG. 6 shows an exploded view of an exemplary embodiment of the pump 10 and FIG. 7 shows the pump 10 for FIG. 6 in an assembled view. To assemble the pump 10, the diaphragm 30 is inserted into the underside of the upper half of the pump body 74. Alternatively, the diaphragm 30 can be co-molded with the upper half of the pump body 74. The outlet valve 62 is held against the pump body 74 by the outlet cap 66 attached thereto. Additionally, as can be seen in the exemplary embodiment shown in FIG. 8, a backplate 82 can be positioned upstream of the outlet valve 62 (not shown in FIG. 8) to help prevent air from entering the diaphragm chamber 42 through the outlet valve 62 on the upstroke. The product valve 58 is held to the lower half of the pump body 78 by the dip tube 38. Further, the air valve 34 is also attached to the lower half of the pump body 78. Then, the upper half of the pump body 74 is attached to the lower half of the pump body 78 via snap fit, heat stake or threading. The upper half of the pump body 74 and the lower half of the pump body 78 can be molded of, for example, polypropylene and thermoplastic elastomer. Alternatively, the upper half of the pump body 74 and/or the lower half of the pump body 78 can be made by another suitable material or by another suitable process. The upper half of the pump body 74 and the lower half of the pump body 78 can be molded in a single piece, and can be connected by a hinge. When the upper half of the pump body 74 and the lower half of the pump body 78 are molded in a single piece, they can be snap fit together. The lower half of the pump body 78 can include two stacked annular rings, and one of the rings may be molded with the elastomer to form a critical seal between the two halves of the pump body. The above-described order of assembly in a non-limiting order of assembly and the pump 10 can be assembled in a different order without departing from the scope of the present invention.

Accordingly, it can be seen that the pump 10 does not require many parts. Thus, assembly of the pump 10 is easier and less costly than conventional vertical displacement pumps.

Additionally, because a diaphragm 30 is used instead of the conventional vertical displacement pump, the pump 10 requires minimal height to function, and thus is a discrete addition to the top of the bottle 20. As discussed above, such a pump 10 can also allow the product in the bottle 20 to be dispensed with one hand. Such a product can have a viscosity of up to 28,000 centipoise or higher. Additionally, a minimum viscosity can be, in an exemplary embodiment, around 20,000 centipoise.

Further, because the pump 10 uses the diaphragm 30, which is not pressed against any sliding parts, there can be less frictional losses than in conventional pumps. Accordingly, the pump 10 can require less force to actuate.

Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.

Claims

1. A diaphragm bottle pump system to dispense a personal care product, comprising:

a bottle that holds the product;

a lower pump body attached to the bottle and having an air inlet extending through the lower pump body;

an upper pump body attached to the lower pump body and having a diaphragm positioned on a top part of the upper pump body, the lower pump body and the upper pump body defining a diaphragm chamber therebetween;

a first valve that passes the product from the bottle to the diaphragm chamber when the diaphragm returns to an original position from a depressed position and that prevents the product from passing to the bottle from the diaphragm chamber;

a second valve that passes the product from the diaphragm chamber to an outside of the system when the diaphragm is moved from the original position to the depressed position and that prevents the product from passing to the diaphragm chamber from the outside of the system; and

a third valve that passes the product from the outside of the system to the bottle when the diaphragm returns to the original position from the depressed position and that prevents the air from passing to the outside of the system from the bottle.

2. The diaphragm pump system according to claim 1, wherein the second valve is a duckbill valve.

3. The diaphragm pump system according to claim 1, wherein the second valve is a flapper valve.

4. The diaphragm pump system according to claim 1, wherein the third valve is a duckbill valve.

5. The diaphragm pump system according to claim 1, wherein the third valve is a flapper valve.

6. The diaphragm pump system according to claim 1, wherein the first valve is an umbrella valve.

7. The diaphragm pump system according to claim 1, further comprising:

the personal care product held in the bottle.

8. A diaphragm pump for dispensing a personal care product, comprising:

a lower pump body having an air inlet extending through a side wall of the lower pump body;

an upper pump body attached to the lower pump body and having a diaphragm positioned on a top part of the upper pump body, the lower pump body and the upper pump body defining a diaphragm chamber therebetween;

a first valve that passes the product from a bottle attached to the lower pump body to the diaphragm chamber when the diaphragm returns to an original position from a depressed position and that prevents the product from passing to the bottle from the diaphragm chamber;

a second valve that passes the product from the diaphragm chamber to an outside of the system when the diaphragm is moved from the original position to the depressed position and that prevents the product from passing to the diaphragm chamber from the outside of the system; and

a third valve that passes the product from the outside of the system to the bottle when the diaphragm returns to the original position from the depressed position and that prevents the air from passing to the outside of the system from the bottle.

9. The diaphragm pump according to claim 8, wherein the second valve is a duckbill valve.

10. The diaphragm pump according to claim 8, wherein the second valve is a flapper valve.

11. The diaphragm pump according to claim 8, wherein the third valve is a duckbill valve.

12. The diaphragm pump according to claim 8, wherein the third valve is a flapper valve.

13. The diaphragm pump according to claim 8, wherein the first valve is an umbrella valve.

14. A method of dispensing a personal care product, comprising:

holding the product in a bottle attached to a diaphragm pump including a diaphragm in an original position on a top of the diaphragm pump;

pressing the diaphragm a first time such that the diaphragm is changed from the original position to a depressed position to expel air held in a diaphragm chamber to an outside of the diaphragm pump through a first valve;

preventing the expelled air from returning to the diaphragm chamber from the outside of the diaphragm pump through the first valve;

releasing the diaphragm a first time such that the diaphragm returns to the original position from the depressed position to create a reduced pressure in the diaphragm chamber;

drawing product from the bottle to the diaphragm chamber through a second valve;

preventing the drawn product from returning to the bottle from the diaphragm chamber through the second valve;

during the drawing the product, drawing new air from an outside of the bottle into the bottle through a third valve;

preventing the drawn air and the product in the bottle from passing through the third valve to the outside of the bottle through the third valve; and

pressing the diaphragm a second time such that the diaphragm is changed from the original position to the depressed position to expel the drawn product held in the diaphragm chamber to the outside of the diaphragm pump through the first valve.

15. The dispensing method according to claim 14, wherein the releasing the diaphragm the first time includes biasing the diaphragm with a spring positioned below the diaphragm such that the diaphragm returns to the original position from the depressed position.

16. The dispensing method according to claim 14, wherein the first valve is a duckbill valve.

17. The dispensing method according to claim 14, wherein the first valve is a flapper valve.

18. The dispensing method according to claim 14, wherein the second valve is a duckbill valve.

19. The dispensing method according to claim 14, wherein the second valve is a flapper valve.