Pump Dispenser and Method of Manufacturing a Pump Dispenser

Abstract

A manually actuated pump dispenser ( 210 ) has a dispenser main body ( 212, 214 ) including a first pump chamber ( 228 ) for a first fluid. An actuator ( 216 ) is mounted to the dispenser main body for movement towards and away from the dispenser main body. A flexible wall member ( 266 ) extends between the dispenser main body and the actuator to define a second pump chamber ( 268 ) between the dispenser main body and the actuator for a second fluid. The flexible wall member ( 266 ) is attached at one end to the actuator or to a part of the dispenser main body and has a distal end ( 266 A) comprising a collar ( 265 ) which is mounted to the other of the actuator and a part of the dispenser main body to form a seal therewith. The flexible wall member may be formed integrally with the actuator or the part of the dispenser main body and the collar, for example by using bi-injection techniques. A method of manufacturing the pump dispenser is also disclosed.

1 . A manually actuated pump dispenser comprising a dispenser main body including a first pump chamber for a first fluid and a substantially rigid actuator mounted to the dispenser main body for movement from a rest position towards the dispenser main body to actuate the dispenser, the dispenser further comprising a flexible wall member extending between the dispenser main body and the actuator to define a second pump chamber between the dispenser main body and the actuator for a second fluid, the dispenser further comprising an outlet valve arrangement for controlling the release of the fluids from the first and second pump chambers, the outlet valve arrangement being configured to allow the first and second fluids to exit the first and second chambers respectively only when the pressure of each the first and second fluids is higher than the atmospheric pressure surrounding the dispenser by a respective minimum threshold amount, the first chamber being defined at least in part by means of a flexible pump member which is subject to the pressure of the second fluid in the second pump chamber, such that, in use, movement of the actuator towards the main dispenser body reduces the volume of the second chamber to pressurize the second fluid, the pressure of the fluid in the second pump chamber acting on the flexible pump member to pressurize the first fluid in the first pump chamber, the actuator comprising abutment means configured to contact the flexible pump member when the actuator is moved towards the main dispenser body from the rest position so as to depress the flexible pump member to eject the fluid from the first pump chamber, characterized in that the second chamber is positioned on top of the first chamber. 
   
   
       2 . A manually actuated pump dispenser as claimed in  claim 1 , in which the outlet valve arrangement is configured to permit the first and second fluids to exit the first and second chambers respectively when the first and second fluids are at the same minimum threshold amount higher than the atmospheric pressure. 
   
   
       3 . A manually actuated pump dispenser as claimed in  claim 1 , in which the outlet valve arrangement is configured to permit the first and second fluids to exit the first and second chambers respectively when the first and second fluids are at different minimum threshold amounts higher than the atmospheric pressure. 
   
   
       4 . A manually actuated pump dispenser as claimed in  claim 1 , the dispenser having an inlet valve through which atmospheric air can be admitted into the second pump chamber in use, the abutment means being spaced from the movable pump member when the actuator is in the rest position. 
   
   
       5 . A manually actuated pump dispenser as claimed in  claim 1 , in which the flexible wall member is attached at one end to one of the actuator and a part of the dispenser main body the flexible wall member having a flexible wall portion with distal end and a collar adjacent the distal end of the flexible wall portion, the collar being formed from a different polymeric material from the flexible wall portion and being mounted to the other of the actuator and a part of the dispenser main body to form a seal therewith. 
   
   
       6 . A manually actuated pump dispenser as claimed in  claim 5 , in which the flexible wall member is an integral part of said one of the actuator and a part of the dispenser main body. 
   
   
       7 . (canceled) 
   
   
       8 . A manually actuated pump dispenser as claimed in  claim 5 , in which the collar locates in a groove in the other of the actuator and a part of the dispenser main body. 
   
   
       9 . A manually actuated pump dispenser as claimed in  claim 8 , in which the distal end of the flexible wall portion extends along one side of the collar and is compressed against the face of groove to form a seal. 
   
   
       10 . (canceled) 
   
   
       11 . (canceled) 
   
   
       12 . A manually actuated pump dispenser as claimed in  claim 1 , in which the dispenser main body comprises a base part and an intermediate part mounted together to define the first pump chamber between themselves, the flexible wall member extending between the actuator and the intermediate part. 
   
   
       13 . A manually actuated pump dispenser as claimed in  claim 12 , in which the intermediate part comprises a rigid portion and the flexible pump member which defines at least part of the first pump chamber. 
   
   
       14 . A manually actuated pump dispenser as claimed in  claim 13 , in which the flexible wall member is attached at one end to the intermediate part, the flexible wall member having a flexible wall portion with distal end and a collar adjacent the distal end of the flexible wall portion, the collar being formed from a different polymeric material from the flexible wall portion and being mounted to the actuator to form a seal there between, the intermediate part and the flexible wall member being integrally formed from at least two polymeric materials, the rigid portion of the intermediate part and the collar being formed from a first rigid polymeric material, the flexible pump member and the flexible wall means being formed from one or more flexible polymeric materials over-moulded into the rigid portion and collar. 
   
   
       15 . (canceled) 
   
   
       16 . A manually actuated pump dispenser as claimed in  claim 14 , in which the actuator comprises a surface and a groove is formed between two wall members which project from the surface towards the intermediate part, the collar locating in the groove with the distal end of the flexible wall portion extending along one side of the collar so as to be compressed against a face of the groove to form a seal. 
   
   
       17 . A manually actuated pump dispenser as claimed in  claim 5 , in which the flexible wall member is an integral part of the actuator, at least part of the actuator and the collar being formed from a first rigid polymeric material and the flexible wall portion being formed from a flexible polymeric material over moulded onto at least a part of the actuator and the collar. 
   
   
       18 . (canceled) 
   
   
       19 . A manually actuated pump dispenser as claimed in  claim 12 , in which at least part of an outlet passage leading from the pump chambers to a dispenser outlet is defined between the intermediate part and the base part. 
   
   
       20 . A manually actuated pump dispenser as claimed in  claim 12 , in which the dispenser has an outlet passage arrangement for directing fluid released from the first and second chambers to the outlet, at least part of the outlet passage being formed between the intermediate part and the base part the outlet passage arrangement being configured so that in use, the fluids from the first and second chambers are mixed prior to them reaching the dispenser outlet in the at least a part of the outlet passage defined between the intermediate part and the base part. 
   
   
       21 . (canceled) 
   
   
       22 . A manually actuated pump dispenser as claimed in  claim 19 , in which the dispenser comprises a common outlet valve for controlling the release of fluids from both the first pump chamber and the second pump chamber, in which the outlet valve is configured so that the fluids are mixed in the valve prior to entering the outlet passage. 
   
   
       23 . A manually actuated pump dispenser as claimed in  claim 19 , in which the dispenser is configured to dispense a mixture of liquid and air as a foam, the outlet passage having a filter support to which a generally planar mesh is fitted to form a filter mesh having two portions extending across the flow path in the outlet passage, such that in use, a liquid and gas mixture passing through the outlet passage is caused to pass through both portions of the mesh. 
   
   
       24 . (canceled) 
   
   
       25 . A manually actuated pump dispenser as claimed in  claim 23 , in which the filter support is generally V or U shaped so that the planar mesh when fitted to the support adopts a V or U type shape. 
   
   
       26 . A manually actuated pump dispenser as claimed in  claim 1 , in which the dispenser comprises an outlet having a nozzle arrangement configured to produce an atomized spray of a liquid passing through the nozzle arrangement in use. 
   
   
       27 . A manually actuated pump dispenser as claimed in  claim 4 , in which the abutment means is spaced from the flexible pump member when the actuator is in a rest position, such that the actuator is able to move towards the main dispenser body by a predetermined amount before the abutment means contacts the flexible pump member, the arrangement being such that, in use, as the actuator moves from the rest position towards the dispenser main body, the pressure of the air in the second chamber is increased to a desired level before the abutment means contacts the flexible pump member. 
   
   
       28 - 30 . (canceled) 
   
   
       31 . A manually actuated pump dispenser as claimed in  claim 5  in which at least part of the collar is positioned outboard of a periphery of the dispenser main body. 
   
   
       32 - 33 . (canceled) 
   
   
       34 . A manually actuated pump dispenser as claimed in  claim 1 , in which the dispenser comprises a trigger adapted to be squeezed by a user to actuate the dispenser 
   
   
       35 - 53 . (canceled)