Trigger sprayer assembly with dual action piston

Abstract

The trigger sprayer includes an engine with a piston chamber and an outlet fluid passageway, and a piston sliding within the piston chamber and defining an internal bellows chamber. A bellows component is movable within the internal bellows chamber between an uncompressed position, where the flow rate within the internal bellows chamber is minimal, and a compressed position, where the flow rate is maximized. The trigger sprayer further includes a trigger lever that pivots between a neutral position and an actuated position using a pair of S-shaped trigger springs. Pivoting of the trigger lever pushes a piston vertically within the piston chamber, forcing fluid from the piston chamber into the internal bellows chamber and moving the bellows component from the uncompressed position to the compressed position. Relaxation of the bellows component forces fluid from the internal bellows chamber to the outlet fluid passageway.

Description

[Technical field]

[0001] [CROSS REFERENCE TO RELATED PATENT APPLICATIONS] This application claims priority to U.S. Provisional Application No. 63 / 212972, filed June 21, 2021, and U.S. Application No. 17 / 841312, filed June 15, 2022, the entireties of which are incorporated by reference herein.

[0002] The present disclosure relates to an improved trigger sprayer assembly with a dual action piston that provides a continuous or long term spray of a fluid. [Background technology]

[0003] Trigger sprayer assemblies provide a convenient way to manually dispense many household and commercial cleaning products in a stream, spray, mist, or foam via actuation of a trigger lever. In some cases, the trigger sprayer assembly may be configured to provide a continuous or extended spray in which fluid is expelled from the trigger sprayer assembly for a period of time after actuation of the trigger lever has ceased. Existing continuous trigger sprayer assemblies are generally very large compared to other trigger sprayer assemblies because they often require a secondary reservoir to store the fluid expelled during extended spray and a means to pressurize the fluid. Thus, an improved trigger sprayer assembly that provides extended spray in a space-optimized package may be useful. Summary of the Invention

[0004] The present invention relates to a trigger sprayer assembly for discharging a continuous or long-term spray or flow of fluid. The trigger sprayer assembly includes an engine including a piston chamber and an outlet fluid passage fluidly connected to the piston chamber, a piston slidably disposed within the piston chamber, the piston defining an internal bellows chamber, and a bellows component disposed within the internal bellows chamber. The bellows component is movable between an uncompressed position where the available flow rate within the internal bellows chamber is lowest, and a compressed position where the available flow rate within the internal bellows chamber is highest. The trigger sprayer assembly further includes a trigger lever, preferably coupled to the engine and the piston with a pair of S-shaped trigger springs, configured to pivot between a neutral position and an actuated position. Pivoting of the trigger lever from the neutral position to the actuated position pushes the piston vertically within the piston chamber to force fluid from the piston chamber into the internal bellows chamber and move the bellows component from the uncompressed position to a partially or fully compressed position. When the trigger lever is pulled, fluid is forced from the internal bellows chamber to the outlet fluid passage, and when the trigger lever is released, fluid continues to be forced from the internal bellows chamber to the outlet fluid passage as the bellows component undergoes relaxation and moves from a compressed position to a decompressed position.

[0005] According to another embodiment of the present invention, a trigger sprayer assembly for discharging a continuous or long-term spray or flow of fluid includes an engine with a piston chamber and a piston valve configured to control unidirectional flow of fluid from the piston chamber through the piston to an internal bellows chamber. The trigger sprayer assembly includes a piston slidably disposed within the piston chamber and defining an internal bellows chamber, and a bellows component disposed within the internal bellows chamber. The bellows component is movable between an uncompressed position where the available flow rate in the internal bellows chamber is lowest, and a fully compressed position where the available flow rate in the internal bellows chamber is highest. The trigger sprayer includes a trigger lever coupled to the engine and the piston, the trigger lever configured to pivot between a neutral position and an actuated position, an input valve configured to control unidirectional flow of fluid from an inlet portion to the piston chamber, a piston valve configured to control unidirectional flow of fluid from the piston chamber to the internal bellows chamber, and an output valve configured to control unidirectional flow of fluid through an outlet portion. Pivoting of the trigger lever from a neutral position to an actuated position pushes a piston vertically within the piston chamber, forcing fluid from the piston chamber through the piston valve and into the internal bellows chamber to move the bellows component from its uncompressed position to its compressed position. When the trigger lever is pulled, fluid is forced from the internal bellows chamber into the outlet fluid passageway, and when the trigger lever is released, fluid continues to be forced from the internal bellows chamber to the outlet and through the outlet valve as the bellows component relaxes and moves from its compressed position to its uncompressed position.

[0006] In another aspect, the invention is a method of discharging fluid from a trigger sprayer assembly that allows for continuous or long-term spraying. The method includes pulling a trigger lever toward a rear end of the trigger sprayer assembly, which causes the trigger lever to push a piston vertically within a piston chamber to force fluid from the piston chamber through a piston valve and into an internal bellows chamber formed within the piston. In response to pulling the trigger lever, a bellows component disposed within the internal bellows chamber moves from an uncompressed position to a compressed position. The method further includes releasing the trigger lever toward a front end of the trigger sprayer assembly. In response to releasing the trigger lever, the bellows component relaxes and moves from the compressed position to the uncompressed position to force fluid from the internal bellows chamber to an outlet fluid passageway. [Brief description of the drawings]

[0007] The present invention is described with reference to the following figures, in which like numbers are used throughout to reference like features and like components: [Figure 1] FIG. 1 is a perspective view of a trigger sprayer assembly according to an exemplary embodiment of the present invention. [Diagram 2] 2 is a side view of the trigger sprayer assembly of FIG. 1. FIG. [Diagram 3] 3 is an exploded view of the trigger sprayer assembly of FIG. 1. FIG. [Figure 4A] 4A is a perspective view of a trigger component used in the trigger sprayer assembly of FIG. 1. FIG. [Figure 4B] FIG. 4B is another perspective view of the trigger component of FIG. 4A. [Figure 5A] 5A is a perspective view of an engine component used in the trigger sprayer assembly of FIG. 1. FIG. [Figure 5B] FIG. 5B is another perspective view of the engine component of FIG. 5A. [Figure 5C]FIG. 5C is a bottom view of the engine component of FIG. 5A. [Figure 5D] FIG. 5D is a cross-sectional side view of the engine component taken along line 5D-5D of FIG. 5B. [Figure 6A] 6A is a perspective view of a piston coupler used in the trigger sprayer assembly of FIG. 1. FIG. [Figure 6B] FIG. 6B is a cross-sectional side view of the piston coupler taken along line 6B-6B of FIG. 6A. [Figure 6C] FIG. 6C is a cross-sectional side view of the piston coupler taken along line 6C-6C of FIG. 6A. [Figure 7A] 7A is a perspective view of a piston used in the trigger sprayer assembly of FIG. 1. FIG. [Figure 7B] FIG. 7B is a cross-sectional side view of the piston taken along line 7B-7B of FIG. 7A. [Figure 7C] FIG. 7C is a bottom cross-sectional view of the piston taken along line 7C-7C of FIG. 7B. [Figure 8A] 8A is a perspective view of an input housing used in the trigger sprayer assembly of FIG. 1. FIG. [Figure 8B] FIG. 8B is a side cross-sectional view of the input housing taken along line 8B-8B of FIG. 8A. [Figure 8C] FIG. 8C is another cross-sectional side view of the input housing taken along line 8C-8C of FIG. 8A. [Figure 9] 9 is a perspective view showing the connection of shroud components used in the trigger sprayer assembly of FIG. 1. FIG. [Figure 10A] FIG. 10A is a side cross-sectional view of the trigger sprayer assembly taken along line 10A-10A of FIG. [Figure 10B] FIG. 10B is another cross-sectional side view of the trigger sprayer assembly illustrating fluid flow as the trigger component moves from the neutral position to the depressed position. [Figure 10C]FIG. 10C is another cross-sectional side view of the trigger sprayer assembly illustrating fluid flow as the trigger component moves from the depressed position to the neutral position and the bellows component partially relaxes from the compressed position. [Figure 10D] FIG. 10D is another cross-sectional side view of the trigger sprayer assembly illustrating fluid flow when the bellows component is fully relaxed from the compressed position. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] 1-3 illustrate an improved trigger sprayer assembly 100 according to an exemplary embodiment of the present invention. The trigger sprayer assembly 100 may be adapted to dispense a fluid (e.g., cleaning product, industrial product, water, cosmetics, food) contained within a bottle or container (not shown) in a stream, spray, or mist dispense pattern. To operate the sprayer assembly 100, a user grasps the trigger component 106 at a front end 136 of the assembly 100 and places their thumb on the shrouds 132, 134 at a rear end 138 of the assembly 100. Pressing or squeezing the trigger component 106 from a relaxed or neutral position toward the rear end 138 to a pressed or actuated position forces fluid from the bottle or container through the nozzle 124. In some embodiments, the nozzle 124 is configured to rotate relative to the shroud components 132, 134 to allow a user to open and close a fluid passageway terminating in the nozzle 124 and to select a desired dispense pattern (e.g., stream, spray, mist).

[0009] With specific reference to the exploded view shown in Figure 3, the internal components of the trigger sprayer assembly 100 are shown. These internal components include an engine 102 having a piston chamber and fluid exit passages (e.g., piston chamber 500, fluid exit passages 502, 504, described in further detail below with reference to Figure 5D), and a piston 104 coupled to a trigger lever 106 with a piston coupler 108. The piston 104 is configured to slide vertically within the piston chamber.

[0010] When the trigger lever 106 is pressed towards the rear end 138 of the assembly 100, the piston component 104 is urged downward by the trigger component 106 within a piston chamber formed in the engine 102. This reduces the available flow rate of the piston chamber, forcing fluid within the piston chamber upwardly into an internal chamber within the piston component 104 via a one-way piston valve 118. A resilient bellows component 112 and a bellows spring 114 are disposed within the internal chamber and are forced therein by fluid flowing through the one-way piston valve 118. Depressing the bellows component 112 and the bellows spring 114 also forces fluid out of the piston component 104, into a fluid exit passage within the engine 102, and out through the nozzle 124 (if the nozzle 124 is rotated to an open position).

[0011] When the actuation force is removed and the trigger component 106 relaxes towards the forward end 136, the trigger component 106 pulls the piston 104 upwardly within the piston chamber, thereby increasing the volume of the piston chamber and drawing a supply of fluid into the piston chamber. At the same time, the bellows component 112 and bellows spring 114 relax from their compressed positions, thereby continuing to force fluid out of the piston component 104 and into a fluid exit passage within the engine 102. In this manner, continuous or extended periods of spraying can be obtained even after the user is no longer actively actuating the trigger lever 106. Further details regarding certain steps in the operation of the trigger sprayer assembly 100 are described below with reference to Figures 10A-10D.

[0012] 3, the input housing 110 is shown disposed beneath the engine 102. The input housing 110 may be configured to be coupled to a dip tube 128 that extends into a fluid bottle or container (not shown) and provides a path for drawing the fluid upwardly into the sprayer assembly 100. The input housing 110 provides a seat for a one-way input valve 116 that regulates the flow of fluid into the engine 102. As shown, in the exemplary embodiment, the one-way input valve 116 is a ball valve, although other types of one-way valves may be utilized.

[0013] A neck closure 126 is shown disposed beneath the input housing 110 and the one-way input valve 116. The neck closure 126 is configured to be utilized to connect the engine 102 to any desired bottle or container. As such, the dimensions (e.g., height, outer diameter, inner diameter) of the neck closure may vary based on the size and shape of the bottle or container that contains the liquid to be dispensed. In an exemplary implementation, the neck closure 126 includes threads and is configured to be threadedly coupled to the neck portion of the bottle or container. In other implementations, the neck closure 126 is coupled to the neck portion of the bottle or container using a snap-fit ​​assembly process. A sealing gasket 130, shown as being located beneath the neck closure 126, may be utilized to ensure that fluid does not leak between the engine 102 and the input housing 110 and out through the neck closure 126, particularly when the trigger sprayer assembly 100 is tilted or inverted.

[0014] The internal components of the trigger sprayer assembly 100 are shown to include an output or nozzle valve 120 and a water jacket 122. The nozzle valve 120, like the input valve 116 and the piston valve 118, may be a one-way valve configured to permit fluid passage only when a fluid pressure threshold is exceeded. Further details regarding the output valve 120 are described below with reference to Figures 10A-10D. The water jacket 122 is disposed adjacent the nozzle valve 120 and may be configured to prevent fluid from leaking at the junction between the engine 102 and the nozzle component 124, particularly when the trigger sprayer assembly 100 is tilted or positioned such that the nozzle component 124 faces downward.

[0015] In the illustrated embodiment, the bellows component 112, piston valve 118, and nozzle valve 120 are made from a thermoplastic elastomer (TPE) using an injection molding process. TPEs exhibit many advantageous properties for valves that come into contact with a variety of fluids, including high abrasion resistance, high fatigue resistance, high elasticity, chemical resistance, and low compression set. In other embodiments, one or more of the bellows component, piston valve 118, and nozzle valve 120 may be made from a different material, such as liquid silicone rubber, or may be made using a different manufacturing process.

[0016] 4A and 4B, a perspective view of the trigger lever component 106 is shown. The trigger lever component 106 is shown as including a primary trigger body 402 from which extends a lever grip portion 400 and a pair of S-shaped springs 408. The springs 408 are configured to be compressed when a user applies an actuation force to the lever grip portion 400 and the trigger lever 106 moves from a neutral position to a depressed position. When the user releases the actuation force, the potential energy stored in the springs 408 returns the trigger component 106 to the neutral position. Because the piston 104 is coupled to the trigger lever 106, the return of the trigger 106 to the neutral position pulls the piston 104 upwardly within the piston chamber, drawing fluid upwardly through the dip tube 128 to fill the piston chamber in preparation for subsequent actuation of the trigger lever 106.

[0017] Each of the S-shaped springs 408 includes a first curved portion 410, a second curved portion 412, and a ball-shaped terminal portion 414. The first curved portion 410 extends from the trigger body 402 toward the lever grip portion 400, while the second curved portion 412 extends in the opposite direction from the first curved portion 410. Existing springs for trigger sprayer assemblies are generally U-shaped and generally have either a convex or concave shape, but not both. The inventors have recognized that an S-shaped trigger spring having both a concave and a convex portion is less susceptible to fatigue damage and provides a smoother actuation feel to the user. In the illustrated embodiment, the first curved portion 410 has a larger radius of curvature than the second curved portion 412 such that the first curved portion 410 is more easily compressed than the second curved portion 412. 5A, 5B, and 10A, the terminal end 414 of the spring 408 is inserted into a receiving area (e.g., spring socket 518) formed in the engine 102 such that the ball-shaped end 414 is vertically constrained but not constrained from pivoting within the receiving area. In an exemplary embodiment, the spring 408 is coupled to the primary trigger body 402 with a living hinge, and seating of the end 414 within the receiving area may include pivoting the spring 408 along the living hinge relative to the primary trigger body 402.

[0018] The trigger lever component 106 is further shown as including a pair of pivot flanges 404 extending rearwardly from the main trigger body 402 opposite the lever grip portion 400. The pivot flanges 404 include a pivot recess 406 formed therein and configured to receive a pivot pin (e.g., pivot pin 514 shown in FIGS. 5A and 5B ) extending from the engine 102. The connection between the pivot pin and the pivot recess 406 acts as a pivot point for the trigger component 106 to rotate relative to the engine 102. In other embodiments, the pin and recess connection may be reversed, such that the pivot flanges 404 include a pin configured to fit within a recess formed in the engine 102.

[0019] Other coupling members on the trigger component 106 include a pair of piston coupling pins 416 (shown in FIG. 4B ) that extend into an interior region of the primary trigger body 402. The piston coupling pins 416 are configured to be received by recesses (e.g., piston coupling recesses 606 shown in FIGS. 6A and 6B ) formed in the piston coupler 108. Engagement of the piston coupling pins 416 within the recesses translates pivotal motion of the trigger lever 106 into linear motion of the piston 104 and piston coupler 108. As with the pivot recesses 406, in other embodiments the pin and recess coupling may be reversed such that the piston coupling recesses are formed in the primary trigger body 402 and the pins are located on the piston coupler 108.

[0020] 5A-5D show perspective, bottom, and cross-sectional side views, respectively, of engine 102. Engine 102 includes a vertically-oriented piston chamber 500 and a vertically-oriented fluid outlet chamber 502 disposed parallel to piston chamber 500. As specifically shown in FIG. 5D, a piston outlet 522 is utilized to fluidly connect piston chamber 500 to outlet chamber 502. Vertically-oriented fluid outlet chamber 502 is also shown as fluidly connecting with horizontally-oriented fluid outlet chamber 504. A nozzle flange 506 extends from horizontally-oriented fluid outlet chamber 504 and provides a seat for mounting output valve 120, water jacket 122, and rotatable nozzle 124.

[0021] The engine 102 is shown as including a pivot wedge body 512 opposite the outlet chamber 504 and the nozzle flange 506, with a pair of opposing pivot pins 514 extending therefrom. The shape of the wedge body 512 may match the contour of the rear side of the shroud components 132, 134 (see FIGS. 10A-10D ) such that the wedge body 512 provides structural support in areas where the shroud components 132, 134 may be gripped by a user's thumbs during actuation to prevent excessive flexing of the shroud components 132, 134. A pivot recess 406 formed in the pivot flange 404 of the trigger lever 106 is configured to fit over the pivot pin 514 such that the trigger lever 106 can pivot relative to the engine 102 about the pivot pin 514. In the illustrated embodiment, the pivot flange 404 is coupled to the pivot pin 514 using a snap-fit ​​assembly process.

[0022] Beneath the pistons and outlet chambers 500, 502, the engine 102 is shown to include a neck connection portion 508. The neck connection portion 508 is generally cylindrical and has a larger outer diameter than the piston 500 and outlet chamber 502 combined. In the exemplary embodiment, the neck connection portion 508 may include a pair of radial openings 510. When the neck connection component 126 (see FIG. 3 ) is connected to the engine 102, a pair of flanges located on the neck connection component 126 may extend through the radial openings 510 to retain the neck connection component 126 on the engine 102.

[0023] The engine 102, located above the neck connection 508 and within the piston chamber 500, is shown as including a fluid input passage 524 and an input valve capture prong 520. The fluid input passage 524 provides a path for fluid to enter the engine 102 after traveling through the dip tube 128 and the input housing 110 (see FIG. 10C). A valve seat for the input ball valve 116 may be provided within the input housing 110 (e.g., valve seat 810, see FIGS. 8B and 8C), and when the input housing 110 is connected to the engine 102, the valve capture prong 520 is located above the input ball valve 116. When the fluid pressure within the dip tube 128 is sufficient to lift the ball valve 116 from its valve seat within the input housing 110, the capture prong 520 inhibits the ball valve 116 from moving into the piston chamber 500 while allowing fluid to flow into the piston chamber 500. In embodiments in which the input valve 116 is a different type of valve other than a ball valve (eg, a resilient cross slit or flap valve), the captured prongs 520 may be omitted from the engine 102 .

[0024] Further coupling members of the engine 102 include a pair of spring receiving recesses 518 located on top of reinforcing ribs 516 extending outwardly from the vertically oriented fluid outlet chamber 502. The spring receiving recesses 518 are configured to receive the terminal end 414 (see FIGS. 4A and 4B) of the trigger spring 408 using a snap-fit ​​assembly process. Once coupled, the terminal end 414 and receiving recesses 518 may operate as a ball joint to allow rotational movement of the trigger spring 408 relative to the engine 102 when the trigger spring 408 is compressed during actuation of the trigger lever 106. A pair of shroud alignment flanges 526, specifically illustrated in FIGS. 5A and 5B, are shown extending outwardly below the pivot wedge body 512. Each of the shroud alignment flanges 526 is configured to fit within a corresponding shroud jacket (shroud jackets 912, 914, see FIG. 9 ) when the shroud components 132, 134 are assembled to the engine 102 to ensure that the shroud components 132, 134 have proper vertical alignment relative to the engine 102.

[0025] 6A-6B, perspective and side cross-sectional views of the piston coupler 108 are shown. The piston coupler 108 is shown as including a generally cylindrical side wall 600 terminating in a top wall 602. A pair of opposing flanges 604 extend upwardly from the top wall 602, each of the flanges 604 having a piston coupling recess 606 formed therethrough. As mentioned above, the recesses 606 are configured to receive the piston coupling pin 416 extending from the trigger lever 106.

[0026] The piston coupler 108 is further shown as including a bellows spring alignment body 608 (see FIGS. 6B and 6C) that extends downwardly from the top wall 602 within an interior region of the coupler 108 that is surrounded by the side wall 600. A bellows spring (e.g., the bellows spring 114 shown in FIGS. 3 and 10A-10D) is configured to be inserted over the spring alignment body 608 during assembly of the trigger sprayer assembly 100. As will be described in more detail below with reference to FIGS. 10A-10D, the spring alignment body 608 ensures that the bellows spring compresses and relaxes along a vertical axis, thereby preventing the bellows spring from tilting at an angle and damaging the bellows components.

[0027] 7A-7C show perspective and cross-sectional views of the piston 104. The piston 104 is shown as including a generally cylindrical sidewall 700 with an upper flange 702 located at the vertical midpoint of the sidewall 700 and a lower flange 704 located at the lower end of the sidewall 700. A number of piston outlets 706 are shown disposed in a radial pattern near the lower flange 704 and extending through the sidewall 700. For example, in the exemplary embodiment shown in FIGS. 7A-7C, the piston 104 includes four piston outlets 706 disposed equidistant from one another (i.e., 90° apart). In other embodiments, the piston 104 may include a greater or lesser number of piston outlets 706. When the piston 104 is inserted into the piston chamber 500 (see FIG. 10A), the upper flange 702 and the lower flange 704 form a substantially watertight seal against the sidewall of the piston chamber 500. This arrangement ensures that all of the fluid exiting through the piston outlet 706 travels circumferentially around the piston sidewall 700 and through the piston outlet 522 formed in the engine 102 (see FIG. 5D).

[0028] The internal structure of the piston 104, specifically depicted in FIG. 7B, is shown as including an internal bellows chamber 708 located above a piston inlet passage 710. The internal bellows chamber 708 and the piston inlet passage 710 are separated by a piston valve structure 712. When a piston valve (e.g., piston valve 118) is placed in the piston valve structure 712 in a closed position, fluid is prevented from flowing from the piston chamber 500 in the engine 102 to the bellows chamber 708. However, when the fluid pressure in the piston chamber 500 is sufficient to lift the piston valve off its seat in the piston valve structure 712 to move it to an open position, fluid flows through the piston inlet passage 710 and the piston valve into the bellows chamber 708. In particular, all fluid flowing through the piston 104 must flow through the piston inlet passage 710 and into the bellows chamber 708 before exiting the piston 104 through one of the piston outlets 706.

[0029] 8A-8C, perspective and cross-sectional views of the input housing 110 are shown. The input housing 110 is shown to include a disk-shaped body 800 with a first cylindrical portion 802 and a second cylindrical portion 804. The first cylindrical portion 802 and the second cylindrical portion 804 are surrounded by a radial flange 806. The first cylindrical portion 802 includes a dip tube connection 808. As shown in FIGS. 10A-10D, the dip tube 128 extending into the fluid container is inserted into the dip tube connection 808 to provide a path for fluid to travel from the fluid container into the trigger sprayer assembly 100. The first cylindrical portion 802 is also shown to include a cup-shaped valve seat 810 for a ball valve (e.g., input valve 116) located at an upper end of the first cylindrical portion 802 opposite the dip tube connection 808. Sufficient fluid pressure in the dip tube connection 808 lifts the ball valve off the valve seat 810, allowing fluid to pass through the valve seat 810 and enter the engine 102. The second cylindrical portion 804 is configured to be inserted into a vertically oriented fluid outlet chamber 502 formed in the engine 102 (see FIGS. 10A-10D).

[0030] The second cylindrical portion 804 includes a drain passage 814. The drain passage 814 allows excess fluid in the chamber 502 to flow back into the fluid container after the trigger lever 106 is deactivated and the bellows component 112 returns to its fully unstressed position, preventing flow through the nozzle 124. The input housing 110 is also shown as including a pair of retention protrusions 812 that extend below the body 800. The retention protrusions 812 are utilized to retain a sealing gasket (e.g., gasket 130 shown in FIG. 3) against the body 800 to prevent leakage of fluid from the engine 102 and the input housing 110.

[0031] An exemplary process for assembling the trigger sprayer assembly 100 is as follows: Insert the piston valve 118 into the piston valve structure 712 of the piston 104. Insert the bellows spring 114 into the bellows 112, and then insert both into the piston 104. Assemble the piston coupler 108 to the piston 104 using a snap-fit ​​assembly process, holding the bellows 112 and bellows spring 114 within the piston 104.

[0032] The assembly process continues as follows: The piston 104 is inserted into the piston chamber 500 of the engine 102. The trigger lever 106 is assembled to the engine by snapping a recess 406 formed in the pivot flange 404 of the trigger lever 106 onto a pivot pin 514 extending from a wedge body 512 of the engine 102. The piston coupling pin 416 of the trigger lever 106 is inserted into a piston coupling recess 606 formed in the piston coupler 108 to couple the trigger lever 106 to the piston 104 and ensure that actuation of the trigger lever 106 results in corresponding movement of the piston 104. The terminal end 414 of each trigger spring 408 is then inserted into a corresponding spring socket 518 on the engine 102.

[0033] From there, the input valve 116 is inserted into the valve seat 810 formed in the input housing 110. The input housing 110 is then coupled to the engine 102 by inserting the first cylindrical portion 802 of the input housing 110 into the fluid inlet passage 524 of the engine 102 and the second cylindrical portion 804 of the input housing 110 into the vertically oriented fluid outlet chamber 502 of the engine 102. The seal gasket 130 is inserted over the retaining prongs 812 of the input housing 110 and the neck closure 126 is snapped onto the engine 102. To assemble the nozzle components of the trigger sprayer assembly 100, the nozzle valve 120 and the water jacket 122 are inserted into the horizontally oriented fluid outlet chamber 504 of the engine 102. The nozzle component 124 is positioned against the nozzle flange 506 to retain the nozzle valve 120 and the water jacket 122 within the engine 102.

[0034] The final steps of the assembly process include coupling the shroud components 132 and 134 to one another and to the engine 102, as described in more detail below with reference to FIG. 9. The dip tube 128 is inserted into the dip tube connection 808, and a fluid bottle or container is coupled to the neck closure 126. In an exemplary embodiment, one or more of the assembly steps detailed above are performed using a pneumatic robotic device to insert and couple the various components to one another. Advantageously, some steps of the assembly method involve moving multiple components along parallel horizontal or vertical axes that are suitable for assembly using a robotic device.

[0035] 9 illustrates the interlocking of shroud components 132 and 134. The right shroud component 132 is shown as including an upper prong 900, a forward lower prong 902, and an aft lower prong 904. The prongs 900-904 are configured to mate with corresponding upper, forward, and lower recess structures 906, 908, and 910 formed in the left shroud component 134 to hold the shroud components 132, 134 in the interlocking position.

[0036] In addition to the retainers 900-910, the shroud components 132, 134 are also shown to include various members that support and align the assembly, including jackets 912 and 914. As discussed above with reference to Figures 5A and 5B, the jackets 912, 914 can be configured to fit around the shroud alignment flange 526 to align the engine 102 relative to the shroud components 132, 134. In the exemplary embodiment, the shroud components 132, 134 use a dual seam design for the fit.

[0037] Figures 10A-10D show side cross-sectional views of the trigger sprayer assembly 100 as it undergoes an actuation cycle. Specifically, Figure 10A shows the trigger sprayer assembly 100 in a neutral or relaxed position prior to application of an actuation force, Figure 10B shows the trigger sprayer assembly 100 in a pressed or actuated position during application of an actuation force, Figure 10C shows the trigger sprayer assembly 100 returning to the neutral or relaxed position due to removal of the actuation force while the bellows component 112 continues to relax and spray through the nozzle 124, and Figure 10D shows the trigger sprayer assembly 100 after the bellows component 112 has returned completely to the relaxed or unstressed position and spraying through the nozzle 124 has ceased.

[0038] As specifically shown in FIG. 10A, many of the fluid inlet and piston components (e.g., dip tube 128, input valve 116, piston component 104, piston valve 118, bellows component 112, bellows spring 114) are positioned such that their centers coincide on the same vertical axis 1050, while the center of the vertically oriented fluid outlet passage 502 is located on a vertical axis 1052 that is parallel to and spaced apart from the vertical axis 1050. This arrangement of the components of trigger sprayer assembly 100, with nested piston and bellows chambers, advantageously minimizes the total volume of trigger sprayer assembly 100 compared to trigger sprayer assemblies in which one or more of the fluid inlet passages, piston chambers, and chambers that capture fluid for long-term spraying are spaced apart from one another. For example, in the illustrated embodiment, trigger sprayer assembly 100 can be used with a standard fluid container having an opening with a diameter of 28 mm. In contrast, existing continuous spray trigger assemblies require a fluid container with an opening with a diameter of at least 33 mm.

[0039] 10B, when a user places finger 1000 on trigger lever 106 and applies an actuation force, represented by arrow 1002, to move trigger lever 106 from a neutral position to an actuated position, the trigger lever 106 pivots downward, as indicated by arrow 1024. The S-shaped trigger spring 408 of trigger lever 106 is compressed, driving piston component 104 downward, thereby decreasing the volume within piston chamber 500. This decrease in volume causes fluid flow, represented by arrow 1004, to move piston valve 118 from a closed position to an open position.

[0040] The piston valve 118 is shown as including a solid plug portion 1006 and a conical seat 1008. A plurality of flexible members 1010 are radially distributed around the circumference of the conical seat 1008 and terminate in a ring-like member 1012. Fluid pressure urges the plug portion 1006 upwardly within the piston valve structure 712. The movement of the plug portion 1006 causes the member 1010 to flex or expand outwardly, thereby displacing the conical seat 1008 from its seated position within the piston 104 and allowing fluid to flow around the flexible member 1010 and into the bellows chamber 708, as shown by arrows 1014.

[0041] Flow into the bellows chamber 708 moves the bellows component 112 and bellows spring 114 from an uncompressed position (see FIG. 10A) to a fully compressed position (see FIG. 10B), thereby maximizing the available fluid volume in the bellows chamber 708. The bellows component 112 is shown as including an upper flange 1016 sandwiched between the piston coupler 108 and the piston component 104, and an accordion-like compressible side wall 1018 extending downwardly from the upper flange 1016. The side wall 1018 terminates in a base 1020. When the bellows component 112 and bellows spring 114 are in the uncompressed position (see FIG. 10A), the base 1020 may rest against the piston valve structure 712. Flow into the bellows chamber 708 lifts the base 1020 off the piston valve structure 712, the side wall 1018, and the bellows spring 114 into the compressed position.

[0042] As soon as fluid begins to flow into the bellows chamber 708 of the piston 104, a portion of the fluid, indicated by arrow 1022, exits the piston 104 via the peripheral piston outlet 706 and into the piston outlet passage 522. The fluid then flows upward through the vertically oriented outlet chamber 502 and into the horizontally positioned outlet chamber 504. Pressure from the fluid flow 1022 against the nozzle valve 120 located within the nozzle component 124 deforms the nozzle valve 120, as well as the piston valve 118, to allow fluid to flow through the nozzle valve 120. When the nozzle component 124 is rotated to an open position, the fluid flow 1022 exits the trigger sprayer assembly 100 through the water jacket 122 and the nozzle component 124.

[0043] In various embodiments, the liquid output per actuation of the trigger lever 106 is at least 1.0 cubic centimeter (CC). In an exemplary embodiment, the liquid output per actuation of the trigger lever 106 is at least 1.3 CC, with each actuation providing at least 2 seconds of spray output. The actuation force to achieve this liquid output is preferably 65-75 N. Three or four actuations of the trigger lever 106 may be required to draw fluid into the dip tube 128 and open the input valve 116.

[0044] 10C, when the user releases the finger 1000 from the trigger lever 106, the S-shaped trigger spring 408 causes the trigger lever 106 to rebound from the actuated position in the direction indicated by arrow 1032 to a neutral position, causing the trigger lever to pivot upward as indicated by arrow 1032. The connection between the trigger lever 106 and the piston component 104 via the piston coupler 108 pulls the piston component 104 upward in the piston chamber 500, creating a vacuum as indicated by arrow 1028 that draws fluid into the piston chamber 500. Fluid flowing in the direction of arrow 1028 flows through the dip tube 128 and moves the input ball valve 116 upward such that the ball valve 116 is lifted off its seat 810, allowing fluid to flow through the ball valve 116 and refill the piston chamber 500. As the piston 104 now moves upward, flow to the bellows chamber 708 is stopped by the lack of pressure against the piston valve's conical seat 1008 (indicated by arrow 1030).

[0045] Once flow into the bellows chamber 708 is stopped, the bellows sidewall 1018 and spring component 114 stop compressing. The potential energy stored in the spring component 114 pushes against the base 1020, causing the bellows component sidewall 1018 to expand. This expansion forces the fluid in the bellows chamber 708 out of the piston 104 through the circumferential piston outlet 706, as shown by arrows 1022. The fluid flows through the piston outlet passage 522 before traveling upward through the vertically oriented outlet chamber 502, through the horizontally oriented outlet chamber 504 and out the nozzle 124. As mentioned above, the flow shown by arrows 1022 continues for at least two seconds due to relaxation of the bellows after the user stops actuating the trigger lever 106.

[0046] 10D, the bellows base 1020 rests against the piston valve structure 712, stopping the flow of fluid from the bellows chamber 708 and the piston 104. Without the power provided by the fluid exiting the bellows chamber 708, the fluid, as indicated by arrow 1036, cannot exert sufficient pressure against the nozzle valve 120 to maintain the valve in an open position, and therefore stops flowing from the nozzle 124. As the fluid, as indicated by arrow 1036, flows downward through the drain passage 814, it returns to the fluid reservoir in preparation to be drawn back upward into the trigger sprayer assembly 100 via the dip tube 128. Thus, FIGS. 10A-10D show a full stroke of the trigger lever 106 and a full cycle of the drain and refill process of the piston chamber 500 and the bellows chamber 708.

[0047] The different systems and methods described herein may be used alone or in combination with other systems and devices. Various equivalents, alternatives, and modifications are possible within the scope of the appended claims.

Claims

1. A trigger sprayer assembly for discharging a fluid, comprising: an engine including a piston chamber and an outlet fluid passage fluidly connected to the piston chamber; a piston slidably disposed within the piston chamber, the piston defining an internal bellows chamber; a bellows component disposed within the internal bellows chamber, the bellows component being movable between a non-compressed position where the available flow rate within the internal bellows chamber is minimized and a compressed position where the available flow rate within the internal bellows chamber is maximized; a trigger lever connected to the engine and the piston using a pair of S-shaped trigger springs, the trigger lever being configured to pivot between a neutral position and an actuated position; and when the trigger lever pivots from the neutral position to the actuated position, the piston is pushed vertically within the piston chamber, fluid is fed from the piston chamber into the internal bellows chamber, and the bellows component is moved from the non-compressed position to the compressed position; a trigger sprayer assembly wherein when the bellows component relaxes and moves from the compressed position to the non-compressed position, fluid is fed from the internal bellows chamber into the outlet fluid passage.

2. The trigger sprayer assembly according to claim 1, wherein the piston includes a cylindrical side wall formed with a plurality of piston outlets in a radial pattern, and the fluid moving from the internal bellows chamber to the outlet fluid passage passes through the plurality of piston outlets.

3. An inlet fluid passage fluidly connected to the piston chamber, wherein when the trigger lever pivots from the actuated position to the neutral position, the piston is vertically pulled into the piston chamber, and fluid flows into the piston chamber from the inlet fluid passage; an input valve configured to control a one-way flow of fluid flowing into the piston chamber through the inlet fluid passage; an output valve configured to control a one-way flow of fluid passing through the outlet fluid passage; The trigger sprayer assembly according to claim 1, further comprising the above.

4. The trigger sprayer assembly according to claim 3, further comprising a dip tube extending from a first end to a second end, the first end being connected to the inlet fluid passage, and the second end being located within a fluid container.

5. The trigger sprayer assembly according to claim 4, wherein a dip tube centerline passing through the center of the dip tube coincides with a piston centerline passing through the center of the piston.

6. The trigger sprayer assembly according to claim 5, further comprising a piston valve configured to control a one-way flow of fluid from the piston chamber to the internal bellows chamber.

7. The trigger sprayer assembly according to claim 6, wherein a piston valve centerline passing through the center of the piston valve coincides with the dip tube centerline and the piston centerline.

8. Each of the piston valve and the output valve includes a plug portion, a conical pedestal extending from the plug portion, and a plurality of flexible members radially distributed around an outer periphery of the conical seat portion and extending from the outer periphery, the plurality of flexible members terminating at a ring member, the plurality of flexible members being configured to deform to allow a flow of fluid through the plurality of flexible members. The input valve includes a ball valve. The trigger sprayer assembly according to claim 7.

9. The trigger sprayer assembly according to claim 6, wherein an outlet centerline passing through the center of a vertical portion of the outlet fluid passage is offset from the piston centerline and parallel to the piston centerline.

10. Each of the pair of S-shaped trigger springs includes a first curved portion having a first radius of curvature and a second curved portion having a second radius of curvature, the first radius of curvature being greater than the second radius of curvature. The trigger sprayer assembly according to claim 1.

11. The bellows component An upper flange configured to be connected to the piston, A compressible sidewall extending downward from the upper flange and terminating at a base portion, the compressible sidewall and the base portion defining a sealed bellows region, the compressible sidewall, The trigger sprayer assembly according to claim 1, including.

12. The trigger sprayer assembly according to claim 11, further comprising a bellows spring disposed within the sealed bellows region, the bellows spring being configured to exert a spring force on the base portion to assist the bellows component in relaxing and moving from the compressed position to the uncompressed position.

13. The trigger sprayer assembly according to claim 1, wherein the bellows component is made of an elastic thermoplastic elastomer material.

14. The trigger sprayer assembly according to claim 3, further comprising a nozzle coupled to the engine, wherein rotating the nozzle relative to the engine changes the spray pattern of the fluid exiting the output valve, and the output valve is at least partially located within the nozzle.

15. A method of discharging fluid from a trigger sprayer assembly, the method comprising: pulling a trigger lever towards the rear end of the trigger sprayer assembly, the trigger lever pushing a piston vertically within a piston chamber such that fluid is fed through a piston valve from the piston chamber into an internal bellows chamber formed within the piston; in response to pulling the trigger lever, moving a bellows component disposed within the internal bellows chamber from an uncompressed position to a compressed position; releasing the trigger lever towards the front end of the trigger sprayer assembly; in response to releasing the trigger lever, relaxing the bellows component to move from the compressed position to the uncompressed position and feeding fluid from the internal bellows chamber into an outlet fluid passage; comprising a method, wherein by releasing the trigger lever towards the front end of the trigger sprayer assembly, the piston is pulled vertically within the piston chamber and fluid flows from an inlet fluid passage into the piston chamber.

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