Reusable Pump Dispenser

Abstract

A pump dispenser is disclosed in which the pump assembly does not require disassembly in order to be reused in the current recycling stream. The pump assembly may include a plastic spring that does not lose stiffness over time and does not interact with the liquid product.

Description

[Technical field]

[0001] The pump dispenser, and in particular the pump dispenser has a pump assembly that does not require disassembly because the used pump assembly is reused in the current recycle stream. [Background technology]

[0002] Pump dispensers are commonly used to dispense a variety of liquids, including lotions, foams, gels, and the like. The pump assembly dispenses liquid when a user depresses (or primes) the pump head, causing the piston to pressurize a spring, moving a ball valve upward, taking with it some liquid product. When the pump head is released, the piston and spring return to a resting position, sealing the housing chamber to stop liquid from flowing back into the bottle. Most pump dispenser components are made from polyethylene (PE) or polypropylene (PP), which can generally be reused in a single recycling stream within acceptable contamination limits. However, the presence of a steel spring in the pump assembly can make it difficult to reuse the pump dispenser in the current recycling stream. Therefore, it may be desirable to make pump dispensers that contain only reusable plastics from the same material recycling class as defined by the Society of Plastics Industry, including the plastic spring.

[0003] However, replacing steel springs with reusable plastic springs made from polyethylene (PE) or polypropylene (PP) is not a simple replacement. Plastic springs have different mechanical and chemical properties compared to steel springs. For example, PE or PP have a modulus of elasticity 50 to 150 times lower than steel. Plastic springs also lose stiffness over time due to creep forces, cyclic loading, and / or can react with liquid products.

[0004] There are several all-plastic springs available today. However, to prevent the spring from contacting the product in the bottle, the spring is integrated into the pump head, which can significantly increase the height of the pump assembly. When selling beauty and personal care products in retail stores, the shelf height is generally set by the retailer. Therefore, to use the all-plastic reusable springs currently available, the size and / or shape of the entire product line would have to be significantly altered. This is not justified, especially for products with iconic packaging. Summary of the Invention [Problem to be solved by the invention]

[0005] Therefore, there is a need for a pump dispenser having a pump assembly that does not require disassembly so that the used pump assembly can be reused in the current recycle stream. In particular, there is a need for a pump assembly having a plastic spring, where the spring does not lose stiffness over time and does not interact with the liquid product. [Means for solving the problem]

[0006] A pump dispenser comprising: (a) a bottle having a neck with a neck landing zone, the bottle consisting essentially of polypropylene, polyethylene, or polyethylene terephthalate; (b) a pump assembly comprising: i) a pump head having a cavity therein, the pump head adapted to receive an end of a first stem; (ii) a closure coupled to the neck of the body; (iii) a first stem having an end rigidly connected to the pump head, a hollow interior cavity fluidly connected to the pump head cavity, and an exterior surface having a first snap and a second snap, the first stem being configured to move relative to the second stem; and (iv) a closure coupling the first stem to a pump head. a pump assembly comprising: (v) a second stem at least partially surrounding the first stem, the second stem having a hollow internal channel in fluid communication with the internal cavity of the first stem, the second stem comprising a platform and a cantilever, the cantilever connecting with the first snap in a locked storage position and connecting with the second snap in a ready-to-dose position; and (vi) a housing at least partially surrounding the spring, the housing comprising a dosing chamber having a hollow interior, the hollow interior being in fluid communication with the internal channel of the second stem, the pump assembly consisting essentially of polypropylene or polyethylene.

[0007] 1. A pump dispenser comprising: (a) a bottle having a neck, the bottle containing a fluent product; and (b) a pump assembly in a locked storage configuration, the pump assembly comprising: i) a pump head having an internal cavity, the pump head adapted to receive an end of a first stem; (ii) a closure coupled to the neck of the body; (iii) a first stem, the first stem having an end rigidly connected to the pump head, a hollow internal cavity fluidly connected to the pump head cavity, and an exterior surface having a first snap, the first stem being configured to move relative to the second stem; and (iv) a second stem at least partially surrounding the first stem, the second stem having a hollow internal channel in fluid communication with the first stem internal cavity, a platform, and a pump assembly comprising: (v) a second stem having a cantilever, the cantilever interlocking with the first snap; (vi) a plastic spring at least partially surrounding the second stem, the spring having no preload and the spring adjacent to and spaced from the platform; and (vi) a housing at least partially surrounding the spring, the housing comprising an inner wall and a dosing chamber having a hollow interior, the hollow interior being in fluid communication with the internal channel of the second stem, wherein the pump assembly comprises at least 80% of one recyclable plastic selected from the group consisting of polyethylene, polypropylene, polyethylene terephthalate, and combinations thereof. [Brief description of the drawings]

[0008] While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter of the invention, it is believed the present invention can be more readily understood from the following description taken in conjunction with the accompanying drawings, in which: [Figure 1] FIG. 2 is a perspective view of a pump dispenser. [Diagram 2] FIG. 2 is a side view of the pump dispenser of FIG. 1 in a locked storage configuration. [Diagram 3] FIG. 2 is a side view of the pump dispenser of FIG. 1 in a ready-to-dispense position. [Figure 4] FIG. 2 is an exploded perspective view of the pump dispenser of FIG. 1. [Diagram 5] FIG. 3 is a cross-sectional view of the pump dispenser of FIG. 2. [Figure 6] 3 is a cross-sectional view of the pump dispenser of FIG. 2 during unlocking of the pump head prior to first use. [Figure 7] 4 is a cross-sectional view of the pump dispenser of FIG. 3 in a ready-to-dispense position before priming. [Figure 8] 4 is a cross-sectional view of the pump dispenser of FIG. 3 in operation. [Figure 9] 4 is a cross-sectional view of the pump dispenser of FIG. 3 in a ready-to-dispense position after priming. [Figure 10] FIG. 4 is a cross-sectional view of the pump dispenser of FIG. 3 during dispensing. [Figure 11] FIG. 1 is a perspective view of a plastic spring having a single helix design with five coils. [Figure 12] FIG. 12 is a side view of the plastic spring of FIG. [Figure 13] FIG. 1 is a perspective view of a plastic spring having a double helix design. [Figure 14] FIG. 14 is a side view of the spring of FIG. 13. [Figure 15] FIG. 1 is a perspective view of a plastic spring having a corrugated plastic design. [Figure 16] FIG. 16 is a side view of the spring of FIG. 15. [Figure 17] FIG. 1 is a perspective view of a plastic spring having a double stack double helix design. [Figure 18] FIG. 18 is a side view of the spring of FIG. 17. [Figure 19] FIG. 13 is a cross-sectional view of the pump dispenser during unlocking of the pump head prior to first use. [Figure 20] 1 illustrates a cross-sectional view of a pump dispenser in a ready to dispense configuration. [Figure 21] 1 shows a cross-sectional view of a pump dispenser with the pump head in operation. [Figure 22] 1 shows a cross-sectional view of the pump dispenser after pump head actuation. [Figure 23] FIG. 23 is an enlarged view of a portion of FIG. 22. [Figure 24A] Pump dispenser C is shown. [Figure 24B] 1 shows a portion of the pump assembly of pump dispenser C. [Figure 24C] 24C shows components of the pump assembly of FIG. 24B. [Diagram 25] 1 is a portion of the pump assembly of pump dispenser D. [Figure 26] 1 is a portion of the pump assembly of pump dispenser E. [Figure 27] 1 shows a portion of a pump assembly of a pump dispenser F. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Consumers may prefer to dispense some liquid beauty and personal care products, such as shampoo, conditioner, and body wash, by using a pump dispenser having a pump assembly. However, most pump assemblies are made from a combination of plastics and / or include a steel spring. Steel springs are common in pump dispensers because they are inexpensive, relatively hard, and do not deform much over time while still being relatively easy to activate, and generally do not react with most liquid beauty and personal care products. However, pump assemblies that include steel springs and / or different types of plastics may be difficult to reuse without disassembling the pump assembly.

[0010] Thus, there is a need for a pump dispenser in which the bottle and pump assembly are made from plastics that are reusable in current plastic recycling streams. For example, the bottle can be designed to fit into current polyethylene terephthalate (PET), PP, or PE recycling streams, and the pump assembly can be designed to fit into current PE or PP recycling streams. The pump dispenser and / or pump assembly can include 80% or more, alternatively 85% or more, alternatively 88% or more, alternatively 90% or more, alternatively 92% or more, alternatively 95% or more, alternatively 97% or more, or alternatively 99% or more of one type of reusable plastic. The pump dispenser can be composed of, or consist essentially of, PE or PP. The bottle can be composed of, or consist essentially of, PE, PP, or PET. The terms "consisting essentially of PE", "consisting essentially of PP", or "consisting essentially of PET" can mean containing PE, PP, or PET and possibly pigments, but not containing other plastics such as high density polyethylene (HDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), and medium density polyethylene (MDPE), except in amounts below current PP, PE, or PET recycling stream thresholds.

[0011] Additionally, during shipping, handling, and storage prior to first use, the pump assemblies of current pump dispensers are in a locked storage configuration, in which the spring is compressed and liquid product cannot be dispensed through the pump assembly. Because steel springs have a relatively high modulus of elasticity, when the pump head is rotated and the pump assembly is unlocked, the spring expands to its original resting state without significant deformation. However, plastic springs have a modulus of elasticity 50 to 150 times lower than steel, and when subjected to this compressive force in the locked storage configuration, significant deformation can occur and the pump assembly will not function as well.

[0012] Furthermore, in pump assemblies with metal springs, the springs are in contact with the liquid product during use. However, plastics such as PP and PE can be more reactive than steel to some chemistries, so the springs can experience modulus changes (either hardening or relaxation) or even stress fractures due to interactions between the spring material and the liquid product. Furthermore, materials from the plastic springs can leach into the liquid product, compromising the safety and effectiveness of the product.

[0013] Currently, there are some pump assemblies with PE or PP springs. However, to prevent the plastic spring from losing its stiffness when the pump head is locked and / or reacts with the liquid product, the spring is assembled in the pump head in an uncompressed state. Unless the bottle height is reduced, the pump dispenser may be too tall for retail shelves when in a storage configuration for transport, handling, and storage.

[0014] The pump dispenser in the storage configuration may fit on a standard store shelf without redesigning the bottle. The spring may not be in contact with the liquid product when in the storage configuration to avoid plastic leaching into the liquid product and / or cracking of the spring due to environmental stress. The pump head may have a height measured from the neck landing zone to the top of the pump head when locked in the locked storage configuration of less than 40 mm, alternatively less than 35 mm, alternatively less than 30 mm, alternatively less than 29 mm, alternatively less than 28 mm, alternatively less than 27 mm, alternatively less than 25 mm, alternatively less than 23 mm or less, alternatively less than 22 mm, alternatively less than 20 mm or less. The pump head may have a height measured from the neck landing zone to the top of the pump head when locked, which may be about 10 mm to about 38 mm, alternatively about 15 mm to about 35 mm, alternatively about 18 mm to about 30 mm, alternatively about 20 mm to about 25 mm in the locked storage configuration.

[0015] 1 is a perspective view of a pump dispenser 1 including a bottle 2 coupled to a pump assembly 3 in a locked storage position. The pump assembly includes a pump head 31 and a closure 35. More specifically, the closure 35 is coupled (e.g., threadedly engaged) to the neck of the bottle 2.

[0016] FIG. 2 is a side view of the pump dispenser of FIG. 1 in a locked storage configuration.

[0017] FIG. 3 is a side view of the pump dispenser of FIG. 1 in a ready-to-dispense position. A user can press pump head 31 downward with the other hand to dispense liquid product from spout 32 into one hand or onto an implement such as a sponge, dish towel, or mesh pouf. The amount of liquid dispensed per pumping action (i.e., dose per stroke) can be the dispensing of about 2 to about 6 mL of liquid product, alternatively about 2.5 to about 5.5 mL, alternatively about 3 to about 5 mL, alternatively about 3.6 to about 4.4 mL of liquid product. The average peak actuation force at 90% stroke can be less than 45 N, alternatively less than 40 N, alternatively less than 35 N, alternatively 30 N or less, as determined by the Average Peak Actuation Force Test Method described below, and the liquid being tested is a personal care composition (e.g., shampoo, conditioner, body wash, liquid hand soap) having a viscosity of about 1 cSt to about 2,000,000 cSt, as measured according to the Viscosity Test Method described herein.

[0018] Figure 4 is an exploded perspective view of the pump dispenser of Figure 1. The pump dispenser may include a bottle 2 with a neck 21 having a thread 22 and a neck landing zone 24, and a pump assembly. The pump assembly may include a pump head 31 with a spout 32, a closure 35, a second stem 40 with a platform 41 and a cantilever 43, a first stem 45 having a snap 46 adapted to rigidly connect with the pump head 31, and snaps 48 and 49 adapted to snap-fit ​​with the second stem in a locked storage position and a ready-to-dispense position, respectively, a spring 50, a first housing 55, a first ball 60, a sub-stem 70, a piston 75, a second ball 80, a second housing 90 with a dosing chamber 91, and a dip tube 95. The pump assembly may be made of PE or PP. In one example, the pump assembly may be compatible with the current PP recycle stream and the bottle may be reusable with the current PET or PP recycle stream, in another example, the pump assembly may be compatible with the current PE recycle stream and the bottle may be compatible with the PE or PET recycle stream.

[0019] 5 is a cross-sectional view of the pump dispenser of FIG. 2 in a locked storage configuration, which occurs prior to initial actuation and use. The pump dispenser 1 can include a bottle 2 and a pump assembly 3. The pump assembly 3 is attached to the bottle 2 by a closure 35, which includes threads 39 that can engage corresponding threads 22 disposed on the neck 21 of the bottle 2. In some examples, the closure can carry a kerf that can limit the ingress of water into the bottle opening. If present, the kerf can be connected to the closure by any suitable means, including, but not limited to, a threaded connection to a surface of the closure, particularly a surface at or near the top of the closure. The kerf can be the same material as the pump assembly.

[0020] The pump assembly 3 includes a pump head 31 that may be rigidly connected to a first stem 45. The first stem 45 may be rigidly connected to the pump head 31 via a snap. The first stem 45 may have a hollow first stem interior cavity 47 that is fluidly connected to the cavity 30 of the pump head 31.

[0021] The second stem 40 may have a channel 42 configured to receive the first stem 45 while allowing vertical movement of the first stem 45. The outer surface of the first stem and the inner surface of the second stem are slidably engaged such that there is substantially no liquid product between the inner surface of the second stem and the outer surface of the first stem. The channel 42 may be fluidly connected to the first stem cavity 47. The second stem 40 may include a cantilever 43 configured to engage the first snap 48 when the pump is in the locked storage configuration, and a platform 41 adapted to compress the spring 50 during actuation. However, in the locked storage configuration, the platform 41 is adjacent to and spaced apart from the spring 50. The spring 50 may be slidably disposed about the second stem 40.

[0022] A first housing 55 may be disposed around the spring 50 in both the locked storage configuration (FIG. 5) and the pump-ready configuration (FIG. 7). The first housing 55 may prevent the spring from contacting the liquid product 100, thereby preventing the spring from weakening due to interaction with the liquid product 100 during storage and use. The first housing 55 may include a platform 59 to counter compression of the spring 50. The first housing may include a lip 56 that is pressed between the closure 35 and the neck landing zone 24. In some examples, the bottom surface of the lip surface may include a PP or PE gasket to form a tight seal with the neck landing zone.

[0023] The hollow sub-stem 70 may be rigidly joined to the second stem 40 at or near its end distal to the platform 41. The hollow sub-stem 70 may be in fluid communication with the channel 42. The sub-stem 70 may be configured to receive a first ball 60, which may be a one-way valve, specifically a one-way ball valve. The ball valve may open and close in response to changes in pressure within the dosing chamber 91. The sub-stem 70 may be in fluid communication with the dosing chamber 91 of the second housing 90. An outer surface of the sub-stem 70 may be rigidly connected to a piston 75. The piston 75 may form a seal and slidably engage an inner wall of the second housing 90.

[0024] As shown in the embodiment of FIG. 5, the second housing 90 may mate with the first housing 55, which may form a rigid snap-fit ​​connection. In an alternative configuration, the first and second housings may be one piece, for example one injection molded piece. The second housing 90 may have a dosing chamber 91. In the locked storage configuration, the dosing chamber 91 does not contain a liquid product. The interior volume 91 may be configured to provide a platform or narrowed area that may limit the downward vertical movement of the piston 75. The second housing 90 also includes a valve seat 94 configured to receive the second ball 80, which may form a one-way valve, in particular a one-way ball valve. The base of the second housing, at the end opposite the top end that engages with the first housing, has an opening configured to receive a dip tube 95. The dip tube 95 is in fluid communication with the dosing chamber of the second housing. The dip tube may be either extrusion cut or press fit.

[0025] The immersion tank 95 is configured to transport the liquid product 100 from the bottle 2, through the one-way valve formed by the second ball 80 and the valve seat 94, through the channel 42 and piston 75, through the first ball valve, into the first stem cavity 47, through the cavity 30, out the spout 32 and into a user's hand or cleaning implement.

[0026] In the locked storage configuration, shown in FIG. 5, prior to initial actuation and use, the spring 50 is stored within the first housing 55 and is substantially uncompressed without any preload. The lack of preload during storage and transport minimizes the spring modulus to counter creep, and therefore actuation force during use may be minimized while still achieving good springback / recovery after actuation. This configuration also allows for the use of a relatively long length and stroke spring for large doses, thus further minimizing actuation force. The height of the pump dispenser is minimized by storing at least a portion of the spring within the neck in the locked storage configuration. The pump head threads 34 of the pump head 31 engage with the corresponding closure threads 36 of the closure 35, thus preventing any accidental actuation. Additionally, the dosing chamber 91, the channel 42, the first stem cavity 47, and the cavity 30 within the pump head 31 all substantially do not contain liquid product in the locked storage configuration.

[0027] Figure 6 is a cross-sectional view of the pump dispenser of Figure 2 during pump head unlocking. Upon first use, the user can rotate the pump head 31, and the pump head threads 34 can disengage from the closure threads 36, and the cantilever 43 of the second stem disengages from the first snap 48 of the first stem. To the user, this appears to be a typical method of opening a pump dispenser commonly used for soap, shampoo, conditioner, lotion, etc., and therefore no new habits are required to be taught and / or adopted.

[0028] FIG. 7 is a cross-sectional view of the pump dispenser of FIG. 3 in a ready-to-dispense position before being primed. Once the threads 34 are fully disengaged from the corresponding closure threads 36, the user can pull the pump head upward. This can cause the cantilever 43 of the second stem to engage with the second snap 49 of the first stem, for example, by a snap fit or other interconnectivity. In this configuration, the first stem 45 and the second stem 40 are rigidly connected. As shown in FIG. 7, the spring 50 may be substantially uncompressed when it is in the ready-to-dispense position. However, in other embodiments, the spring may have a slight compression when in the ready-to-dispense position, as described below.

[0029] Figure 8 is a cross-sectional view of the pump dispenser of Figure 3 during actuation. During depression of the pump head 31, the piston 75 is pushed downwards, thus decreasing the volume of the chamber 91. The second stem 40 compresses the spring 50 via the platform 41. Upon releasing the pressure on the pump head, a vacuum is created, drawing the product from the bottle via the dip tube. After several actuations (typically 1-10, depending on the volume of the conduit and the pump dose), the dip tube 95, the pump inner chamber 91, the channel 42, the first stem cavity 47, and the cavity 30 are filled with liquid product 100 and the pump assembly is "primed".

[0030] Figure 9 is a cross-sectional view of the pump dispenser of Figure 3 in a ready-to-dispense position after being primed. Liquid product 100 resides in the area below piston 75 which includes dip reservoir 95.

[0031] Figure 10 is a cross-sectional view of the pump dispenser of Figure 3 during dispensing of a primed pump. As shown in Figure 10, the spring 50 is not in contact with the liquid product 100 during dispensing. The liquid product 100 is not in contact with the spring in the locked and ready to store position (see Figures 2 and 4), the ready to dispense position, before priming (see Figure 7), during priming (see Figure 8), the ready to dispense position, after priming (see Figure 9), and the dispense position (see Figure 10).

[0032] 11 and 12 are perspective and side views, respectively, of a single helix plastic spring with five coils (commercially available from Braskem® as FT200WV homopolymer pp) that may be used as a spring in the pump assembly described herein. Immediately after priming, this spring was found to have an average peak force of 20 N at 90% of the full stroke as determined by the spring specifications and average peak operating force test method described below. During use, the spring was found to reduce its length by approximately 1 mm due to permanent deformation.

[0033] 13 and 14 are perspective and side views, respectively, of an embodiment of a double helix plastic spring that may be used as a spring in the pump assemblies described herein.

[0034] 15 and 16 are perspective and side views, respectively, of an example of a corrugated plastic spring design that may be used as a spring in the pump assemblies described herein.

[0035] 17 and 18 are perspective and side views, respectively, of an example of a double stack double helix spring design that may be used as a spring in the pump assemblies described herein.

[0036] By performing simulations, it was found that selecting a double helical plastic spring (as illustrated in Figures 13 and 14), a corrugated plastic spring design (as illustrated in Figures 15 and 16), and a double stack double helical spring design (as illustrated in Figures 17 and 18) could be advantageous to increase the spring constant while decreasing the spring length compared to a single helical plastic spring (as illustrated in Figures 11-12). However, it was found that these springs, when actuated, result in high permanent deformation and therefore result in higher dosage variability.

[0037] 19 is a cross-sectional view of the pump dispenser 1' during unlocking of the pump head for first use. In this embodiment, the inner wall of the first housing 55' has a retention mechanism 63' that does not engage the spring 50' while in the locked transport configuration or when the pump head 31' is unlocked. In the locked storage configuration, when the pump head is unlocked, the platform 41' of the second stem 40' is spaced apart from the spring 50'.

[0038] 20 shows a cross-sectional view of the pump dispenser 1' in a ready-to-dispense configuration. Once the pump head threads 34' are fully disengaged from the closure threads 36', the user can pull the pump head 31' upward, causing the second stem cantilever 43' to interlock or otherwise engage with the first stem 45' at the second snap-fit ​​portion 49'. In this configuration, the first stem 45' and the second stem 40' may be rigidly connected. In this configuration, the retention mechanism 63' still does not engage the spring 50' and the platform 41' is spaced apart from the spring 50'.

[0039] Figure 21 shows a cross-sectional view of the pump dispenser 1' during pump head actuation. During pressing of the pump head 31', the piston 45' is pressed downwards, thus reducing the volume of the dosing chamber 91'. The second stem 40' compresses the spring 50' via the platform 41'.

[0040] FIG. 22 shows a cross-sectional view of the pump dispenser 1' after pump head actuation. During release of pressure on the pump head, the piston 45' returns in response to pressure exerted by the spring 50' on the platform 41'. However, the expansion of the spring is countered by contact between the cantilever 43' of the second stem 40' and the retention mechanism 63'. This preloads the spring 50' to help generate a consistent stroke between actuations over the life of the pump dispenser. In this configuration, the retention mechanism 63' engages the spring 50' and the platform 41' is adjacent to the spring 50' and does not space away from the spring 50'.

[0041] Figure 23 is an enlarged view of a portion of Figure 22. Figure 23 shows a retention mechanism 63' that couples or otherwise engages with the cantilever 43' to place the spring 50' in compression after the first pump.

[0042] Tables 1-6 below describe various attributes of the following six pump dispensers: Pump Dispenser A: Control (LC Metal): Model L509-316-0.85mm manufactured by ZHONGSHAN LUENCHOENG DISPENSING PUMP LTD. (CLC) Pump dispenser B: an embodiment of the present invention · Drawings of Pump Dispenser C: ZHONGSHAN LUENCHOENG DISPENSING PUMP LTD. (CLC) Plastic Pump Dispenser E50AAA-33 / 410A is shown in FIG. 24A. FIG. 24B is a diagram of the assembled pump assembly without the dip tube. FIG. 24C is a diagram of the components of the pump assembly of FIG. 24B. Pump Dispenser D: commercially available from Taplast® as MONO PUMP and shown in Figure 25. Components of Pump Dispenser D are described in U.S. Patent Publication No. 2017 / 0326567, which is incorporated herein by reference. Pump Dispenser E: commercially available from Silgan® as the LIFE CYCLE PUMP and shown in Figure 26. The components of Pump Dispenser E are described in U.S. Patent No. 10,138,971, which is incorporated herein by reference. Pump dispenser F: commercially available as ECO GREEN from Hana® and shown in FIG.

[0043] Table 1 below compares the locked pump height, spring material, and recyclability of pump dispensers A-F. The locked pump height is measured from the neck landing zone to the top of the pump head when the pump dispenser is in the locked storage position. The neck landing zone is the highest part of the bottleneck measured from the base (see reference number 24 in Figures 4-5). If the locked pump height is less than 25mm, it can be used on current store shelves with minimal impact on cost.

[0044] [Table 1]

[0045] The pump assembly of Dispenser A has a metal spring, which is generally considered a contaminant in current recycle streams.

[0046] The pump assembly of Pump Dispenser B is reusable in current PE, PP and PET recycling streams and has a locked pump height of 23mm to fit on current store shelves.

[0047] The pump assembly of dispenser C shown in Figures 2A-2C is 90% by weight of the pump assembly is PP including the dip tube. Figure 24C shows the components of pump dispenser C including gasket 380 and piston 375, which constitute 5% by weight of the pump dispenser and are made of PE, and spring 350, which constitutes 5% by weight of the pump dispenser and is made of polybutylene terephthalate (PBT). Since PBT is considered a contaminant in the PET stream, pump dispenser C can be considered reusable without separating the pump assembly and bottle only if the bottle is made of PP (preferably) or HDPE (less so, for a mixture of HDPE and PP, the package is more likely to be downcycled with some yield loss beyond a certain threshold). However, PP bottles have poor drop resistance at low temperatures that may be encountered during shipping or storage. PP bottles are generally not preferred by consumers for many products, especially beauty care products, and consumers often desire clear bottles that are sturdy, shiny, and can convey quality. PP bottles can be cloudy, brittle and dull feeling, which may be less than desirable. Pump dispenser C has a locked pump height of 40mm, which may be too tall to fit on current store shelves without redesigning the bottle or modifying the shelf height.

[0048] The pump assembly of pump dispenser D shown in FIG. 25 is 98% PP by weight of the pump assembly and therefore can be reused in current recycle streams. The spring of this pump is a bellows 550 made of a thermoplastic polyolefin (TPO) / PP blend, which is typically compatible with PP recycle streams. The bottle can be made of PP or PET to minimize HDPE contamination with PP. The pump can be reused with HDPE bottles for some down cycle applications that reduce yields. The height of the pump when locked is 20mm, which fits on current store shelves.

[0049] The pump assembly of pump dispenser E shown in Figure 26 is made primarily from HDPE (about 90%) and can be reused in current recycling channels along with both HDPE and PET bottles. The locked pump height is slightly greater than 25mm, which may be undesirable as the pump dispenser is too tall to fit on current store shelves without redesigning the bottle or modifying the shelf height.

[0050] The pump assembly of pump dispenser F shown in FIG. 27 is made of PP-based grade materials with 100% by weight of the pump dispenser being made from PP-based grade materials and therefore can be reused in current recycle streams. The bottles can be made of PP or PET to minimize HDPE contamination with PP. Alternatively, the pumps can be reused if the bottles are HDPE in down cycle applications. The locked pump height is slightly greater than 25mm, which may be undesirable as standard bottles may have to be redesigned to fit on current store shelves.

[0051] Table 2 below compares spring lengths at different points in the life cycle of a pump dispenser for different pump assemblies. The spring may provide sufficient recovery force after actuation to provide an acceptable recovery rate (preferably less than 0.5 seconds after actuation) throughout the life of the pump. However, if the spring is too stiff, it may be difficult for the consumer to dispense the intended amount of product in one stroke with an acceptable actuation force.

[0052] Spring length was measured under the following conditions: (1) no deformation at free natural rest (F), (2) deformation due to the same preload applied during pump storage (non-operating) assembled condition (P), and (3) deformation at test deflection (TD) when the pump undergoes 90% of the intended full operating stroke (defined as test stroke, or TS). Spring length at rest and pump storage positions was measured using calipers and in some examples, an opening was made in the shroud to view the spring if it was not visible. The deflection of the force gauge was tracked to measure spring length for any loading condition. Spring force at 90% stroke was measured using the spring specifications and average peak operating force test method described below.

[0053] [Table 2]

[0054] The pump assembly configuration for Pump Dispenser A included a linear spring with a single arm helical design, which required a large compression of the spring in the locked storage position, as shown by the 11.5 mm compression in the spring preload in Table 2. This design approach becomes challenging when transitioning to plastic springs, as the spring may need to be over-designed to compensate for the loss of elastic modulus caused by spring creep during storage. This can result in compromises that are unacceptable to consumers, such as excessive actuation force or low dose per stroke.

[0055] The pump assembly configuration for Pump Dispenser B included a spring with a single helical arm design and had no spring preload, which limited the stress on the spring during storage, as indicated by the 0 mm compression in the spring preload in Table 2. Pump Dispenser B experienced spring preload after the first actuation, but not during shipping and storage.

[0056] The pump assembly configurations for pump dispensers C, D, and E all had relatively small amounts of preload as indicated by the 1-4 mm compression in the spring preloads in Table 2. The spring used in dispenser C was a linear S-type. The spring used in dispenser D was a non-linear bellows. The spring used in dispenser E was a C-spring, i.e., one that included a slotted tubular elastic element compressed between two load supports. Because the product is stored for long periods of time before use, it was found that even small amounts of compression stressed the springs to strain levels that required compensation.

[0057] The configuration of the assembly for pump dispenser F included a linear spiral plastic polypropylene spring with a relatively large compression in the locked storage position as indicated by the 10 mm compression in the spring preload in Table 2. This configuration is expected to stress the plastic spring during storage causing irreversible deformation.

[0058] Table 3 below shows the average peak force per stroke and displacement for pump dispensers A-F when dispensing water. The actuation force and return time at 90% stroke were measured using the Pump Average Peak Actuation Force and Return Time test method described below at a test speed of 200 mm / min. The average power per stroke was determined by the Average Power Per Stroke test method described below. For pump dispensers A, E, and F, the water was in contact with a spring.

[0059] [Table 3]

[0060] As shown in Table 3, the average peak forces were found to be generally consistent with the forces measured in the spring compression experiments, except for pump dispenser D. All pumps were found to deliver an output per stroke of 4.0 + / - 0.4 mL, except for pump dispenser F. Return times were found to be less than 0.5 seconds for all pump dispensers.

[0061] Table 4 below shows the average peak force per stroke and displacement for pump dispensers A-F when dispensing shampoo (Head & Shoulders® Classic Clean Shampoo commercially available in China in 2020). The spring force and return time at 90% stroke were measured using the Pump Average Peak Actuation Force and Return Time test method described below at a test speed of 200 mm / min. The average power per stroke was determined by the Average Power Per Stroke test method described below. For pump dispensers A, E, and F, the shampoo was in contact with the spring.

[0062] [Table 4]

[0063] As shown in Table 4, Pump Dispenser B met the average actuation force and dosing success criteria, resulting in similar dispensing performance as Pump Dispenser A, a pump assembly with a metal spring. Pump Dispenser D demonstrated high actuation force compared to the other examples. The power per stroke delivered by Pump Dispensers C-F was lower than those tested with water (see Table 3) and was overall suboptimal for this application.

[0064] Table 5 below tests the average peak force and displacement per stroke of pump dispensers A-F when dispensing a conditioner (Pantene® Smooth & Sleek Conditioner commercially available in the United States in 2020). At a test speed of 200 mm / min, the spring force and return time at 90% stroke were measured using the Pump Average Peak Actuation Force and Return Time test method described below. The average power per stroke was determined by the Average Power Per Stroke test method described below. For pump dispensers A, E, and F, the conditioner was in contact with the spring.

[0065] [Table 5]

[0066] As shown in Table 5, Pump Dispenser B met the average actuation force and dosing success criteria, resulting in similar dispensing performance to Pump Dispenser A, a pump assembly with a metal spring. As with both the shampoo (see Table 4) and water (see Table 3) examples, Pump Dispenser D had a high actuation force compared to the other examples. The power per stroke delivered by Pump Dispensers C-F was lower than that tested with water and was found to be overall suboptimal for this application.

[0067] Table 6 below summarizes the data from Tables 1-5 and shows that Pump Dispenser B was the only dispenser tested that met all criteria.

[0068] [Table 6]

[0069] Test Method Average Power Per Stroke (OPS) This test method involves measuring the average weight of liquid dispensed from a mechanical dispenser on each actuation. The test method is identical in procedure to ASTM D4336-18 (Gravimetric Method #1). See standard for accuracy, repeatability, and sensitivity.

[0070] Apparatus: A direct reading balance capable of taring the package to 0.01 g increments, the sample to be tested held by a rigid means, and the test solution.

[0071] Material preparation: Samples must be conditioned at room temperature (20±3°C) for at least 4 hours before the start of the test.

[0072] Procedure: (1) Fill container with product to the level that will be found on the final package and secure a mechanical pump dispenser to the container. (2) Prime the pump dispenser by activating the pump dispenser until complete release of product occurs. (3) Place package on scale and tare to zero weight. (4) Activate pump dispenser by hand 10 times (60 strokes / min) (Note: Care must be taken to use a full stroke with each activation). (5) Reweigh package and record value to the nearest 0.01 as appropriate for scale used and recorded. (6) Repeat steps (1) through (5) for a minimum of three packages. (7) Report the following information: (a) description of mechanical pump dispenser and product tested, (b) number of samples tested, (c) average and standard deviation of weight per pump.

[0073] Pump average peak operating force and return time. Equipment and materials: (1) Force Meter: Instron® 8500; (2) At least 5 pump dispensers.

[0074] Preparation: Condition the samples at room temperature (20±3°C) for 24 hours.

[0075] Procedure: (1) Fill container with liquid product to the level that will be seen on the final package and secure mechanical pump dispenser to container. (2) Place pump package in force meter. (3) Operate pump 5 times at 90% full stroke with head speed of 200 mm / sec and measure and record peak force each time. The recovery speed of the mechanical device should be faster than the recovery speed of the pump head, i.e., the device should not remain in contact with the pump head while the pump is recovering. Use a high speed camera to determine the return time. (4) Calculate average peak force. (5) Repeat steps (1)-(4) for a minimum of three packages. (6) Report the following information: (a) description of mechanical pump dispenser and product tested, (b) number of samples tested, (c) mean and standard deviation of average actuation force per pump.

[0076] Spring specifications and average peak operating force Equipment and materials: (1) Force meter: Instron® 8500; (2) Calipers (±0.1 mm); (3) At least five spring specimens per type (for force testing).

[0077] Preparation: Condition the spring specimens at room temperature (20±3°C) for 24 hours.

[0078] procedure: The free height (F) is the height of the spring without any load applied and is determined by placing a straightedge across the top of the spring and measuring with a vernier caliper the vertical distance from the plate on which the spring stands to the bottom of the straightedge, approximately at the center of the spring.

[0079] The preload spring length (P) is the height of the spring when assembled in the pump in the storage (rest) configuration, i.e. when the pump is not actuated. This can be measured from the pump footprint or using an X-ray or CT scan. The spring preload (PL) is calculated by subtracting the preload spring length from the free height.

[0080] Full Stroke (FS) is the spring deflection measured when the spring is assembled in the pump and undergoes maximum compression during pump operation. The Test Stroke (TS) is calculated to be 90% of the Full Stroke (FS). The Test Deflection (TD) is calculated by adding the Test Stroke (TS) to the Spring Preload (PL).

[0081] The spring force at test deflection is measured by fixing the spring on a force tester mounting support that ensures that the spring ends are parallel and no load is applied to the spring. The entire setup should be inside a protective cage for safety. Load the spring with an appropriate weight using the force tester and record the corresponding axial compression. Increase the load and read the corresponding axial deflection. Plot the curve between load and deflection. The reported spring force at test deflection corresponds to an axial deflection equal to the test deflection (TD) height.

[0082] combination A. A pump dispenser comprising: a) a bottle having a neck with a neck landing zone, the bottle consisting essentially of polypropylene, polyethylene, or polyethylene terephthalate; b) a pump assembly comprising: i) a pump head having a cavity therein, the pump head adapted to receive an end of the first stem; ii) a closure coupled to the neck of the body; iii) a first stem having an end rigidly connected to the pump head, a hollow interior cavity fluidly connected to the pump head cavity, and an exterior surface having a first snap and a second snap, the first stem being configured to move relative to the second stem; iv) a second stem at least partially surrounding the first stem, the second stem having a hollow interior channel in fluid communication with the first stem interior cavity, the second stem comprising a platform and a cantilever, the cantilever interlocking with the first snap in the locked storage position and interlocking with the second snap in the ready-to-dose position; v) a plastic spring at least partially surrounding the second stem; vi) a pump assembly comprising: a housing at least partially enclosing the spring, the housing comprising a dosing chamber having a hollow interior, the hollow interior being in fluid communication with an internal channel of the second stem; A pump dispenser, wherein the pump assembly consists essentially of polypropylene or polyethylene. B. A pump dispenser comprising: a) a bottle having a neck with a neck landing zone, the bottle containing a fluent product; b) a pump assembly in a locked storage configuration, i) a pump head having a cavity therein, the pump head adapted to receive an end of the first stem; ii) a closure coupled to the neck of the body; iii) a first stem having an end rigidly connected to the pump head, a hollow interior cavity fluidly connected to the pump head cavity, and an exterior surface having a first snap, the first stem being configured to move relative to the second stem; iv) a second stem at least partially surrounding the first stem, the second stem having a hollow interior channel in fluid communication with the first stem interior cavity, the second stem comprising a platform and a cantilever, the cantilever interfacing with the first snap; v) a plastic spring at least partially surrounding the second stem, the spring having no preload, the spring adjacent to the platform and spaced apart from the platform; and vi) a pump assembly comprising: a housing at least partially enclosing the spring, the housing comprising an inner wall and a dosing chamber having a hollow interior, the hollow interior being in fluid communication with the internal channel of the second stem; A pump dispenser, wherein the pump assembly comprises at least 80% of one recyclable plastic selected from the group consisting of polyethylene, polypropylene, polyethylene terephthalate, and combinations thereof. C. The pump dispenser of paragraph A or B, wherein the distance from the neck landing zone to the top of the pump head is less than 25 mm, preferably less than 23 mm, more preferably less than 22 mm, and even more preferably less than 20 mm. D. The pump dispenser of paragraphs A-C, wherein the plastic spring comprises a design selected from the group consisting of a single helix, a double helix, a stacked double helix, a wave spring, and combinations thereof. E. The pump dispenser of paragraphs A-D, wherein the housing includes a first housing and a separate second housing, the first housing partially enclosing the spring and the second housing comprising a dosing chamber. F. The pump dispenser of paragraphs A-E, wherein the pump head further comprises threads that mate with corresponding threads on the exterior surface of the closure. G. The pump dispenser of paragraphs A-F, wherein the plastic spring does not contact the fluid product in the locked storage configuration. H. The pump dispenser of paragraphs A-G, wherein the plastic spring is not preloaded in the locked storage configuration. I. The pump dispenser of paragraphs A-H, wherein the pump dispenser comprises at least 90% of one recyclable plastic selected from the group consisting of polyethylene, polypropylene, polyethylene terephthalate, and combinations thereof. J. The pump dispenser of paragraphs A-I, wherein the pump dispenser comprises at least 95% of one recyclable plastic selected from the group consisting of polyethylene, polypropylene, polyethylene terephthalate, and combinations thereof. K. The pump dispenser of paragraphs A-J, wherein the pump head further comprises pump head threads and the closure further comprises corresponding closure threads, the pump head threads being threadably engaged with the corresponding closure threads. L. The composition of paragraphs A-K, wherein the inner wall of the housing includes one or more retention features adapted to engage a surface of the second stem. M. A method of dispensing a liquid product from a pump dispenser according to paragraphs A-L, comprising: a) disengaging the cantilever from a first snap; b) engaging the cantilever with a second snap; c) pressing the pump head downward about 1 to about 10 times to prime the pump assembly; and d) depressing the pump head, thereby compressing the spring to dispense the liquid product from the pump dispenser. N. The method of paragraph M, wherein the pump dispenses from about 2 mL to about 6 mL, preferably from about 2.5 mL to about 5.5 mL, more preferably from about 3 mL to about 5 mL, and even more preferably from about 3.6 mL to about 4.4 mL of liquid product per pumping stroke. O. The method of paragraph M or N, wherein the pump assembly comprises a peak operating force at 90% stroke of less than 40 N, preferably less than 35 N, and more preferably less than 30 N, as determined by the average peak operating force test method using water described herein. P. The method of paragraphs M-O, wherein the plastic spring does not contact the fluid product during dispensing. Q. The method of paragraphs M-P, wherein the inner wall of the housing further comprises one or more retention features adapted to engage a surface of the second stem, and the spring is partially compressed after priming and / or dispensing. R. The method of paragraphs M-Q, wherein the pump head further comprises pump head threads and the closure further comprises corresponding closure threads, the pump head threads being threadably engaged with the corresponding closure threads, and the pump head is rotated simultaneously with or prior to step (a) to disengage the pump head threads.

[0083] Dimensions and values ​​disclosed herein should not be understood as being strictly limited to the exact numerical values ​​recited. Instead, unless otherwise indicated, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm."

[0084] All documents cited herein, including any cross-referenced or related patents or patent applications, and any patent applications or patents to which this application claims priority or benefit, are incorporated herein by reference in their entirety, unless expressly stated to the contrary. The citation of any document shall not be deemed to be prior art to any invention disclosed or claimed herein, or to teach, suggest or disclose such invention, either alone or in combination with any other reference(s). Furthermore, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

[0085] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims

1. 1. A pump dispenser comprising: a) a bottle having a neck with a neck landing zone, the bottle containing a fluent product; b) a pump assembly in a locked storage configuration, i) a pump head having an internal cavity, the pump head adapted to receive an end of a first stem; ii) a closure coupled to the neck of the body; and iii) the first stem, the first stem comprising an end rigidly connected to the pump head, a hollow interior cavity fluidly connected to the pump head cavity, and an exterior surface having a first snap, the first stem being configured to move relative to the second stem; iv) a second stem at least partially surrounding the first stem, the second stem having a hollow interior channel in fluid communication with an interior cavity of the first stem, the second stem comprising a platform and a cantilever, the cantilever interlocking with the first snap; v) a plastic spring at least partially surrounding the second stem; and vi) a pump assembly comprising: a housing at least partially enclosing the spring, the housing comprising an inner wall and a dosing chamber having a hollow interior, the hollow interior being in fluid communication with the internal channel of the second stem; A pump dispenser, wherein the pump assembly comprises at least 80% of one recyclable plastic selected from the group consisting of polyethylene, polypropylene, polyethylene terephthalate, and combinations thereof.

2. 2. The pump dispenser of claim 1, wherein the distance from the neck landing zone to the top of the pump head is less than 25 mm.

3. 3. The pump dispenser of claim 1 or 2, wherein the plastic spring comprises a design selected from the group consisting of single helix, double helix, stacked double helix, wave spring, and combinations thereof.

4. A pump dispenser according to any one of claims 1 to 3, wherein the housing comprises a first housing and a separate second housing, the first housing partially enclosing the spring and the second housing comprising the dosing chamber.

5. The pump dispenser of any one of claims 1 to 4, wherein the pump head further comprises threads that mate with corresponding threads on an exterior surface of the closure.

6. The pump dispenser of any one of claims 1 to 5, wherein the plastic spring does not contact the fluent product in the locked storage configuration.

7. A pump dispenser according to any preceding claim, wherein the plastic spring is not preloaded in the locked storage configuration.

8. The pump dispenser of any one of claims 1 to 7, wherein the pump dispenser comprises at least 90% of one recyclable plastic selected from the group consisting of polyethylene, polypropylene, polyethylene terephthalate, and combinations thereof.

9. The pump dispenser of any one of claims 1 to 8, wherein the housing includes an inner wall, the inner wall of the housing comprising one or more retention features adapted to engage a surface of the second stem.

10. A method of dispensing a liquid product from a pump dispenser according to any one of claims 1 to 9, comprising the steps of: the pump dispenser further comprising a second snap on the exterior surface; a) disengaging the cantilever from the first snap; b) engaging the cantilever with the second snap; c) priming the pump assembly by pressing the pump head downward about 1 to about 10 times; and d) depressing the pump head, thereby compressing the spring to dispense the liquid product from the pump dispenser.

11. The method of claim 10, wherein the pump dispenses from about 2 mL to about 6 mL of the liquid product per pumping stroke.

12. 12. The method of claim 10 or 11, wherein the pump assembly comprises a peak operating force at 90% stroke of less than 40 N as determined by the average peak operating force test method using water described herein.

13. The method according to any one of claims 10 to 12, wherein the plastic spring does not come into contact with the fluent product during dispensing.

14. 14. The method of any one of claims 10 to 13, wherein the inner wall of the housing further comprises one or more retention features adapted to engage a surface of the second stem, and the spring is partially compressed after priming and / or dispensing.

15. 15. The method of any one of claims 10 to 14, wherein the pump head further comprises pump head threads and the closure further comprises corresponding closure threads, the pump head threads being threadably engaged with the corresponding closure threads, and the pump head is rotated simultaneously with or prior to step (a) to disengage the pump head threads.

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