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 / 212,972, filed Jun. 21, 2021, and U.S. Application No. 17 / 841,312, filed Jun. 15, 2022, the entireties of which are incorporated herein by reference.

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

Background Art

[0003] Trigger sprayer assemblies provide a convenient way to manually dispense many household and commercial cleaning agents in the form of a stream, spray, mist, or foam via the actuation of a trigger lever. In some cases, a trigger sprayer assembly can be configured to provide a continuous or long - term spray where fluid is dispensed from the trigger sprayer assembly for a certain period of time after the actuation of the trigger lever has ceased. Existing continuous trigger sprayer assemblies are generally very large compared to other trigger sprayer assemblies. This is because continuous trigger sprayer assemblies often require a secondary reservoir for storing the fluid dispensed during long - term spraying and a means for pressurizing that fluid. Thus, an improved trigger sprayer assembly that provides long - term spraying in an optimized space - saving package could be useful.

Summary of the Invention

[0004] The present invention relates to a trigger sprayer assembly for discharging a continuous or long-duration spray or flow of fluid. The trigger sprayer assembly includes an engine including a piston chamber and an outlet fluid passage fluid-coupled to the piston chamber, and 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 in the internal bellows chamber is smallest, and a compressed position, where the available flow rate in the internal bellows chamber is largeest. The trigger sprayer assembly further includes a trigger lever preferably connected to the engine and piston using a pair of S-shaped trigger springs, the trigger lever configured to pivot between a neutral position and an operating position. The pivoting of the trigger lever from the neutral position to the operating position pushes the 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 a partially or fully compressed position. When the trigger lever is pulled, fluid is supplied from the internal bellows chamber to the outlet fluid passage, and when the trigger lever is released, fluid continues to be supplied from the internal bellows chamber to the outlet fluid passage even as the bellows component relaxes and moves from the compressed to the uncompressed position.

[0005] According to another embodiment of the present invention, a trigger sprayer assembly for discharging a continuous or long-duration spray or flow of fluid includes an engine comprising a piston chamber and a piston valve, the piston valve configured to control a unidirectional flow of fluid through the piston from the piston chamber to an internal bellows chamber. The trigger sprayer assembly includes a piston slidably positioned within the piston chamber and defining an internal bellows chamber, and a bellows component positioned 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 smallest and a fully compressed position where the available flow rate in the internal bellows chamber is largest. The trigger spray includes a trigger lever connected to the engine and piston, the trigger lever configured to pivot between a neutral position and an operating position, an input valve configured to control a unidirectional flow of fluid from an inlet portion to the piston chamber, a piston valve configured to control a unidirectional flow of fluid from the piston chamber to the internal bellows chamber, and an output valve configured to control a unidirectional flow of fluid through an outlet portion. When the trigger lever pivots from the neutral position to the operating position, the piston is pushed vertically within the piston chamber, forcing fluid through the piston valve from the piston chamber to the internal bellows chamber, and moving the bellows component from the uncompressed position to the 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 and through the outlet valve, even as the bellows component relaxes and moves from the compressed position to the uncompressed position.

[0006] In another embodiment, the present invention is a method for discharging fluid from a trigger sprayer assembly that enables continuous or long-term spraying. The method includes pulling a trigger lever toward the rear end of the trigger sprayer assembly, the trigger lever pushing the piston vertically within the piston chamber so that fluid is fed through the piston valve from the piston chamber into an internal bellows chamber formed within the piston. In response to pulling the trigger lever, the bellows component located within the internal bellows chamber moves from an uncompressed position to a compressed position. The method further includes releasing the trigger lever toward the 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 an uncompressed position, feeding the fluid from the internal bellows chamber into an outlet fluid passage. [Brief explanation of the drawing]

[0007] The present invention will be described with reference to the following figures. The same numbers are used throughout the figures to refer to similar features and components. [Figure 1] Figure 1 is a perspective view of a trigger sprayer assembly according to an exemplary embodiment of the present invention. [Figure 2] Figure 2 is a side view of the trigger sprayer assembly shown in Figure 1. [Figure 3] Figure 3 is an exploded view of the trigger sprayer assembly shown in Figure 1. [Figure 4A] Figure 4A is a perspective view of the trigger component used in the trigger sprayer assembly shown in Figure 1. [Figure 4B] Figure 4B is another perspective view of the trigger component in Figure 4A. [Figure 5A] Figure 5A is a perspective view of the engine components used in the trigger sprayer assembly shown in Figure 1. [Figure 5B] Figure 5B is another perspective view of the engine components shown in Figure 5A. [Figure 5C]Figure 5C is a bottom view of the engine components shown in Figure 5A. [Figure 5D] Figure 5D is a side cross-sectional view of the engine component along the line 5D-5D in Figure 5B. [Figure 6A] Figure 6A is a perspective view of the piston coupler used in the trigger sprayer assembly shown in Figure 1. [Figure 6B] Figure 6B is a side cross-sectional view of the piston coupler along the line 6B-6B in Figure 6A. [Figure 6C] Figure 6C is a side cross-sectional view of the piston coupler along line 6C-6C in Figure 6A. [Figure 7A] Figure 7A is a perspective view of the piston used in the trigger sprayer assembly shown in Figure 1. [Figure 7B] Figure 7B is a side cross-sectional view of the piston along the line 7B-7B in Figure 7A. [Figure 7C] Figure 7C is a cross-sectional view of the bottom of the piston along the line 7C-7C in Figure 7B. [Figure 8A] Figure 8A is a perspective view of the input housing used in the trigger sprayer assembly shown in Figure 1. [Figure 8B] Figure 8B is a side cross-sectional view of the input housing along line 8B-8B in Figure 8A. [Figure 8C] Figure 8C is another side cross-sectional view of the input housing along line 8C-8C in Figure 8A. [Figure 9] Figure 9 is a perspective view showing the connection of the shroud components used in the trigger sprayer assembly of Figure 1. [Figure 10A] Figure 10A is a side cross-sectional view of the trigger sprayer assembly along line 10A-10A in Figure 1. [Figure 10B] Figure 10B is another side cross-sectional view of the trigger sprayer assembly showing the fluid flow as the trigger component moves from the neutral position to the depressed position. [Figure 10C]Figure 10C is another side cross-sectional view of the trigger sprayer assembly showing the 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] Figure 10D is another side cross-sectional view of the trigger sprayer assembly showing the fluid flow when the bellows component is fully relaxed from the compressed position. [Modes for carrying out the invention]

[0008] Figures 1 to 3 show an improved trigger sprayer assembly 100 according to an exemplary embodiment of the present invention. The trigger sprayer assembly 100 can be adapted to dispense a fluid (e.g., cleaning products, industrial products, water, cosmetics, food) contained in a bottle or container (not shown) in a stream, spray, or mist discharge pattern. To operate the sprayer assembly 100, the user grasps the trigger component 106 at the front end 136 of the assembly 100 and places their thumb on the shrouds 132, 134 at the rear end 138 of the assembly 100. By pressing or pushing the trigger component 106 from the relaxed or neutral position to the pressed or activated position toward the rear end 138, the fluid from the bottle or container is dispensed through the nozzle 124. In some embodiments, the nozzle 124 is configured to rotate relative to the shroud components 132, 134 so that the user can open and close the fluid passage terminating at the nozzle 124 and select a desired discharge pattern (e.g., stream, spray, mist).

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

[0010] When the trigger lever 106 is pressed toward the rear end 138 of the assembly 100, the piston component 104 is biased downward by the trigger component 106 within the piston chamber formed in the engine 102. As a result, the available flow rate of the piston chamber decreases, and the fluid within the piston chamber is pushed upward through the one-way piston valve 118 into the internal chamber within the piston component 104. The elastic bellows component 112 and the bellows spring 114 are disposed within the internal chamber and are pushed into the internal chamber by the fluid flowing through the one-way piston valve 118. When the bellows component 112 and the bellows spring 114 are pushed in, the fluid also flows out of the piston component 104, enters the fluid outlet passage within the engine 102, and exits through the nozzle 124 (when the nozzle 124 is rotated to the open position).

[0011] When the actuating force is removed and the trigger component 106 relaxes toward the front end 136, the trigger component 106 pulls the piston 104 upward within the piston chamber, increasing the volume of the piston chamber and drawing the fluid supply into the piston chamber. At the same time, as the bellows component 112 and the bellows spring 114 relax from the pushed-in position, the fluid continues to be pushed out of the piston component 104 and enters the fluid outlet passage within the engine 102. Thus, continuous or long-term spraying can be obtained even after the user is no longer actively operating the trigger lever 106. Further details regarding specific steps in the operation of the trigger sprayer assembly 100 will be described below with reference to FIGS. 10A - 10D.

[0012] Still referring to FIG. 3, the input housing 110 is shown to be disposed below the engine 102. The input housing 110 can be configured to be connected to a dip tube 128 that extends into a fluid bottle or container (not shown) and provides a path for drawing fluid upward into the nebulizer assembly 100. The input housing 110 provides a pedestal for a one-way input valve 116 that regulates the flow of fluid into the engine 102. As shown, in the illustrated embodiment, the one-way input valve 116 is a ball valve, although other types of one-way valves may be utilized.

[0013] The neck closure 126 is shown to be disposed below 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 of the neck closure (e.g., height, outer diameter, inner diameter) can be variable based on the size and shape of the bottle or container that houses the liquid to be dispensed. In the illustrated embodiment, the neck closure 126 includes threads and is configured to be threadedly coupled to the neck portion of the bottle or container. In other embodiments, 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 below the neck closure 126 can be utilized to ensure, among other things, that fluid does not leak between the engine 102 and the input housing 110 and does not leak out through the neck closure 126, particularly when the trigger nebulizer assembly 100 is tilted or inverted.

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

[0015] In the exemplary embodiment, the bellows component 112, piston valve 118, and nozzle valve 120 are made from thermoplastic elastomer (TPE) using an injection molding process. TPE exhibits many properties advantageous for valves that come into contact with various fluids, including high wear 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 different materials, such as liquid silicone rubber, or may be made using different manufacturing processes.

[0016] Next, with reference to Figures 4A and 4B, a perspective view of the trigger lever component 106 is shown. The trigger lever component 106 is shown including a main trigger body 402, from which a lever grip portion 400 and a pair of S-shaped springs 408 extend. The springs 408 are configured to compress when the user applies an operating force to the lever grip portion 400, causing the trigger lever 106 to move from the neutral position to the pressed position. When the user releases the operating force, the potential energy stored in the springs 408 returns the trigger component 106 to the neutral position. Since the piston 104 is connected to the trigger lever 106, the return of the trigger 106 to the neutral position pulls the piston 104 upward within the piston chamber, drawing fluid upward through the immersion tube 128 and filling the piston chamber in preparation for subsequent operation 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 end 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 found that S-shaped trigger springs having both a concave and a convex portion are less susceptible to fatigue damage and provide the user with a smoother operating feel. In the exemplary embodiment, the first curved portion 410 has a larger radius of curvature than the second curved portion 412 so that the first curved portion 410 is more easily compressed than the second curved portion 412. As will be described in more detail below with reference to Figures 5A, 5B and 10A, the end portion 414 of the spring 408 is inserted into a receiving region (e.g., a spring socket 518) formed in the engine 102, so that the ball-shaped end portion 414 is constrained vertically but not constrained in pivoting within the receiving region. In the exemplary embodiment, the spring 408 is connected to the main trigger body 402 using a living hinge, and the placement of the end portion 414 within the receiving region may include pivoting the spring 408 along the living hinge relative to the main trigger body 402.

[0018] The trigger lever component 106 is further shown to include a pair of pivot flanges 404 extending rearward from the main trigger body 402 opposite the lever grip portion 400. The pivot flanges 404 include a pivot recess 406 formed in the pivot flange 404 and configured to receive a pivot pin (e.g., a pivot pin 514 shown in Figures 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 connection between the pin and the recess may be reversed so that the pivot flange 404 includes a pin configured to fit into a recess formed in the engine 102.

[0019] Other connecting members on the trigger component 106 include a pair of piston coupling pins 416 extending into the internal region of the main trigger body 402 (shown in Figure 4B). The piston coupling pins 416 are configured to be received by recesses formed in the piston coupler 108 (e.g., piston coupling recesses 606 shown in Figures 6A and 6B). The engagement of the piston coupling pins 416 within the recesses converts the rotational motion of the trigger lever 106 into linear motion of the piston 104 and the piston coupler 108. Similar to the pivot recess 406, in other embodiments, the connection between the pins and the recesses may be reversed so that the piston coupling recesses are formed in the main trigger body 402 and the pins are located on the piston coupler 108.

[0020] Figures 5A to 5D show perspective, bottom, and side section views of the engine 102, respectively. The engine 102 includes a vertically-oriented piston chamber 500 and a vertically-oriented fluid outlet chamber 502 positioned parallel to the piston chamber 500. As specifically shown in Figure 5D, the piston outlet 522 is used to fluidize the piston chamber 500 to the outlet chamber 502. The vertically-oriented fluid outlet chamber 502 is also shown to fluidize a horizontally-oriented fluid outlet chamber 504. A nozzle flange 506 extends from the horizontally-oriented fluid outlet chamber 504 and provides a base for mounting the output valve 120, water jacket 122, and rotatable nozzle 124.

[0021] The engine 102 is shown including a pivot wedge body 512 on the opposite side of the outlet chamber 504 and nozzle flange 506, from which a pair of opposing pivot pins 514 extend. The shape of the wedge body 512 may match the rear contour of the shroud components 132, 134 (see Figures 10A to 10D) so that the wedge body 512 provides structural support in areas where the shroud components 132, 134 may be grasped by the user's thumb during operation, thereby preventing excessive deflection of the shroud components 132, 134. A pivot recess 406 formed in the pivot flange 404 of the trigger lever 106 is configured to engage with the pivot pin 514 so that the trigger lever 106 can pivot relative to the engine 102 about the pivot pin 514. In the exemplary embodiment, the pivot flange 404 is connected to the pivot pin 514 using a snap-fit ​​assembly process.

[0022] Below the pistons and outlet chambers 500, 502, the engine 102 is shown to include a neck coupling 508. The neck coupling 508 is generally cylindrical and has a larger outer diameter than the combined pistons 500 and outlet chambers 502. In the exemplary embodiment, the neck coupling 508 may include a pair of radial openings 510. When the neck coupling component 126 (see Figure 3) is coupled to the engine 102, a pair of flanges located on the neck coupling component 126 extend through the radial openings 510 to hold the neck coupling component 126 on the engine 102.

[0023] The engine 102, located above the neck coupling 508 and within the piston chamber 500, is shown to include 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 it has traveled through the immersion tube 128 and the input housing 110 (see Figure 10C). The valve seat of the input ball valve 116 may be located within the input housing 110 (e.g., valve seat 810, see Figures 8B and 8C), and when the input housing 110 is coupled to the engine 102, the valve capture prong 520 is located above the input ball valve 116. If the flow pressure in the immersion tube 128 is sufficient to lift the ball valve 116 from its valve seat in the input housing 110, the capture prong 520 prevents the ball valve 116 from moving into the piston chamber 500 while allowing fluid to flow into the piston chamber 500. In embodiments where the input valve 116 is a different type of valve other than a ball valve (e.g., an elastic cross-slit or flap valve), the capture prong 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 at the top of a reinforcing rib 516 extending outward from a vertically oriented fluid outlet chamber 502. The spring-receiving recesses 518 are configured to receive the end portion 414 of the trigger spring 408 (see Figures 4A and 4B) using a snap-fit ​​assembly process. Once coupled, the end portion 414 and the receiving recesses 518 can act as a ball joint, allowing the trigger spring 408 to rotate relative to the engine 102 when the trigger spring 408 is pressed during the operation of the trigger lever 106. A pair of shroud-aligned flanges 526, specifically shown in Figures 5A and 5B, are shown extending outward beneath the pivot wedge body 512. Each of the shroud alignment flanges 526 is configured to fit into the corresponding shroud jackets (shroud jackets 912, 914, see Figure 9) when the shroud components 132, 134 are assembled to the engine 102, ensuring that the shroud components 132, 134 have proper vertical alignment with respect to the engine 102.

[0025] Next, with reference to Figures 6A and 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 at an upper wall 602. A pair of opposing flanges 604 extend upward from the upper wall 602, and each flange 604 has a piston coupling recess 606 formed through it. As described above, the recess 606 is configured to receive a piston coupling pin 416 extending from the trigger lever 106.

[0026] The piston coupler 108 is further shown to include a bellows spring alignment 608 (see Figures 6B and 6C) extending downward from the upper wall 602 within the internal region of the coupler 108 surrounded by the side wall 600. The bellows spring (e.g., the bellows spring 114 shown in Figures 3 and 10A-10D) is configured to be inserted onto the spring alignment 608 during the assembly of the trigger sprayer assembly 100. As will be described in more detail below with reference to Figures 10A-10D, the spring alignment 608 ensures that the bellows spring compresses and relaxes along its vertical axis, thereby preventing the bellows spring from tilting and damaging the bellows component.

[0027] Figures 7A to 7C show perspective and cross-sectional views of the piston 104. The piston 104 is generally shown to include a cylindrical side wall 700, with an upper flange 702 located at the vertical midpoint of the side wall 700 and a lower flange 704 located at the lower end of the side wall 700. Multiple piston outlets 706 are shown arranged in a radial pattern near the lower flange 704 and extending through the side wall 700. For example, in the exemplary embodiments shown in Figures 7A to 7C, the piston 104 includes four piston outlets 706 arranged equidistant from each other (i.e., 90° apart). In other embodiments, the piston 104 may include more or fewer piston outlets 706. When the piston 104 is inserted into the piston chamber 500 (see Figure 10A), the upper flange 702 and the lower flange 704 form a substantially watertight seal against the side wall of the piston chamber 500. This arrangement ensures that all fluid flowing out through the piston outlet 706 travels circumferentially around the piston sidewall 700 and through the piston outlet 522 formed within the engine 102 (see Figure 5D).

[0028] The internal structure of the piston 104, specifically shown in Figure 7B, is shown to include an internal bellows chamber 708 located above the piston inlet passage 710. The internal bellows chamber 708 and the piston inlet passage 710 are separated by a piston valve structure 712. When the piston valve (e.g., piston valve 118) is in the closed position within the piston valve structure 712, the flow of fluid from the piston chamber 500 in the engine 102 to the bellows chamber 708 is blocked. However, if the flow pressure in the piston chamber 500 is sufficient to lift the piston valve from its valve seat in the piston valve structure 712 to move it to the open position, the fluid will flow 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 into the bellows chamber 708 before exiting the piston 104 through one of the piston outlets 706.

[0029] Next, with reference to Figures 8A to 8C, perspective and cross-sectional views of the input housing 110 are shown. The input housing 110 is shown to include a disc-shaped body 800 comprising 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 an immersion tube connector 808. As shown in Figures 10A to 10D, an immersion tube 128 extending into the fluid container is inserted into the immersion tube connector 808, providing a path for the fluid to move 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 the upper end of the first cylindrical portion 802 opposite to the immersion tube connector 808. Sufficient fluid pressure within the immersion pipe connection 808 lifts the ball valve from the valve seat 810, allowing the 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 within the engine 102 (see Figures 10A to 10D).

[0030] The second cylindrical section 804 includes a discharge passage 814. The discharge passage 814 allows excess fluid in the chamber 502 to return to the fluid container after the trigger lever 106 is deactivated and the bellows component 112 is returned to a position where it is not fully pressed, preventing the flow from passing through the nozzle 124. The input housing 110 is also shown to include a pair of retaining projections 812 extending below the body 800. The retaining projections 812 are used to hold a sealing gasket (e.g., gasket 130 shown in Figure 3) against the body 800, preventing fluid leakage from the engine 102 and the input housing 110.

[0031] The following is an example process for assembling the trigger sprayer assembly 100: 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 onto the piston 104 using a snap-fit ​​assembly process, holding the bellows 112 and bellows spring 114 inside the piston 104.

[0032] The assembly process continues as follows: Insert the piston 104 into the piston chamber 500 of the engine 102. Assemble the trigger lever 106 to the engine by snapping the recess 406 formed in the pivot flange 404 of the trigger lever 106 onto the pivot pin 514 extending from the wedge body 512 of the engine 102. Connect the trigger lever 106 to the piston 104 and insert the piston coupling pin 416 of the trigger lever 106 into the piston coupling recess 606 formed in the piston coupler 108 to ensure that the operation of the trigger lever 106 results in the corresponding movement of the piston 104. Next, insert the end 414 of each trigger spring 408 into the corresponding spring socket 518 located in the engine 102.

[0033] Next, the input valve 116 is inserted into the valve seat 810 formed in the input housing 110. The input housing 110 is then connected 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 snap-fitted to the engine 102. To assemble the nozzle components of the trigger sprayer assembly 100, the nozzle valve 120 and 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 hold the nozzle valve 120 and water jacket 122 inside the engine 102.

[0034] The final step of the assembly process includes connecting the shroud components 132 and 134 to each other and to the engine 102, as will be described in more detail below with reference to Figure 9. The immersion tube 128 is inserted into the immersion tube connector 808, and the fluid bottle or container is connected to the neck closure 126. In the exemplary embodiment, one or more of the assembly steps detailed above are performed using a pneumatic robotic device to insert and connect the various components to each other. Advantageously, some steps of the assembly method involve moving multiple components along parallel horizontal or vertical axes, which are suitable for assembly using a robotic device.

[0035] Figure 9 shows the connection of shroud components 132 and 134. The right-hand shroud component 132 is shown including an upper prong 900, a front lower prong 902, and a rear lower prong 904. The prongs 900-904 are configured to fit into the upper recess structure 906, the front lower recess structure 908, and the front lower recess structure 910 formed on the left-hand shroud component 134, thereby holding shroud components 132 and 134 in the connected position.

[0036] In addition to the retaining portions 900-910, the shroud components 132, 134 are also shown as including various members that support and align the assembly, including the jackets 912 and 914. As described above with reference to Figures 5A and 5B, the jackets 912, 914 may be configured to fit around the shroud alignment flange 526 in order to align the engine 102 with respect to the shroud components 132, 134. In the exemplary embodiment, the shroud components 132, 134 employ a double-seam design for mating.

[0037] Figures 10A to 10D show side cross-sectional views of the trigger sprayer assembly 100 when an operating cycle occurs. Specifically, Figure 10A shows the trigger sprayer assembly 100 in the neutral or relaxed position before the operating force is applied; Figure 10B shows the trigger sprayer assembly 100 in the pressed or operating position while the operating force is applied; Figure 10C shows the trigger sprayer assembly 100 returning to the neutral or relaxed position after the operating force is removed, while spraying continues through the nozzle 124 due to the relaxation of the bellows component 112; and Figure 10D shows the trigger sprayer assembly 100 after the bellows component 112 has completely returned to the relaxed or unpressed position and spraying through the nozzle 124 has stopped.

[0038] As specifically shown in Figure 10A, many of the fluid inlet and piston components (e.g., immersion tube 128, input valve 116, piston component 104, piston valve 118, bellows component 112, bellows spring 114) are positioned so 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 away from the vertical axis 1050. By arranging the components of the trigger sprayer assembly 100, in which the piston chamber and bellows chamber are nested, the total volume of the trigger sprayer assembly 100 can be advantageously minimized compared to a trigger sprayer assembly in which one or more of the fluid inlet passage, piston chamber, and chamber for capturing fluid for long-term spraying are spaced apart from each other. For example, in the exemplary embodiment, the 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 having an opening with a diameter of at least 33 mm.

[0039] Next, referring to Figure 10B, when the user places their finger 1000 on the trigger lever 106 and applies the operating force shown by arrow 1002 to move the trigger lever 106 from the neutral position to the operating position, the trigger lever 106 pivots downward as shown by arrow 1024. The S-shaped trigger spring 408 of the trigger lever 106 is compressed, driving the piston component 104 downward, thereby reducing the volume in the piston chamber 500. This reduction in volume causes the fluid flow shown by arrow 1004 to move the piston valve 118 from the closed position to the open position.

[0040] The piston valve 118 is shown as including a solid plug portion 1006 and a conical seat portion 1008. Multiple flexible members 1010 are distributed radially around the outer circumference of the conical seat portion 1008 and terminate at a ring-shaped member 1012. Flow pressure moves the plug portion 1006 upward within the piston valve structure 712. The movement of the plug portion 1006 causes the members 1010 to bend or bulge outward, thereby moving the conical seat portion 1008 from its seating position within the piston 104, allowing the fluid to flow around the flexible members 1010 as indicated by arrow 1014 and into the bellows chamber 708.

[0041] The inflow into the bellows chamber 708 moves the bellows component 112 and the bellows spring 114 from an uncompressed position (see Figure 10A) to a fully compressed position (see Figure 10B), thereby maximizing the available fluid volume within the bellows chamber 708. The bellows component 112 is shown to include an upper flange 1016 sandwiched between the piston coupler 108 and the piston component 104, and an accordion-shaped compressible side wall 1018 extending downward from the upper flange 1016. The side wall 1018 terminates at a base 1020. When the bellows component 112 and the bellows spring 114 are in an uncompressed position (see Figure 10A), the base 1020 may be positioned relative to the piston valve structure 712. The inflow into the bellows chamber 708 lifts the base 1020 away from the piston valve structure 712, the side wall 1018, and the bellows spring 114 to the compressed position.

[0042] As soon as the 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 through the surrounding piston outlet 706 and flows into the piston outlet passage 522. The fluid then flows upward through the vertically oriented outlet chamber 502 and flows into the horizontally positioned outlet chamber 504. The 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 the fluid to flow through the nozzle valve 120. When the nozzle component 124 is rotated to the 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 the exemplary embodiment, the liquid output per actuation of the trigger lever 106 is at least 1.3 CC, and each actuation provides a spray output for at least 2 seconds. The actuation force required to achieve this liquid output is preferably 65 to 75 N. Three or four actsuations of the trigger lever 106 may be required to draw fluid into the immersion tube 128 and open the input valve 116.

[0044] As shown in Figure 10C, when the user releases their finger 1000 from the trigger lever 106, the S-shaped trigger spring 408 causes the trigger lever 106 to rebound from the operating position to the neutral position in the direction indicated by arrow 1032, and the trigger lever pivots 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 within the piston chamber 500, creating a vacuum that draws fluid into the piston chamber 500 as indicated by arrow 1028. The fluid flowing in the direction of arrow 1028 flows through the immersion tube 128, moving the input ball valve 116 upward so that the ball valve 116 is lifted from its valve seat 810, allowing the fluid to flow through the ball valve 116 and replenish the piston chamber 500. At this time, since the piston 104 is moving upward, the pressure on the conical seat portion 1008 of the piston valve (indicated by arrow 1030) becomes insufficient, and the flow to the bellows chamber 708 is stopped.

[0045] Once the flow into the bellows chamber 708 is stopped, the compression of the bellows sidewall 1018 and spring component 114 ceases. The potential energy stored in the spring component 114 pushes the base 1020, causing the sidewall 1018 of the bellows component to expand. This expansion pushes the fluid in the bellows chamber 708 out of the piston 104 through the circumferential piston outlet 706, as indicated by arrow 1022. The fluid flows through the piston outlet passage 522 before moving upward through the vertically oriented outlet chamber 502, and then exits from the nozzle 124 after passing through the horizontally oriented outlet chamber 504. As described above, the flow indicated by arrow 1022 continues for at least 2 seconds due to the relaxation of the bellows after the user stops operating the trigger lever 106.

[0046] Next, referring to Figure 10D, the base 1020 of the bellows is positioned relative to 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 indicated by arrow 1036 cannot exert sufficient pressure on the nozzle valve 120 to maintain the valve in the open position, thus stopping the flow from the nozzle 124. The fluid indicated by arrow 1036 flows downward through the drainage passage 814 and returns to the fluid container in preparation for being drawn upward back into the trigger sprayer assembly 100 via the immersion pipe 128. Thus, Figures 10A to 10D show the entire stroke of the trigger lever 106 and the entire cycle of the discharge and refilling 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, substitutes, and modifications are possible within the scope of the appended claims.

Claims

1. A trigger sprayer assembly for discharging fluid, A housing including a piston chamber and an outlet fluid passage fluidly connected to the piston chamber, A piston slidably arranged within the piston chamber, the piston defining an internal bellows chamber, A bellows component disposed within the internal bellows chamber, wherein the bellows component is movable between an uncompressed position where the available flow rate within the internal bellows chamber is smallest and a compressed position where the available flow rate within the internal bellows chamber is largest. A trigger lever connected to the housing and the piston using a pair of S-shaped trigger springs, wherein the trigger lever is configured to pivot between a neutral position and an operating position, Includes, As the trigger lever pivots from the neutral position to the operating position, the piston is pushed vertically within the piston chamber, fluid is supplied from the piston chamber to the internal bellows chamber, and the bellows component is moved from the uncompressed position to the compressed position. A trigger sprayer assembly in which the bellows component relaxes and moves from the compressed position to the uncompressed position, thereby sending fluid from the internal bellows chamber to the outlet fluid passage.

2. The trigger sprayer assembly according to claim 1, wherein the piston includes a cylindrical side wall formed of 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 fluid-connected to the piston chamber, wherein when the trigger lever pivots from the operating position to the neutral position, the piston is pulled vertically into the piston chamber, and fluid flows from the inlet fluid passage into the piston chamber; An input valve configured to control the unidirectional flow of fluid through the inlet fluid passage into the piston chamber, An output valve configured to control the unidirectional flow of fluid through the outlet fluid passage, The trigger sprayer assembly according to claim 1, further comprising:

4. The trigger sprayer assembly according to claim 3, further comprising an immersion 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 the fluid container.

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

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

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

8. Each of the piston valve and the output valve includes a plug portion, a conical base extending from the plug portion, and a plurality of flexible members distributed radially around the outer circumference of the conical base portion and extending from the outer circumference, wherein the plurality of flexible members are terminated by a ring member, and the plurality of flexible members are configured to deform to allow fluid flow 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 the outlet centerline passing through the center of the vertical portion of the outlet fluid passage is offset from the piston centerline and parallel to the piston centerline.

10. The trigger sprayer assembly according to claim 1, wherein 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.

11. The bellows component described above is An upper flange configured to be connected to the piston, A compressible side wall extending downward from the upper flange and terminating at the base portion, wherein the compressible side wall and the base portion define a sealed bellows region, The trigger sprayer assembly according to claim 1, including the following:

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 connected to the housing, wherein the spray pattern of the fluid coming out of the output valve is changed by rotating the nozzle relative to the housing, and the output valve is at least partially located within the nozzle.

15. A method for discharging fluid from a trigger sprayer assembly, the method being The act of applying an operating force to a trigger lever, thereby pulling the trigger lever toward the rear end of the trigger sprayer assembly, wherein the trigger lever includes a spring configured to compress when the trigger lever is pulled, and the trigger lever pushes the piston vertically within the piston chamber, so that fluid is delivered through the piston valve from the piston chamber into an internal bellows chamber formed within the piston. In response to pulling the trigger lever, the bellows component located within the internal bellows chamber is moved from an uncompressed position to a compressed position, Releasing the operating force applied to the trigger lever, releasing the potential energy stored in the spring, and returning the trigger lever towards the front end of the trigger sprayer assembly, In response to returning the trigger lever, the bellows component is relaxed to move from the compressed position to the uncompressed position, thereby sending fluid from the internal bellows chamber to the outlet fluid passage. Includes, A method wherein the trigger lever is released toward the front end of the trigger sprayer assembly, thereby pulling the piston vertically within the piston chamber, causing fluid to flow from the inlet fluid passage into the piston chamber.

Images