The present invention relates to dispensers, and especially to pump dispensers for use in dispensing liquids from cartons and the like.

Background

Pump dispensers in which a plunger-actuated pump is mounted in the neck of a container by a closure cap are well-known. The closure cap is designed so as to fit onto standard container neck openings, enabling use with a wide variety of commercial containers. Typically, the container with which the pump is used is a plastic bottle or tub. It is also known to use such pumps in combination with cartons.

Cartons to contain liquids are typically made of e.g. paperboard or cardboard for structural strength, laminated with thin layers of other materials such as foils and polymers to make them impermeable to liquid. Usually the carton has a top (or end) wall with an opening for

dispensing the product. The carton is usually designed for single use and the opening may have a foil or plastics seal layer which must be broken or torn away before dispensing. The opening may be defined in a neck component, usually a plastics moulding fixed into the wall of the carton, and this neck component may have a neck with a closure-securing formation such as a thread, or one or more snap ribs, for fixing a removable lid or cap.

A pump assembly can be attached to this neck component, with a dip tube extending down into the carton interior from the pump inlet. However, dispensers in which pumps are fitted to cartons tend to be unstable and inconvenient in use because of the carton's deformability .

The Invention

An aim herein is to provide new and useful dispensers and pump assemblies therefor, particularly of the hand- operable plunger-actuated type, which may be connected to cartons or other readily deformable containers for pumping of liquid from the cartons with less distortion of the container, improved stability and better convenience of use.

The invention proposes a pump assembly, for dispensing liquid from a carton or other deformable container

(hereinafter "container") to which the pump assembly is attached. The pump assembly comprises a pump having a pump body and a movable actuator, such as a reciprocable plunger. The pump body defines a pump chamber with an inlet, and a dip tube is connected to the pump inlet to extend into liquid product in the container in use. The actuator is movable relative to the pump body in a pumping stroke to alter the volume of the pump chamber for dispensing. The assembly also comprises a closure component for mounting the pump body in an opening of the container. According to our proposal the dip tube has a foot which, in use, engages with a wall of the container to maintain orientation of the pump when the plunger is actuated.

The foot has an engagement portion including an engagement face for engaging a wall of the container to inhibit movement of the foot relative to the wall.

Preferably the engagement face is on a distal side of the foot relative to the dip tube. Usually the pump assembly is configured for attachment at a container opening in a top wall of the container, and the engagement face of the foot engages with a bottom wall or floor of the container. The dip tube may be straight, and/or the engagement portion of the foot may engage with a bottom wall of the container at a location directly below the neck of the container.

The engagement face desirably comprises a grip

formation to enhance engagement with the wall to reduce or restrict movement of the foot. Preferably most,

substantially all, or all of the engagement face has such a grip formation. In general terms this corresponds to the engagement face being textured for improved grip. The grip formation may comprise an array of grip projections, such as ridges and/or teeth, distributed over the engagement face.

The engagement face is preferably flat or substantially generally flat (disregarding the non-uniformity of grip formations) so as to make substantial area contact against a generally flat container wall. The engagement face may be a single face or provided as two or more separate sub-regions e.g. distributed around or across the dip tube axis; each such sub-region may have a respective grip formation.

Desirably the area of the engagement face constitutes at least 5%, at least 10%, at least 15%, at least 20%, at least 25% or at least 30% of the projected area of the foot and dip tube that overlies the container wall engaged thereby. A substantial proportion of this projected area may be open and non-contacting, to maximise liquid

admission. If however the foot has an engagement portion that extends further beneath the dip tube, e.g. so that all liquid inflow is above the level of the engagement portion, a higher area percentage of engagement face area (up to 100%) is possible. The larger the engagement area and friction or interlock, the greater the stabilising effect. Correspondingly, said projected area of the engagement face is desirably as large as practically possible, such as at least 75%, at least 80%, at least 85% or at least 90% of the area of the container opening (through which usually it must be passed for assembly) .

The foot may have a connector formation for attaching to the dip tube. The connector formation may be e . g . a socket into which the dip tube fits or a spigot onto which the dip tube fits. The connector formation may have one or more retaining elements such as retaining ribs located on a surface thereof to help retain the foot on the dip tube.

The foot preferably has an end stop to limit and define the distance the dip tube overlaps into or onto the foot. This is valuable because achieving a predetermined length of the tube/foot assembly helps promote reliable engagement of the foot with the container wall. For example, the end-stop may comprise one or more projections formed in a socket, or a plate against which the end of the dip tube abuts when inserted into the socket.

The foot generally allows for and preferably defines a flow path for liquid to enter the dip tube, typically under suction from the pump above. The flow path may have one or more entry openings, which may be defined by one or more wall portions of the foot. The one or more entry openings may be directed laterally/radially relative to the dip tube axis direction at the foot. One or more wall portions of the foot may extend down past the opening (s) e.g. connecting down to the engagement portion(s). Plural radially-directed entry openings, e.g. two oppositely-directed openings, may be defined between such wall portions. An entry opening may be upwardly-convergent e.g. inverted V-shaped in form to promote clearance flow.

The foot may be formed separately from the dip tube by e.g. injection moulding or any other suitable process.

Forming the foot as a separate component may be advantageous as the dip tube and the foot can be formed of different materials. Furthermore, providing the foot as a separate component may allow the invention to be more easily

implemented in pumps with a range of different dip tube lengths. However, in some embodiments, the foot may be integrally formed with the dip tube. This may allow for increased ease of assembly of the invention.

Drawing together the above proposals, a preferred dip tube foot herein is a one-piece moulded component comprising a proximal tubular male or female connector formation for the dip tube, a distal engagement portion having a generally flat engagement face with a grip formation, one or more wall portions connecting between the connector formation and the engagement portion, the component defining a flow path communicating between the connector formation and one or more laterally-directed entry openings defined by or between the one or more wall portions, and an integral filter portion spanning the flow path.

To exploit the stabilising effect of the foot, is preferred that the dip tube is relatively rigid, so as to resist sideways bending, or buckling when compressed along its axis. Usually the dip tube has a circular cross- section, and preferably is cylindrical. A relatively large transverse dimension, e.g. diameter, is one means for providing relative rigidity. Desirably this dimension is at least 30%, at least 40% or at least 50% of the transverse dimension e.g. diameter of the pump body that inserts into the container opening, and/or of the container opening itself. Another means is the use of a relatively stiff material. Thus, while many typical dip tubes are made of e.g. low density polyethylene (LDPE) , high density

polyethylene (HDPE), or 50:50 mixture of LDPE and HDPE, the present dip tube may be made of a stiffer material such as a polyester e.g. copolyester, polypropylene (PP), or other suitable material. Preferably the material of the dip tube is a food-grade material. The dip tube material may have a

Young's Modulus of at least 1 GPa, more preferably at least 1.5 GPa. The skilled person can also select an appropriate tube wall thickness to combine economy with adequate rigidity. Providing the dip tube with substantial rigidity helps to maintain orientation of the pump when the plunger is actuated, by reducing bending or buckling of the dip tube as the foot of the dip tube contacts the wall of the container .

The shape and/or length of the assembly are selected so that when the pump is attached to the container such as a carton, the foot engages with an opposed wall of the container, at least when the pump is actuated. More preferably, the shape and/or length of the dip tube are selected so that the foot engages the wall of the container also when the pump is not actuated, and desirably with interference so that the dip tube is compressed along its axis, between opposed container walls, when the pump is attached to the container. Δ said wall may be deformed outwardly by the assembly in this condition. By selecting dip tube and foot dimensions, pump assemblies according to the present invention may be used in containers of a wide range of sizes . The tolerance in cutting of dip tube length during production may be ±2 mm or less, more preferably ±1 mm or less. By reducing the tolerance during production, greater reliability may be achieved.

Preferably, the pump assembly includes a filter. It is desirable that the filter should prevent passage of

particles having a diameter or maximum dimension greater than or equal to 0.5 mm. Particles of 0.5 mm and above are particularly an issue where the liquid to be pumped is for human consumption. Such particles may enter the liquid e.g. during attachment of the pump assembly to the container. As the assembly is inserted into the container once an outer container closure has been removed, there may be shearing of plastic from around the opening, e.g. from a ruptured seal member.

In some applications, particles smaller than 0.5 mm may also pose problems, and so it is envisaged that the size of filter may be selected as appropriate for the desired application. Therefore, in some applications, it may be desirable that the filter prevents passage of particles with a diameter of less than 0.4 mm, less than 0.3 mm or less than 0.2 mm. The size of the filter should also be selected to be appropriate to the desired flow through the filter during a pumping operation of the pump.

Conveniently, such a filter is provided as a filter portion of the foot, spanning a liquid flow path thereof. The filter may be integrally formed as part of the foot e.g. during moulding, as a foraminate, porous or perforated part thereof which may be in the form of a layer or plate spanning the flow path. Or, it may be added as a separate component . Such a layer or plate may also be a stop for location of the inserted dip tube, where the foot has a receiving socket for the foot.

Preferably at least 50% of the axial length of the pump body is recessed inside the container. This may be

implemented by the closure component engaging the pump body at or adjacent its top, or at least in the top (outer) half of the axial length thereof. More preferably, substantially all of the pump chamber or pump body lies between the closure component and the dip tube . Such an arrangement reduces leverage at the actuator tending to swing the pump assembly relative to the container in use, because there is a less significant length of pump projecting from the neck opening. Furthermore, such an arrangement may be more aesthetically appealing.

Preferably, the closure component e.g. cap has a screw thread for reversible engagement with a corresponding screw thread on the neck of the container to which the pump is attached when in use. The neck of the container may be any one of several standard thread closures, but in particular may be of a size typically used in e.g. food packaging. For example, the diameter of the neck may be 50 mm or less.

Aspects of our invention include the pump assembly as described, a dispenser comprising the pump assembly fitted to a container such as a carton, and the described foot component which can be used to adapt a dip tube. The container and pump may additionally have any of the features discussed in the Background section above.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described by way of example with reference to the accompanying drawings in which:

Fig. 1 shows a schematic cross-sectional view through a typical carton and pump arrangement in use, showing

distortion of the carton; Fig. 2 shows one embodiment of a pump assembly of the present invention;

Figs. 3(a), (b) and (c) show three different

perspective views of a dip tube foot of an embodiment of the present invention, and

Figs. 4(a), (b) and (c) show three different

perspective views of a dip tube foot according to a second embodiment of the present invention. DETAILED DESCRIPTION, FURTHER OPTIONAL FEATURES

Fig. 1 shows a schematic cross-sectional view through a typical carton and pump arrangement 100 in use, showing distortion of the carton 101 on actuation of the pump. The pump has a pump body 103 including a plunger 105, for actuating the pump in a pumping stroke to dispense liquid from a pump chamber (not shown) defined by the pump body. The pump body is mounted on a closure cap 107, which attaches to a standard closure of the carton. A dip tube 109 extends from the pump body.

As the plunger 105 is actuated in a pumping stroke by depression on the plunger, this force on the pump causes buckling and distortion of the carton. The orientation of the pump is also altered. Such distortion occurs because actuation of the plunger involves application of a downwards force on the plunger, thus putting the carton in

compression. As typical cartons are made of laminated paperboard, they are susceptible to distortion in

compression, and accordingly distortion of the carton and misorientation of the pump can occur. Such problems may be exacerbated depending on the exact combination of materials which the carton is made from.

Such problems may also be present where the pump dispenser is used in combination with other containers that are susceptible to distortion during use of the pump. For example, a similar problem may occur when a pump is used in combination with a bottle made from a flexible plastic. Distortion of the container to which the pump is attached is undesirable as it can lead to damage of the container, which can shorten the container lifespan. Furthermore,

misorientation of the pump can reduce the ease with which a consumer may use the pump.

Figure 2 shows an embodiment of a pump 1 of the present invention. The pump has a pump body 3 and a plunger 5 for actuating the ump. The plunger is reciprocable relative to the pump body in a pumping stroke to alter the volume of a pump chamber (not shown) defined by the pump body and accordingly dispense liquid from the pump chamber. The pump body is mounted on a closure component, here a closure cap 7, such that the pump body passes through the closure cap. In this particular embodiment, the closure cap has a screw thread which, in use, engages with a corresponding standard

28/400 neck screw thread on the neck of a container to affix the pump to the container, however the exact size of the closure cap may be selected as appropriate for the intended use of the pump. The pump has a dip tube 9 extending from the pump body 3. In this embodiment the dip tube is made of a polymer having Young's Modulus greater than about 1 GPa . For example, the dip tube is made from polypropylene (PP) . In this way, the dip tube is relatively rigid compared to a dip tube made from, e.g. LDPE.

Substantially all of the pump chamber is intermediate the closure cap and the dip tube. Accordingly, when in use, most or all of the pump chamber sits within the container to which the pump is attached when in use. The diameter of the pump body at all points intermediate the closure cap and the dip tube is less than the diameter of the closure cap. This enables the entire pump body to fit easily through a neck of a container to which the pump is attached in use.

The dip tube has a foot 11 attached at a free end of the dip tube 9 (i.e. at an opposing end to the end which is attached to the pump body 3) . In this specific embodiment, the dip tube is held by a connector formation which is a receiving socket 13 of the foot which surrounds the end of the dip tube. The foot may have a filter portion (shown in Figs. 4(a), (b) and (c)). In use, an engagement face of an engagement portion of the foot engages with a bottom wall of the container to maintain orientation of the pump when the plunger is actuated. In this embodiment, the container wall engaged by the foot (generally the bottom wall) is the opposing wall of the container to the wall of the container in which the container neck is formed (generally the top wall) . As mentioned at the outset the container may be e.g. a carton or other deformable container 101 of the kind described, e.g. made from paperboard or cardboard, as shown schematically in Fig. 1.

As the foot engages with a wall of the container in use, a liquid path through or past the foot is provided to enable liquid to enter the dip tube. Here, a 'V-shaped' entry opening 15 is defined by the foot and provides a flow channel (typical flow during use being indicated by an arrow) . Liquid is drawn into this channel during operation of the pump, before travelling up the dip tube 9 into the pump chamber and being dispensed from the pump 1.

Figs. 3(a), (b) and (c) show three different

perspective views of one type of dip tube foot 11 proposed herein. Here, the foot is a separate component from the dip tube. Accordingly, such a foot may be retro-fitted to any suitable pump that otherwise fulfils the requirements of the present invention.

The foot has an end-stop plate 16 located within the receiving socket 13 of the foot. This limits the distance which the dip tube can be inserted into the socket. A filter portion 17 is integrally formed in this end-stop plate. Accordingly in this configuration, the end of the dip tube abuts the filter portion of the foot. The filter portion is sized to prevent passage of particles having a diameter of 0.5 mm or larger through the filter portion. In this embodiment, the filter portion is located such that it is abutted by a dip tube, when said dip tube is inserted into the receiving portion 13 of the foot. To provide a flow path for liquid during operation of the pump, wall portions 14 define two entry openings 15. During operation, liquid may therefore flow through these openings, then through the filter portion of the foot to enter the dip tube .

The foot has an engagement portion 21 which in use engages with a wall of a container to which the pump having the foot is attached. The engagement portion 21 has an engagement face 22 comprising a grip formation. The engagement face is located on an opposing side of the foot to the retaining socket which connects to a dip tube of the pump. In this embodiment, the grip formation is a ridged gripping portion comprising an array of ridges which covers the entire engagement face, however in other embodiments, the gripping portion may only cover part of the engagement face. The array of ridges which form the grip formation can help to prevent movement of the foot with respect to the wall of the container.

Figs. 4(a), (b) and (c) show three different

perspective views of a second type of dip tube foot 11 proposed herein (as also seen in Fig. 2) . Here, the foot has a 'V-shaped' end-stop plate 16 located in a receiving socket 13 of the foot. Wall portions 14 of the foot define

'inverted V-shaped' openings 15 which define a liquid flow conduit or channel (indicated by an arrow in Fig. 4(a)) which is located between the foot and the wall of the container with which the foot is engaged in use. Such a foot can provide for improved evacuation of a container to which the pump is attached. A filter portion 17 is located in the -shaped end-stop plate, the filter portion here being formed of an array of suitably-sized apertures passing through the end-stop plate.

The foot has flange-like engagement portions 21a, 21b which extend from the receiving socket 13 of the foot. Here, the engagement portions 21a, 21b form, a continuous flange with wall portions 14. The engagement portions have respective engagement faces 22a, 22b, each of which has a respective grip formation covering the whole engagement face. Here, the grip formation is an array of ridges or grooves .

In this embodiment, the receiving socket has retaining ribs 23 disposed on an inner surface of the socket. These ribs are not essential, but can help retain a dip tube inserted into the socket.

While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. For example, a further embodiment contemplated includes a foot having an angled end-stop plate, which may provide improved evacuation of a container, and may be particularly suitable for use with dip-tubes having a bevel-cut free end.

Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the invention .