WO2006028582A1

WO2006028582A1 - Sleeve for recharging a cleaning, sanitizing or disinfectant fluid spray system

Info

Publication number: WO2006028582A1
Application number: PCT/US2005/025881
Authority: WO
Inventors: Albert R. Kelly; George Schmidt
Original assignee: Nordico Market Development Inc.
Priority date: 2004-09-07
Filing date: 2005-07-20
Publication date: 2006-03-16

Abstract

A recharge sleeve, for use with a spray dispenser device, made of a matrix comprising an absorptive material which has been impregnated with a chemical which becomes dissolved in solution when contacted with a diluent fluid such as water but which remains dry to the touch until contacted with diluent fluid. The recharge sleeve is formed in an elongated shape with a center opening parallel to the long edges of the sleeve for mounting on the standard plastic downtube of the spray dispenser device. A plug formed of a rigid plastic is provided for attachment to the lower end of the downtube for holding the sleeve clear of the lower end of the downtube, after the sleeve has been applied to the downtube. When the spray bottle is filled with fluid, such as water, sealed, and shaken, the fluid penetrates into the matrix material, and the chemical composition becomes dissolved in solution, thereby creating a cleaning, sanitizing or disinfectant solution that will remain stable and fully active in use.

Description

Sleeve for Recharging a Cleaning, Sanitizing or Disinfectant Fluid Spray System

FIELD OF THE INVENTION

This invention generally relates to spray bottle systems for dispensing cleaning, sanitizing or disinfectant fluids, and more particularly, to a recharge sleeve for placement over the downtube provided with a position-fixing plug mounted on the bottom-most portion of the downtube for maintaining the sleeve clear of the lower intake end of the downtube.

BACKGROUND OF THE INVENTION

Due to regulations curtailing the use of aerosol dispensers for chemical reagents that discharge foaming or pressurized gases or hydrocarbons into the atmosphere, the use of spray bottles that are manually pumped has become widespread. The typical spray bottle dispenser consists of a plastic container holding fluid with chemical reagent dissolved therein, which is sealed by a threaded cap mounting a sprayhead from which a downtube projects and extends downwardly into the body of the container. When the user operates a trigger on the sprayhead, the contents of the downtube are pumped up into the sprayhead and sprayed out from a directional orifice or nozzle. Many vendors sell separately bottles of fluid for refilling the spray dispenser bottle, or for transferring the sprayhead thereto when the contents of the first-purchased dispenser bottle are used up, so that the sprayhead and bottle can be reused. Often, the refill bottles contain a large volume of fluid so that the original dispenser bottle can be refilled several times before another refill bottle needs to be purchased.

This widely used type of spray dispenser system has associated therewith several problems which the present invention seeks to eliminate. One problem is that the refill bottles take up a large volume which incurs additional shipping costs, storage costs, and demand for shelf space. Another problem is that a refill bottle must be sold for the specific types of fluid it is intended as a refill. Thus, if a vendor sells different formulations of the same cleaner (ordinary cleaning, high strength) or different types of cleaners under the same product name (lemon-scented, disinfecting, kitchen/bath tile cleaner), then a refill bottle must be sold for each grade and type of fluid.

A further problem is that pouring fluid from the refill bottle can incur spills or require potentially hazardous handling of caustic or toxic fluids. On the other hand, if the fluids must be made in very dilute concentrations for public safety in handling, then the cleaning ability or effectiveness of the product may be compromised. The refill bottles themselves are discarded after use, thus adding to plastic pollution and landfill waste. There have been various proposals for providing a rechargeable insert holding chemical in concentrated form which can be used with a spray dispenser system. For example, U.S. Pat. Nos. 3,655,096, 3,966,089, 4,088,246, and 5,421,483 show a capsule or cartridge holding concentrated material which is secured in the neck of the bottle and released by threading the sealing cap or a ringnut against it to puncture its bottom walls aglϊnst^' a'sϊiaηp^' element^' of fd' squeeze the concentrate out. These types ofpuncturable or burstable cartridge systems are costly to fabricate, complicated to operate, and potentially hazardous if a problem occurs and the user must open the container and reposition or remove a failed cartridge. U.S. Pat. No. 5,529,216 shows another rechargeable spray dispenser system in which an elongated insert having one or more concentrate-containing compartments is inserted in the bottle, and a sharp end of the downtube is used to puncture through upper and/or lower sealing membranes in order to release the concentrate into the diluent fluid (water) filled into the bottle. However, this type of recharge insert must be purchased with a sharp downtube, and cannot be used with an existing or currently marketed spray dispenser bottle that has a blunt downtube. Moreover, the sealing walls must be punctured by the user manipulating the downtube while the container is open, thereby presenting a risk that concentrate will be ejected under the pressure applied to the sealing walls back at the user. U.S. Pat. No. 6,540,109 discloses a rechargeable spray bottle dispenser including at least one chemical reservoir received within the bottle. The reservoirs contain concentrated chemicals and can be released into the bottle by bursting, puncturing or other suitable means. This type of design requires the modification of the spray bottles at the point of manufacture and cannot be used economically on the conventional spray bottles.

U.S. Pat. No. 6,250,511 discloses dry-to-the touch elongated rechargeable inserts, which contain chemicals that can be dissolved in water for cleaning purposes. The inserts are applied to the outside of the downtube in a spray bottle and the insert is prevented from Blocking tE^'e ^"intake end (ϊowefend) of the downtube by employing one of the following designs: tight fitting between the downtube and the insert, the use of lower spacer legs, the use of an upper retaining disk, or wrapping the slotted insert around the downtube.

SUMMARY OF THE INVENTION

In the present invention, there is provided a recharge sleeve, for use with a spray dispenser device having a container body, a sprayhead mounted with a sealing cap, and an elongated downtube which is inserted into the container body during use, and a plug applied to the lower (intake) end of the downtube to prevent the sleeve from blocking the lower end of the downtube. The sleeve is comprised of absorptive material, of one or multiple layers with at least one of the layers being an absorptive material. The absorptive material or the at least one layer thereof in the latter case is impregnated with a non-aqueous chemical composition which will dissolve when contacted with a diluent fluid such as water. The recharge sleeve is formed in an elongated rectangular shape with a center opening for mounting on the downtube. The sleeve material has an outer surface which is porous to fluid filled into the container body so that the fluid can penetrate into the sleeve material and dissolve the chemical composition which has been impregnated therein. A substantially rigid plug is provided and attached to the lower end of the downtube preferably after the sleeve has been applied to the downtube to keep the sleeve from blocking the intake of the downtube and impeding or blocking the liquid flow into the downtube. Di'a^rfe^'ferria'emB'ϋdihϊeritt tne sleeve material is a multiple layered synthetic, binder-free, nonwoven substrate enclosing an opening along its center axis for inserting the downtube therethrough. The multiple layers are bonded together without a chemical binder, such as by heat bonding, ultrasonic bonding, stitching, or mechanical or hydraulic entanglement, or are constituted of an open-celled foam material. The cleaning, sanitizing or disinfectant chemical composition is impregnated into the absorptive material or a layer thereof by coating or spraying the adsorptive material or layer with a treatment solution. The sleeve material has a desired porosity, in order to allow fluid to penetrate through the material and dissolve the chemical composition impregnated therein. The plug which is substantially rigid, is preferably made of a polymeric material or a blend thereof, such as polyester or polypropylene. The upper end of the plug possesses an inside diameter that can receive the lower (intake) end of the downtube and allow for attachment to the downtube.

When the spray bottle is filled with water, sealed, and shaken, the chemical composition becomes dissolved in the water, thereby creating a cleaning, sanitizing or disinfectant solution that will remain stable and fully active.

The objects, features, and advantages of the present invention will be explained in the following detailed description of the invention having reference to the appended drawings. BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. IA to IF illustrate a preferred embodiment of a recharge sleeve in accordance with the invention, and the steps for using it. FIG. 2 illustrates a preferred embodiment of a recharge sleeve and the steps of making it.

FIG. 3A and 3B illustrate a preferred embodiment of the plug to be used in conjunction with the sleeve in accordance with the invention. 3 A is a top view and 3B is a side view with the right side in 3B shown as a cross section along the A-C-B line in 3 A.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. IA to IF, a preferred embodiment of a recharge sleeve 20 in accordance with the present invention is illustrated for use with a standard spray dispenser device having a container body 12 for holding fluid, a sprayhead 14 mounted with a sealing cap 14a, spray trigger 14b, and spray orifice or nozzle 14c, an elongated downtube 10 which is inserted into the body of the container 12 during use, and a plug 30 attached to the lower end of the downtube. The recharge sleeve 20 is comprised of an absorbent matrix material with one or multiple layers wherein at least one layer is impregnated with a chemical composition, leaving the sleeve dry-to-the-touch, the chemical composition becoming dissolved in solution with a diluent fluid such as commonly available tap water W.

The recharge sleeve 20 is shaped as an rectangular elongated sleeve by adding or combining at least two layers of water insoluble fibrous material sealed along their elongated edges, and having an open channel parallel to the elongated edges with openings on the short edges. When the original contents of the spray bottle are used up, the sealing cap is removed (typically by unthreading) from the container body. In the preferred embodiment, the^r°recn^"arge "sleeve is mounted by inserting it over the downtube 10 until the intake end of the downtube projects from the end of the sleeve 20. The plug 30 is thereafter attached to the intake end of the plastic downtube of a spray dispenser so that it can keep the sleeve at its position above the lower intake end of the downtube. When the spray bottle is filled with water W, sealed with the sealing cap 14a, and shaken, the chemical composition impregnated in the absorptive material of the sleeve 20 becomes dissolved by the fluid to form a cleaning, sanitizing or disinfectant solution WS. The sleeve material and/or each layer thereof comprises a water insoluble, binder- free fibrous substrate. The layers are bonded together without a chemical binder, such as by ultrasonic bonding, stitching, or mechanical or hydraulic entanglement. For example, the layers can be made up of synthetic fibers processed into woven, knitted, or nonwoven forms, or synthetic fibers combined with natural fibers. The substrate can also be a flexible, open-celled foam material. Use of a chemical binder is avoided to prevent such chemicals from being dissolved by and leaching into the fluid, thereby contaminating or reducing the effectiveness of the cleaning, sanitizing or disinfectant solution. The nonwoven substrate can be fabricated and/or processed so that its outer surface has a desired porosity to allow fluid to readily penetrate into the adsorptive material and dissolve the chemical impregnated therein. The fluid penetration is significantly facilitated by the use of needle bonding in the manufacture of the sleeve material for joining multiple layers to form a unitary composite material. The sonic and needling processes leave pores in the material which allow efficient fluid flow. If there is more than one layer, the layers can be bonded together using any of the above-mentioned bonding methods. Needling clearly offers the added benefit of enhanced fluid flow efficiency. The layer or multiple layers can be made into the sleeve after sealing along the elongated edges using any of the means mentioned above.

In an embodiment of the sleeve, as shown in FIG. 2, two layers (200) of the fibrous material form the sleeve (20), and each layer is further divided to two layers (101 and 102). The layer facing outside (102) comprises non- woven synthetic material that provides enhanced structural integrity to minimize the damage to the sleeve during vigorous shaking. The layer facing inside (101) comprises non- woven synthetic material that is optimized to absorb large amount of cleaning composition. In an alternative mode of the preferred embodiment, each layer of the sleeve comprises three layers, the middle layer being the absorptive layer, and the outmost and innermost layers being structural mechanical stabilization layers. Each layer is needle punched (pores introduced by needling and shown as 201), as the bonding methods for layers comprising multiple layers, which further provides pores that facilitate the liquid flow across the layer(s). The two layers of fibrous material are preferably joined together to form the sleeve by ultra- sonically bonding them along the two elongated edges.

The desired cleaning, sanitizing or disinfectant chemical composition can be impregnated in the matrix material by any suitable means. For example, a simple chemical impregnation process is described in commonly owned U.S. Pat. No. 5,091,102 to Sheridan, which is incorporated in its entirety herein by reference. In the Sheridan process, the matrix substrate is coated with non aqueous treatment solution so that the resulting material is dry to the touch and has the desired amount of chemical composition impregnated therein so that it can be released by contact with water prior to use. The absorptive material is capable of absorbing a cleaning composition in an amount of up to at least six times of its basis ^"welgBtr'The treatment solution can comprise between about 25% and 75% of at least one glycol compound, between 0.2% and 60% of an antimicrobial component, between about 5% and 45% of a surfactant, and optionally effective amounts of fragrances, dyes and other additives. The preferred means of holding the sleeve in its position on the downtube and therefore preventing it from blocking the intake end of the downtube during use or recharging, the latter typically involving vigorous shakings, is by the application of a plug (30 in FIG. 1) onto the lower end of the downtube after the sleeve has been applied to the tube. One example of a plug that can be used for this purpose is illustrated in FIG. 3a and FIG. 3b. The upper end of the plug has an opening (300) larger than the outside diameter of the downtube, and an inside diameter (301) that can allow the plug to tightly fit onto the lower end of the downtube. The lower end of the plug has an inside diameter (302) that is smaller than the outside diameter of the downtube, and therefore does not allow the downtube to protrude out of the lower end of the plug. Multiple ridges (400) are provided on the outside surface of the plug in a radial manner. During application, the plug is attached to the lower end of the downtube after the sleeve has been applied to the downtube. The combination of a tight fitting between the plug and the downtube, and the enlarged effective diameter of the plug through the introduction of the ridges can prevent the sleeve from sapping downwardly on the downtube. The lower end of the plug possesses at least one opening to the side (500). The opening allows the solution to flow into the downtube in the event that the lower end of the plug is in contact with the bottom of the spray bottle. Because downtubes employed in various commercial spray bottles may possess different outside diameters, multiple plugs are necessary for typical daily recharging operations with each combination of the upper end and lower end inside diameters optimized for a downtube with a particular outside diameter. Alternatively, instead of having two distinct inside diameters for the upper and lower ends, the plug can possess a void with a conical shape, with the upper end opening larger than the lower end opening. Plugs designed in this manner have the potential of universally fitting downtubes with different outside diameters, provided that the upper end opening is large enough to accommodate the outside diameter of the thickest downtubes, and the lower end opening is smaller than the outside diameter of the narrowest downtubes. Another design of the plug can have multiple inside diameters in the central void in a decreasing and stepwise order from the upper end opening to the lower end opening. Plugs designed in this manner also possess the capability of universally fitting downtubes with different outside diameters. The plug can be manufactured using various materials with appropriate mechanical strength, ease of manufacturing, low cost, and chemical stability toward typical cleaning, sanitizing and disinfecting compositions. The preferred materials are rigid synthetic polymers. The most preferred synthetic polymers for this purpose are polyesters or polypropylene.

Of course, other modes for mounting the recharge sleeve on the downtube of a standard spray dispenser can be used, such as those discussed in U.S. Pat. No. 6,250,511. The invention thus provides a dry-to-the-touch recharge sleeve for allowing convenient re-use of a spray dispenser bottle. The recharge sleeve and the plug are preferably provided together as an entirely self-contained unit which does not require any modification to standard spray dispenser devices for its use. The dry-to-the-touch recharge sleeve eliminates the need to ship, stock, and stack refill bottles for each type and grade of cleaning fluid of the original product. They are a fraction of the weight and volume of refills in solution, and can be manufactured at low cost. It can also be installed easily, without potential hazards to the user due to spillage, or puncturing or bursting of cartridges.

The recharge sleeves have been described herein for use with a spray dispenser device for delivering cleaning, sanitizing and the like solutions. The recharge sleeves can additionally be used to deliver flavorants, medicinals or nutriceuticals by impregnating the sleeve matrix material with a composition which when the sleeve is introduced into a delivery bottle or container such as conventionally used for water, juice or the like provided with a cap having attached on its inner aspect a downtube by placement of the sleeve over the downtube, on contact with the water or other fluid in the bottle or container the impregnated flavorant, nutriceuticals, etc., will be dissolved in the water or other fluid. When the container is emptied all that is necessary is to remove the recharge sleeve and replace it with another. An early appreciated advantage appreciated advantage of this aspect of the invention is that it is no longer necessary to ship or carry filled bottles, or to refrigerate filled bottles. The bottle once emptied can have a new recharge sleeve inserted at the point or time of use.

Another advantage lies in the economics; a packet of sleeve inserts can be purchased without having to repurchase a bottle or container for each use.

It is to be understood that many modifications and variations may be devised given the above description of the principles of the invention. It is intended that all such modifications and variations be coήsiSered as within the spirit and scope of this invention, as defined in the following claims.

Claims

I claim: L A recharge sleeve for use with a spray dispenser device having a container body, a spray head removably mounted with a sealing cap to said container body and an elongated down tube connected to said spray head, which is inserted into and extends into the container body during use, and a hollow plug which is attached to the intake and bottom-most end of the downtube, the sleeve comprising a matrix material made from natural or synthetic woven or nonwoven or knitted fibers or combinations thereof, impregnated with a chemical composition so that the matrix material remain dry to the touch, said chemical composition being capable of being dissolved in solution with a diluent fluid present in said container body, said matrix material having an outer surface which is porous to fluid present in said container body whereby fluid can penetrate into the matrix material and dissolve the chemical composition impregnated therein for forming solution thereof in the fluid, said recharge sleeve being adapted for removal when spent and being replaced with another impregnated sleeve, said sleeve matrix material comprising at least one rectangular shaped layer bonded along its elongated edges so as to form an opening in the center thereof parallel to the elongated edges for mounting on said down tube.

2. A recharge sleeve according to claim 1, wherein the said matrix material comprises at least two layers.

J. A recharge sleeve according to claim 2, wherein the said at least two layers are joined by mechanical bonding.

4. A recharge sleeve according to claim 3, wherein the bonding is achieved by needle punching through at least the two layers.

5. A recharge sleeve according to claim 3, wherein the bonding is achieved by ultrasonic bonding through at least the two layers.

6. A recharge sleeve according to claim 1, wherein the matrix is, at least in part, a synthetic, binder-free, nonwoven material.

7. A recharge sleeve according to claim 1, wherein the matrix is made of, at least in part, a synthetic, polymer material.

8. A recharge sleeve according to claim 1, wherein the matrix is, at least in part, an open- celled foam material.

9. A recharge sleeve according to claim 1, wherein the said hollow plug possesses multiple ridges on its outside surface protruding outward radially for holding the sleeve clear of the lower end of the downtube.

10. A recharge sleeve according to claim 1, wherein the said hollow plug possesses at least one opening to the side at the lower end for allowing the solution to flow into the downtube in the event that the lower end of the plug is in contact with the bottom of the spray dispenser.

11. A recharge sleeve according to claim 1, wherein the plug possesses an inside diameter at its upper end opening substantially equal to the outside diameter of the downtube so that the plug can fit tightly on the downtube, and an inside diameter at its lower end opening smaller than the outside ^"diameter of the downtube so that the downtube can not protrude from the lower end of the plug.

12. A recharge sleeve according to claim 1, wherein the plug possesses a continuously decreasing inside diameter from its upper end opening to its lower end opening, the upper end opening inside diameter large enough to receive the downtube into the plug and the lower end inside diameter small enough to prevent the downtube from protruding from the lower end of the plug.

13. A recharge sleeve according to claim 1, wherein the plug possesses a stepwise decreasing inside diameter from its upper end opening to its lower end opening, one of the inside diameters other than the lower end inside diameter being substantially equal to the outside diameter of the downtube and therefore capable of fitting tightly on the downtube, and the lower end inside diameter being smaller than the outside diameter of the downtube to prevent the downtube from protruding from the lower end of the plug.

14. A recharge sleeve according to claim 1, wherein the plug is made of a synthetic polymer.

15. A recharge sleeve according to claim 14, wherein the said polymer is selected from the group consisting essentially of polyester and polypropylene.

16. A recharge sleeve according to claim 1, wherein the said matrix is capable of holding chemicals in an amount of at least six times of its basis weight.

17. A spray dispenser system comprising a container body for containing diluent fluid therein, a spray head removably mounted with a sealing cap to said container body and an elongated down tube connected to said spray head which is inserted into and extends into the container body during use, and a hollow plug which is attached to the intake bottom- most end of the downtube for holding the sleeve above the lower intake end of the downtube, a recharge sleeve comprising at least two rectangular shaped layers bonded along its elongated edges so as to form an opening in the center thereof parallel to the elongated edges for mounting on said downtube, said sleeve comprising a matrix material made from natural or synthetic woven or nonwoven or knitted fibers or combinations thereof, impregnated with a chemical composition so that the matrix material remain dry to the touch, said chemical composition being capable of being dissolved in solution with a diluent fluid present in said container body, said matrix material having an outer surface which is porous to fluid present in said container body whereby fluid can penetrate into the matrix material and dissolve the chemical composition impregnated therein for forming solution thereof in the fluid, said recharge sleeve being adapted for removal when spent and being replaced with another impregnated sleeve

18. A spray bottle system for dispensing, cleaning, sanitizing or disinfectant fluids having a container body, a spray head removably mounted with a sealing cap to said container body and an elongated down tube connected to said spray head, which is inserted into and extends into the container body during use, the improvement of a recharge sleeve and plug according to claim 1.

19. A kit comprising a sleeve and a hollow plug according to claim 1.