Field of the invention

The present invention relates to bottle caps and dispensers for dispensing a viscous or fluid product from a bottle. The invention may find particular application in dispensing such products as soap, sanitiser, moisturiser, and like products. The bottle caps may find particular, though not exclusive, application for use with an automated or manual dispenser housing.

Background of the invention

Dispensers that dispense viscous or fluid products such as soap, sanitiser and moisturiser are often found in a healthcare environment, for example in hospitals and medical clinics. They may also be utilised in public environments such as shopping centres, as well as in the home.

The present invention is directed to bottle caps for dispensers that receive bottles that already contain the product to be dispensed. There are a number of separate problems associated with such dispenser systems.

The dispensers are often designed for use with a particular bottle and cap, such that a competitor's bottle cannot be fitted into the dispenser. However one problem faced by dispenser bottle manufacturers is that there is a further desire to prevent users from refilling and reusing the original manufacturer's bottle with a competitor's product. One solution is to make the cap permanently attached to the bottle. However this inhibits easy recycling of the bottle.

Another problem faced by manufacturers and distributors is where a number of different products are housed within the same sized and shaped bottles, such that bottles with different products are interchangeable. In a hospital environment at a particular location there may be multiple dispensers mounted together, each intended to contain a different product, such as soap, sanitiser and moisturiser. Maintenance staff may inadvertently refill a dispenser with a bottle containing an incorrect product, such that the particular location ends up having multiples of one type of product and none of another. Users and distributors may also wish to monitor the usage of products, for example for determining when a product is about to run out so that it may be reordered. To enable this to happen in a more cost-effective manner, it is the dispenser that communicates information back to a central database, rather than the individual bottles. Therefore if the wrong product bottle is placed in the wrong dispenser housing, the data collected is inaccurate. A known solution includes using mechanical keys to identify products, such that only a matching key on a bottle with its correct dispenser allows insertion into the dispenser. However this solution requires variations in tooling and production to ensure that there is a variety of different bottles produced to match the number of different products so that each product has a different key. This is quite an expensive solution particularly where there are a significant number of product variant options. Another option that doesn't require variations in bottle tooling is to use an RFID tag with a product identifier that is applied to the bottle after filling with the product. However RFID is expensive considering both programming and assembly costs, as well as on-board hardware costs for the reader, particularly given that the bottle is a consumable item.

Another issue with dispensers relates to the pump mechanism that is part of the bottle cap. Particularly where highly viscous product is dispensed, there is often a small portion of product that hangs below the dispenser outlet, which may be referred to as a 'dag'. As this dag is exposed to air flow it hardens and 'gunks up' the dispenser outlet. When the dispenser is next used the hardened 'dag' can affect the direction and pressure of the following dispensed product, such that the product can squirt in undesired directions, such as in the user's eye or onto their clothes. There is therefore a desire to minimise the amount of product remaining below the outlet that is exposed to air.

Embodiments of the present invention aim to address at least one of the above issues with existing dispensers, or provide a useful alternative.

Reference to any prior art in the specification is not an acknowledgment or suggestion that this prior art forms part of the common general knowledge in any jurisdiction or that this prior art could reasonably be expected to be understood, regarded as relevant, and/or combined with other pieces of prior art by a skilled person in the art. Summary of the invention

According to a first aspect, the present invention provides a tamper-resistant bottle cap for dispensing a viscous or fluid product, the bottle cap including: an inner member having an inner bore, a portion of the inner member being insertable into the neck of a bottle containing a viscous or fluid product to be dispensed through the inner bore; an outer member disposed peripherally about the inner member and having an inner surface with a thread enabling connection to an outer threaded portion of the neck of a bottle by means of rotating the cap in a first direction; the inner member and the outer member being connected by a coupling mechanism; the cap including at least one locking formation for engagement with the bottle such that once engaged the cap is prevented from rotating in a second direction opposite the first direction whilst the inner member and the outer member are connected; wherein, when a predetermined force is applied to the outer member in the second direction, the coupling mechanism fractures such that the outer member and inner member separate allowing rotation of the outer member in the second direction to be removed from the bottle. The locking formation is preferably on the inner member, such that the inner member cannot rotate in the second direction once the locking formation is engaged.

The inner member preferably includes a sealing portion, being an outwardly projecting and returning lip. The lip creates a channel into which the end of the bottle neck is received, sealing the bottle. Preferably, the locking formation is located on the inside surface of the returning portion of the lip. A corresponding formation is provided on the external surface of the bottle neck, such that once rotated in the first direction past the locking formation on the neck, rotation in the second direction causes the corresponding formations to abut and prevent further rotation in the second direction. The coupling mechanism may be a series of fins extending between the outer member and the returning lip portion. The fins are preferable weak in torsion, such that once the outer member is rotated in the second direction beyond the predetermined force, with the inner member being held against such rotation by the locking formation, the fins fracture allowing further rotation of the outer member in the second direction. Once fractured, the inner member may be free to move away from the bottle neck in a direction perpendicular to the first and second directions.

In a second aspect, the bottle cap according to the first aspect may further include: a plunger having a proximal end received within the inner bore, and a distal end, the plunger including a dispensing chamber having a product opening at the distal end; a flexible valve positioned within the dispensing chamber and dividing the dispensing chamber into a first area and a second area, the second area being adjacent the product opening, the valve having a resting, closed position and an open position, wherein the volume of the second area is larger when the valve is in the resting, closed position; the plunger having an extended position whereby the inner bore and first area of the dispensing chamber are loaded with product and, when moved into a retracted position the product is dispensed through the valve and product opening under pressure, moving the valve into the open position; wherein, as the plunger moves back from the retracted position to the extended position, the valve returns to its resting, closed position via the vacuum created subsequently causing a pressure change within the second area of the chamber, drawing air through the product opening and thereby drawing any underlying product back into the second area of the chamber.

According to a third aspect, the present invention provides a bottle cap with a pump arrangement for dispensing a viscous or fluid product, the bottle cap including: a body for connection to a bottle containing a viscous or fluid product, the body having an inner bore; a plunger having a proximal end received within the inner bore, and a distal end, the plunger including an internal dispensing chamber having a product opening at the distal end; a flexible valve positioned within the dispensing chamber and dividing the dispensing chamber into a first area and a second area, the second area being adjacent the product opening, the valve having a resting, closed position and an open position, wherein the volume of the second area is larger when the valve is in the resting closed position; the plunger having an extended position whereby the inner bore and first area of the dispensing chamber are loaded with product and, when moved into a retracted position the product is dispensed through the valve and product opening under pressure, moving the valve into the open position; wherein, as the plunger moves back from the retracted position to the extended position, the valve returns to its resting, closed position via the vacuum created subsequently causing a pressure change within the second area of the chamber, drawing air through the product opening and thereby drawing any underlying product back into the second area of the chamber.

The flexible valve may be configured to form a generally top-hat shape in the resting, closed position. In the open position the flexible valve may be configured to form an inverted, generally top-hat shape.

The flexible valve is preferably a one-way valve. The flexible valve may be made from any suitable material, for example silicone. The flexible valve may have a central slit opening, which could be a cross-slit opening.

The orientation of the bottle cap and pump arrangement is to be described in relation to the bottle being positioned upside down with the bottle neck opening downwards. As such, when the plunger is extended it is in a lowered position. And when the plunger is retracted it is in a raised position, forcing the product to be dispensed in a downwards direction. However, it will be appreciated that for certain aspects of the invention, the orientation of the bottle cap is irrelevant and this will be understood by a person skilled in the art. The flexible valve, in the resting, closed position, may have a generally horizontal portion that may have an upper surface that is generally flat and an under surface that forms a downwardly pointing cone, thus allowing the valve to open under downward pressure, but not in an upwards direction. The flexible valve is sized to extend across the width of the dispensing chamber internally dividing the dispensing chamber. The outer periphery of the flexible valve is preferably held in position with respect to the dispensing chamber such that the perhiphery does not move when the valve moves from the resting, closed position to the open position and back again. The top end of the inner bore may include a one-way valve such that product enters the dispensing chamber and inner bore through the one-way valve as a vacuum is created in the inner bore as the plunger is extended. An air inlet vent may be provided in the bottle cap body to allow air to enter the bottle as the product is drawn into the dispensing chamber. A bottle cap according to the first, second or third aspect may further include a selected colour identifier that is associated with the particular product contained within that bottle.

According to a fourth aspect, the present invention provides a system for dispensing viscous or fluid product, the system including: a dispenser housing; an optical sensor associated with the dispenser housing; a processor in communication with the optical sensor; a bottle filled with a viscous or fluid product, the bottle being removably receivable within the dispenser housing; and a bottle cap connected to the bottle for dispensing the product from the bottle, wherein the bottle cap includes a selected colour identifier that is associated with the particular product contained within that bottle; wherein the optical sensor detects the colour identifier and the processor associates the bottle cap colour with a particular product, such that the product being dispensed can be logged and monitored.

According to a fifth aspect, the present invention provides a dispensing apparatus, including: a housing for removably receiving a bottle filled with a viscous or fluid product, the bottle having a bottle cap connected to the bottle for dispensing the product from the bottle, wherein the bottle cap includes a selected colour identifier that is associated with the particular product contained within that bottle; an optical sensor associated with the dispenser housing; and a processor in communication with the optical sensor; wherein the optical sensor detects the colour identifier and the processor associates the bottle cap colour with a particular product, such that the product being dispensed can be logged and monitored. Brief description of the drawings

Further aspects of the present invention and further embodiments of the aspects described in the preceding paragraphs will become apparent from the following description, given by way of example and with reference to the accompanying drawings, in which: Figure 1 is a front view of a bottle with a bottle cap according to an embodiment;

Figure 2 is a cross-sectional side view through lines B-B of Figure 1 ;

Figure 3 is a cross-sectional bottom view through lines A-A of Figure 1 ;

Figure 4 is an exploded front view of the bottle cap after fracture;

Figure 5 is a cross-sectional side view through lines C-C of Figure 4; Figure 6 is a front view of a bottle cap with a pump arrangement in an extended position according to another embodiment; Figure 7 is a cross-sectional side view through lines D-D of Figure 6;

Figure 8 is a cross-sectional side view of the bottle cap of Figure 7 attached to a bottle;

Figure 9 is a cross-sectional front view of the bottle cap in the direction of lines J- J of Figure 7;

Figure 10 is a front view of the bottle cap of Figure 6 with pump arrangement in a retracted position;

Figure 1 1 is a cross-sectional side view through lines F-F of Figure 10;

Figure 7A is an enlarged view of the bulbous end of the plunger circled E in Figure 7;

Figure 1 1 A is an enlarged view of the bulbous end of the plunger circled G in Figure 1 1 ;

Figure 12 is a cross-sectional side view of an alternative bottle cap with pump arrangement; Figure 13 is a perspective view of the bottle cap of Figure 12 with a lid closure; and

Figure 14 is a schematic illustration of a system for dispensing viscous or fluid product according to a further embodiment.

Detailed description of the embodiments Figure 1 illustrates a bottle cap 10 connected to the neck 12 of a bottle 14 containing a viscous or fluid product. Suitable product could be soap, sanitiser, disinfectant, or hand cream, being products typically found in a healthcare environment such as a hospital or in the home. The bottle cap shown in Figures 1 through 5 could have any type of dispensing mechanism whereby the product is dispensed through an inner bore, an example of which is described below. The bottle cap is tamper-resistant such that when the bottle cap is screwed onto the bottle it cannot be removed and replaced in order to refill the bottle with additional product for reuse. Removal of the bottle cap results in the bottle cap being unusable.

As shown in Figures 1 and 2 the bottle cap 10 includes an inner member 16 and an outer member 18 dispose peripherally about it. The outer member 18 is a collar that extends about the outside of the bottle neck 12 and has an internal threaded surface 20 that mates with the external thread 22 of the neck 12. The bottle cap can be screwed onto the neck 12 when rotated in a first direction, typically being clockwise.

The inner member 16 includes an inner bore 24 (see Figure 2) that runs from a proximal opening 26 to a distal opening 28. The inner bore 24 is defined by an inner cylindrical sleeve 30. Extending about sleeve 30 is a chamber 32, to be described further below. Extending radially outwards from the cylindrical sleeve and chamber is an outwardly projecting and returning lip 34. The returning portion 46 of the lip creates a channel 36 into which the end of the bottle neck 12 is received when a portion of the inner member 16 is inserted into the neck. A seal (not shown) is positioned in the channel 36 sealing the product in the bottle.

Two locking formations 40 are provided on opposing sides of the bottle cap as shown in Figure 3. Each locking formation includes a protrusion 42 extending inwardly from the inner surface 44 of the returning portion 46 of the lip 34. There is also a corresponding formation 48 provided on the external surface 50 of the bottle neck above the external thread 22. As can be seen in Figure 3 the protrusions each have ramp sections 52 so that they can be rotated over each other in the first direction. However, opposing faces 54 abut against each other when rotated in the opposing second direction (e.g. counter clockwise) once engaged, preventing further rotation and removal of the cap.

The outer collar 18 and inner member 16 are connected by a coupling mechanism. In the embodiment illustrated (see Figure 1 ) the coupling mechanism is a series of fins 56 spaced radially about the returning lip portion 46. The fins connect to the distal end 58 of the collar 18. When a force is applied to the collar 18 in the second direction, the inner member

16 cannot rotate with respect to the neck past the locking formations 40. When the force exceeds a predetermined value, the connection of the fins 56 at their proximal end to the distal end 58 of the collar is fractured under the torsional stress. This results in the collar being free to rotate in the second direction and the inner member being free to fall away from the collar and the bottle. Figures 4 and 5 show the collar 18 and inner member 16 after fracture and separation, where the fins 56 have broken off from the distal end 58 of the collar. Once fractured, the collar 18 can be screwed off the bottle neck as it does not include any of the locking formations 40 that previously prevented rotation in the second direction. As the inner member 16 does not include a thread, it is not directly connected to the bottle neck and may also be removed.

The advantage of this arrangement is that the cap 10 includes a deliberately weak failure point so that it can be removed to allow the bottle to be recycled. However it prevents the cap from being reused by simply refilling the bottle with a competitor's product. The same bottle could be reused with a new bottle cap, however the bottle cap would advantageously be designed to specifically fit within an associated dispenser housing, so that a competitor's cap could not be substituted.

The particular design shown in Figures 1 to 5 allows for a single moulding whilst providing two members that can be separated when required. This significantly reduces tooling and manufacturing costs compared to known solutions. A second embodiment of a bottle cap is illustrated in Figures 6 through 1 1 , which also incorporates a body 60 having the tamper-resistant features of the bottle cap shown in Figures 1 through 5, with the same reference numerals being used to identify similar parts.

The bottle cap of this embodiment includes a pump arrangement for dispensing viscous or fluid product from within the bottle. A plunger 62 has a proximal end 64 and a stem portion 72 that is received within the inner bore 24. The stem portion 72 can slide within the inner bore 24 from an extended position, as shown in Figures 6 and 7, to a retracted position, as shown in Figures 10 and 1 1 . The stem portion 72 is prevented from removal from the inner bore 24 by step 73 on the plunger abutting against lip 75 at the distal end of the inner bore 24. The lip 75 is created by an end cap 77 that closes the lower end of the inner bore 24, attaching to sleeve 30 at point 31 . The distal end of the plunger 62 is a bulbous portion 66 having a greater diameter than the stem portion 72 that fits within the inner bore 24. The bulbous portion 66 and stem portion 72 are manufactured as 3-parts that are sealingly joined together. Whilst the end cap 77 is removed, the stem portion 72 is inserted from below into inner bore 24. The end cap 77 is then passed over the bottom of the stem portion 72 and attached to sleeve 30 at point 31 , retaining the stem portion in the inner bore 24. The bulbous portion 66 is then joined to stem portion 72.

The bulbous portion 66 is formed from 2-parts, upper portion 66a and lower portion 66b. Upper portion 66a connects to stem portion 72, whilst lower portion 66b contains product opening 69. The combined inside cavity of the stem portion 72 and bulbous portion 66 forms a dispensing chamber 68 with the product opening 69 at the distal end 70.

A flexible valve 74, typically made of a material such as silicone, is positioned in the dispensing chamber 68 within the bulbous portion 66. The valve 74 extends across the whole cross-section of the dispensing chamber and divides it into a first area 76 above the valve and a second area 78 below the valve adjacent the product opening 69.

The flexible valve 74 is clamped around its peripheral edge 80 (see Figure 7A) within the wall 82 of the bulbous portion 66, between the upper portion 66a and the lower portion 66b. The valve has side walls 84 and a top section 86 that is generally horizontally extending in the resting, closed position, as shown in Figure 7A. The side walls 84 and their bases 88 being relatively thin compared to the top section 86. This allows the valve to take two different positions, a resting, closed position, as shown in Figure 7A, where the valve is shaped like an upright top-hat, and a second open position, as shown in Figure 1 1 A, where the valve forms an inverted generally top-hat shape.

The flexible valve 74 is a one-way valve that only allows product to flow in the downward direction. A cross slit 90 is provided in the centre of the top section 86. In the resting, closed position the top section 86 has an upper surface 89 that is generally flat or slightly convex as shown in Figure 7A. The under surface 95 is slightly concave with a downwardly pointing cone section 96. The cone section 96 prevents the slit 90 opening in an upwards direction under pressure due to the portions of the cone section abutting. As shown in Figure 1 1 A, when the valve is in the second, open position the cone sections 96 flex outwardly opening the slit 90 allowing product to be dispensed.

In operation the dispensing chamber 68 is filled with product and sits in a position shown in Figure 7 ready for dispensing. When activated the plunger 62 is pushed into the inner bore 24 increasing the pressure of the product against the valve 74 causing it to transition from the resting, closed position to the second, open position, opening the slit 90. The product is forced through the valve 74 and through the second area 78 out of the product opening 69 and onto the user's hand, as illustrated in Figures 1 1 and 1 1 A. As the pump is reversed from the raised retracted position to the lowered extended position, the dispensing chamber is reloaded with product through a duckbill valve 92 from the bottle 14, as shown in Figure 8. A problem that can occur with inverted pump dispensers when the bottle nears empty is that the pump starts to draw air. This is because the pump draws from the centre of the bottle, but the product doesn't always flow into the centre where the opening is located. This is particularly a problem for higher viscosity products such as hand sanitizer that can stick to the sides of the bottle until it is pulled into the neck. A vortex is created at the bottom of the bottle and air is drawn through the pump, rather than the last 10% of the product.

The location of the duckbill valve 92 has therefore been designed to position it spaced downwardly from the start 99 of the neck, so that the cross-sectional area surrounding the pump opening is minimised.

To achieve this, in one embodiment at the top end of the sleeve 30 is connected a cap 91 that sits above the duckbill valve 92 and includes extensions 32a of chambers 32 to allow airflow into the bottle. The cap 91 is generally T-shaped (as shown in Figure 9) and has inlets 93 that are shielded by an overhanging roof 97. The inlets 93 allow product to flow from the bottle 14 into the inner bore 24 via the duckbill valve 92. The roof 97 acts as a flow disruptor, creating a longer path for the vortex to flow around. The lowering of the valve 92 means that the product is drawn from within the neck 12, so that the vortex is formed when there is less product in the bottle. This increases the amount of product that can be drawn from the bottle. As the pump reloads product through the duckbill valve 92, the flexible valve 74 inverts back to the top-hat shape increasing the volume of the second area 78. This generates a vacuum inside the second area 78 and causes a pressure change with the path of least resistance to equalise the pressure being through the product opening 69. As air is drawn through the product opening 69, any residual product that is underlying the product opening 69 is also drawn back inside the second area 78. This prevents a 'dag' from hanging under the opening 69, removing it from an environment where evaporation will cause it to harden. Any hardened product underlying the opening could cause issues with subsequent dispensing. As the plunger 72 is extended a vacuum is created in the inner bore 24 drawing the product into the dispensing chamber 68 from the bottle through the valve 92. To allow for this pressure change in the bottle 14 and so as not to collapse the side walls of the bottle, an air path is provided through chamber 32, 32a on the outside of sleeve 30 and through the top of the roof 97. A one-way ball valve 94 is provided at the bottom of chamber 32, in end cap 77, so the air can be drawn into the bottle as product is drawn from the bottle through the duckbill valve 92.

The use of the flexible one-way valve 74 prevents air being drawn back into the plunger, which can cause a subsequent dose of product being undersized. The creating of the vacuum through the product outlet 69 and sealing of all other air paths into the dispensing chamber means that the 'dag' will be drawn back into the chamber and removed from airflow external to the dispenser, thus preventing hardening. The ability to prevent a hardened 'dag' from forming minimises the need to clean or de-gunk the dispenser, minimising maintenance costs and reducing premature replacement of the bottle. Creating the vacuum effect using the valve 74 means there is no additional parts to the pump arrangement and therefore negligible additional costs.

An alternative design of the top end of the sleeve 30 is shown in Figures 12 and 13. In this embodiment, the cap 91 is omitted and sleeve extensions 30a extend further into the bottle creating chamber extensions 32a. The duckbill valve 92 remains at a similar location spaced downwardly from the start 99 of the bottle neck 12. The chambers 32 include the ball valve 94 to allow air into the bottle as product is drawn out of it through the duckbill valve 92. The sleeve extensions 30a are two semi-circular sections that end with an angled edge, as shown in Figure 13. A lid 87 can be provided to sit over and protect the plunger during transport, as shown in Figure 13. The lid prevents the pump arrangement from being activated until positioned in a dispenser housing.

The pump arrangement may be driven by a drive mechanism (not shown) associated with the dispenser housing. Such driving may be accomplished by a reciprocating arm attached to the flange 98 about the bulbous portion 66. A sensor could be used to activate the driver when a user's hand is sensed underneath the product opening 69.

Another aspect is shown in Figure 14, which could utilise any of the embodiments of the bottle cap described above. The additional feature of this bottle cap is the use of a selected colour identifier that is associated with the particular product contained within that bottle. All of the bottle cap 10, or a component, for example the sleeve 30 or end cap 77, could be moulded in a selected colour. Different colours being associated with the different types of product housed within the different bottles. For example blue for soap, green for sanitiser, and yellow for hand cream.

The bottles 14 are removably received within the dispenser housing 100. An optical sensor 102 and a processor 104 are located within the housing 100. At least one LED 106 is used to illuminate the cap 10 to ensure that only the cap's colour components are reflected. It will be appreciated that a single white LED may be used or alternately multiple coloured LEDs can be used to give a more accurate reading of colour and hence a larger range of colours can be used. The optical sensor 102 includes a photodetector (not shown) that converts the reflected light into an RGB signal and the processor 104 processes that signal into a digital numerical value. This value may be compared against stored data to identify the colour of the cap and therefore the contents of the bottle. Alternatively, the RGB value is reported to a remote device and identified remotely. The information about the product may then be recorded and communicated to the user or the manufacturers, for example the number of pumps to determine when the bottle needs replacing.

It will be appreciated that the colour identifier may be provided by a coloured sticker rather than by moulding the cap in the selected colour. By using this product identification system, each separate product is packaged on a production line and a cap installed as the closure without requiring different tooling for each product. An infinite number of products could be dispensed in the dispenser via the same cap type. Therefore each separate product line will have a different colour associated with it. The product loaded into the dispenser can then be detected by the optical sensor by identifying the associated colour.

It will be understood that the invention disclosed and defined in this specification extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention.