WO2024243282A1

WO2024243282A1 - Free liquid applicator

Info

Publication number: WO2024243282A1
Application number: PCT/US2024/030519
Authority: WO
Inventors: Patrick NIEMCZYK; Luis PAGAN
Original assignee: Porex Technologies Corp
Current assignee: Porex Technologies Corp
Priority date: 2023-05-22
Filing date: 2024-05-22
Publication date: 2024-11-28
Anticipated expiration: 2025-11-22

Abstract

A free liquid applicator includes a housing containing a free liquid and a dispensing opening. An insert is secured in the dispensing opening of the housing. The insert includes an applicator portion and a vent portion. The applicator portion exerts a capillary force on the free liquid that is higher than the capillary force exerted on the free liquid by the vent portion.

Description

FREE LIQUID APPLICATOR

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This patent application claims priority to and the benefit of the filing date of United States provisional patent application serial number 63/468,182 filed May 22, 2023 for "Vented Free Ink Devices, Systems, and Methods," the entire contents of which are incorporated by this reference.

BACKGROUND

[0002] Typical free ink systems usually include an applicator tip and a vent. The applicator absorbs the free ink and the vent works to displace the loss of ink with air to allow the applicator to absorb the ink. The vent is typically placed in another location separate from the applicator. See US Patent 6,322,269 Bl for one example of a free ink system.

[0003] Ink reservoir systems usually include an applicator tip, a reservoir, and a vent. The applicator absorbs the ink from the reservoir. The reservoir works to hold onto the ink to prevent leakage from the system. The vent works to displace the loss of ink within the reservoir to allow the applicator to absorb the ink. The vent is typically a hole in the assembly body.

[0004] These typical systems leave room for improvement. For instance, it is not always possible, practical, and/or convenient to include a separate vent hole in the device. Moreover, these typical systems do not always allow for compete dispensing of all of the liquid from the device, with some liquid remaining trapped in the device that cannot be dispensed.

SUMMARY

[0005] We have developed a vented applicator for free ink devices that does not require the addition of a separate vent hole in the assembly body. An applicator insert works as both the applicator tip and the vent. No reservoir is required to hold the ink to prevent leakage.

[0006] In a first example a free liquid applicator includes a housing and an insert. The housing has an interior containing a free liquid and a dispensing opening extending from the interior to an exterior of the housing. The insert is secured in the dispensing opening of the housing and includes an applicator portion configured to apply the free liquid from the interior onto a surface and a vent portion configured to equalize pressure between the interior of the housing and an external environment. The applicator portion exerts a first capillary force on the free liquid, the vent portion exerts a second capillary force on the free liquid, and the first capillary force is higher than the second capillary force. Both the applicator portion and the vent portion of the insert extend through the dispensing opening from the interior of the housing to the exterior of the housing.

[0007] In some implementations of this first example the applicator portion has an interior surface exposed to the interior of the housing and an exterior surface exposed to the external environment, and the vent portion has an interior surface exposed to the interior of the housing and an exterior surface exposed to the external environment.

[0008] In some implementations of this first example the applicator portion and the vent portion physically contact each other along an entire length of the dispensing opening.

[0009] In some implementations of this first example the applicator portion is a porous polymer portion featuring a first pore size, the vent portion is a porous polymer portion featuring a second pore size, and the first pore size is smaller than the second pore size.

[0010] In some implementations of this first example the first pore size is 60% or less than the second pore size.

[0011] In some implementations of this first example the first pore size is 35% or less than the second pore size.

[0012] In some implementations of this first example the first pore size is in the range of 5-35 microns and the second pore size is in the range of 55-100 microns.

[0013] In some implementations of this first example the first pore size is in the range of 10-25 microns and the second pore size is in the range of 65-90 microns.

[0014] In some implementations of this first example the applicator portion and the vent portion are sintered polymer particles.

[0015] In some implementations of this first example the applicator portion and the vent portion are an assembly of individual components.

[0016] In some implementations of this first example the applicator portion and the vent portion are a unitary component.

[0017] In some implementations of this first example the applicator portion is a fibrous portion with a first fiber density, the vent portion is a fibrous portion with a second fiber density, and the first fiber density is lower than the second fiber density. [0018] In some implementations of this first example: (a) the interior surface of the applicator portion has a first surface area exposed to the interior of the housing; (b) the interior surface of the vent portion comprises a second surface area exposed to the interior of the housing; (c) the insert has a total surface area exposed to the interior of the housing; (d) the first surface area is in the range of 35% - 65% of the total surface area; and (e) the second surface area is in the range of 35% - 65% of the total surface area.

[0019] In some implementations of this first example: the first surface area is in the range of 45% - 55% of the total surface area; and the second surface area is in the range of 45% - 55% of the total surface area.

[0020] In some implementations of this first example the insert is configured such that when the applicator portion dispenses the free liquid onto the surface, the applicator portion draws at least some of the free liquid from vent portion as the vent portion allows a gas to move into the interior from the external environment through the vent portion.

[0021] In a second example a free liquid applicator includes a housing and an insert. The housing having an interior containing a free liquid and a dispensing opening extending from the interior to an exterior of the housing. The insert is secured in the dispensing opening of the housing. The insert includes a porous applicator portion configured to apply the free liquid from the interior onto a surface and a porous vent portion configured to equalize pressure between the interior of the housing and an external environment. In this example the applicator portion features a first pore size, the vent portion features a second pore size, the first pore size is smaller than the second pore size, and both the applicator portion and the vent portion of the insert extend through the dispensing opening from the interior of the housing to the exterior of the housing.

[0022] In some implementations of this second example the applicator portion has an interior surface exposed to the interior of the housing and an exterior surface exposed to the external environment, and the vent portion has an interior surface exposed to the interior of the housing and an exterior surface exposed to the external environment.

[0023] In some implementations of this second example the applicator portion and the vent portion physically contact each other along an entire length of the dispensing opening.

[0024] In some implementations of this second example the first pore size is 60% or less than the second pore size. [0025] In some implementations of this second example the first pore size is in the range of 5-35 microns and the second pore size is in the range of 55-100 microns.

[0026] In some implementations of this second example the applicator portion and the vent portion comprise sintered polymer particles.

[0027] In some implementations of this second example the applicator portion and the vent portion comprise an assembly of individual components or a unitary component.

[0028] In some implementations of this second example: (a) the interior surface of the applicator portion has a first surface area exposed to the interior of the housing; (b) the interior surface of the vent portion has a second surface area exposed to the interior of the housing; (c) the insert has a total surface area exposed to the interior of the housing; (d) the first surface area is in the range of 35% - 65% of the total surface area; and (e) the second surface area is in the range of 35% - 65% of the total surface area.

[0029] In some implementations of this second example the insert is configured such that when the applicator portion dispenses the free liquid onto the surface, the applicator portion draws at least some of the free liquid from vent portion as the vent portion allows a gas to move into the interior from the external environment through the vent portion.

[0030] In a third example a free liquid applicator includes a housing and an insert. The housing has an interior containing a free liquid and a dispensing opening extending from the interior to an exterior of the housing. The insert is secured in the dispensing opening of the housing, the insert including a fibrous applicator portion configured to apply the free liquid from the interior onto a surface, the insert further including a fibrous vent portion configured to equalize pressure between the interior of the housing and an external environment. The applicator portion features a first fiber density, the vent portion features a second fiber density, and the first fiber density is greater than the second fiber density. Both the applicator portion and the vent portion of the insert extend through the dispensing opening from the interior of the housing to the exterior of the housing.

[0031] In some implementations of this third example the applicator portion has an interior surface exposed to the interior of the housing and an exterior surface exposed to the external environment; and the vent portion has an interior surface exposed to the interior of the housing and an exterior surface exposed to the external environment.

[0032] In some implementations of this third example the applicator portion and the vent portion physically contact each other along an entire length of the dispensing opening. [0033] In some implementations of this third example (a) the interior surface of the applicator portion has a first surface area exposed to the interior of the housing; (b) the interior surface of the vent portion has a second surface area exposed to the interior of the housing; (c) the insert has a total surface area exposed to the interior of the housing; (d) the first surface area is in the range of 35% - 65% of the total surface area; and (e) the second surface area is in the range of 35% - 65% of the total surface area.

[0034] In some implementations of this third example the insert is configured such that when the applicator portion dispenses the free liquid onto the surface, the applicator portion draws at least some of the free liquid from vent portion as the vent portion allows a gas to move into the interior from the external environment through the vent portion.

BRIEF DESCRIPTION OF FIGURES

[0035] FIG. 1 shows an example of a free liquid applicator.

[0036] FIG. 2 shows the housing of the free liquid applicator of FIG. 1.

[0037] FIG. 3 shows the insert of the free liquid applicator of FIG. 1.

[0038] FIGS. 4a-f show examples of inserts for a free liquid applicator.

[0039] FIG. 5 includes photographs of prototype free liquid applicators.

[0040] FIG. 6 shows a simple experiment using one of the prototype free liquid applicators of FIG. 5, illustrating how the prototype applicator allows complete dispensing of the liquid from the applicator.

DETAILED DESCRIPTION

[0041] FIGS. 1-3 show an example of a free liquid applicator 10. In this example the free liquid applicator 10 includes a housing 12 and an insert 14. FIG. 1 shows the insert 14 secured in the housing 12. FIG. 2 shows just the housing 12. FIG. 3 shows just the insert 14.

[0042] The housing 12 has an interior 16 for containing a free liquid 18 and a dispensing opening 20 extending from the interior 16 to an exterior 22 of the housing 12. In the example shown in the figures the dispensing opening 20 is the only opening extending from the interior 16 to the exterior 22 of housing 12. In other words, housing 12 does not have one opening for dispensing liquid and a separate opening for venting. In some implementations the housing may be made of a material that is not conducive to incorporating a separate venting opening (e.g. housing may be a glass ampule or other glass container with a single opening at its end). In some implementations housing may be of a preset design that cannot be revised to incorporate a separate venting opening (e.g. due to engineering constraints or simply due to practical constraints of the design and commercialization process).

[0043] The liquid in the housing 12 may be an in k, cosmetic, adhesive, formulation, or other liquid.

[0044] The insert 14 includes an applicator portion 24 and a vent portion 26. The applicator portion 24 is configured to apply the free liquid 18 from the interior 16 of the housing 12 onto a surface. The vent portion 26 is configured to equalize pressure between the interior 16 of the housing 12 and the external environment 28. The applicator portion 24 and vent portion 26 perform these different functions by exerting different capillary forces of the free liquid 18. More specifically, the applicator portion 24 exerts a capillary force of the free liquid 18 that is higher than the capillary force exerted by the vent portion 26 on the free liquid 18.

[0045] In some implementations this differential capillary force allows the applicator portion 24 to continue to apply the free liquid 18 onto a surface and the vent portion 26 to continue to provide a venting function even when both the applicator portion 24 and vent portion 26 are fully saturated with the liquid 18. While not wishing to be bound by a specific mechanism of operation, it is believed that the differential capillary forces exerted by the applicator and venting portions 24, 26 causes liquid 18 to be at least partially drawn from the saturated vent portion 26 into the applicator portion 24 such that a venting pathway through the vent portion 26 at least intermittently opens during application of the liquid 18 onto a surface, such that air can flow into the interior of housing 12 during application of the liquid 18 to equalize pressures between the interior 16 of housing and the external environment 28. It should be noted that the vent portion 24 will not necessarily always become fully saturated with liquid during use, but that the vent portion 24 is capable of continuing to perform its venting function even when fully saturated.

[0046] FIG. 5 show examples of prototypes free liquid applicators constructed by the inventors that have been used to experimentally confirm that the inserts are capable of providing venting functionality during liquid application even when the inserts are fully saturated with liquid. FIG. 6 shows the results of a simple test conducted by the inventors to confirm that a prototype free liquid applicator was capable of completely applying the entire liquid contents from the applicator onto a surface, with little to no residual liquid remaining trapped in the applicator's housing. [0047] In the example of FIGS. 1-3, both the applicator portion 24 and the vent portion 26 of the insert 14 extend through the dispensing opening 20 of the housing 12 from the interior 16 to the exterior 22 of the housing 12. More specifically, in this example, the applicator portion 24 includes an interior surface 30 that is exposed to the interior 16 of the housing and also includes an exterior surface 32 that is exposed to the external environment 28. The vent portion 26 similarly includes an interior surface 34 that is exposed to the interior 16 of the housing and also includes an exterior surface 36 that is exposed to the external environment 28.

[0048] In some implementations the surface area of the interior surface 30 of the applicator portion 24 exposed to the interior 16 of the housing 12 is approximately the same as the surface area of the interior surface 34 of the vent portion 26. For instance, the surface area of the interior surface 30 of the applicator portion 24 exposed to the interior 16 of the housing 12 may be in the range of 35%-65% of the total surface area of the insert 14 exposed to the interior 16 of the housing 12, and the surface area of the interior surface 34 of the vent portion 34 exposed to the interior 16 of the housing 12 may also be in the range of 35%-65% of the total surface area of the insert 14 exposed to the interior 16 of the housing 12. As another example, the surface area of the interior surface 30 of the applicator portion 24 exposed to the interior 16 of the housing 12 may be in the range of 45%-55% of the total surface area of the insert 14 exposed to the interior 16 of the housing 12, and the surface area of the interior surface 34 of the vent portion 34 exposed to the interior 16 of the housing 12 may also be in the range of 45%-55% of the total surface area of the insert 14 exposed to the interior 16 of the housing 12.

[0049] As shown in FIG. 1, the applicator portion 24 and the vent portion 26 physically contact each other along an entire length of the dispensing opening 20. In this particular implementation, the applicator portion 24 is longer than the vent portion 26, with the applicator portion 24 in physical contact with the vent portion 26 along the entire length of the vent portion 26. In the particular example shown in FIGS. 1-3, the applicator portion 24 is over twice the length of the vent portion 26. In other implementations the applicator portion 24 may be at least 10% longer, 25% longer, 50% longer, 75% longer, or 100% longer than the vent portion 26.

[0050] The insert 14 is secured in the dispensing opening 20 of the housing 12. The insert 14 may be secured in the dispensing opening 20 of the housing 12 in a variety of ways. In some implementations the insert 14 may be secured in the dispensing opening 20 by a press fit or friction fit. In some implementations ribs and/orgrooves may be included on facing surfaces of the housing 12 and/or insert 14 to secure the insert 14 in the dispensing opening 20. In some implementations the insert 14 may be secured in the dispensing opening 20 using adhesives or heat welds.

[0051] The applicator and vent portions 24, 26 of insert 14 may be formed in a variety of shapes and configurations. FIG. 4a shows a top view of the insert 14 of FIGS. 1-3 with the applicator portion 24 having a circular shape inside of a collar surrounding the applicator portion 24 and serving as a vent portion 26. FIGS. 4b-4f show examples of other possible shapes of applicator portions 24 and vent portions 26.

Porous Inserts

[0052] In some implementations the insert 14, including the applicator portion 24 and vent portion 26, may be formed of porous polymers, for instance sintered polymer particles. The applicator and vent portions 24, 26 may be an assembly of separately formed individual components or may be a unitary component formed in a single sintering process.

[0053] In one example the applicator portion 24 is a porous polymer with pore sizes that are on average smaller than the pore sizes of the vent portion 24 porous polymer. The pore size differential between the applicator portion 24 and vent portion 26 may cause the differential capillary forces exerted by the applicator portion 24 and vent portion 26 on the free liquid 18. In some implementations the pore size of the applicator portion 24 material may be 60% or less than the pore size of the vent portion 26 material. In some implementations the pore size of the applicator portion 24 material may be 35% or less than the pore size of the vent portion 26 material. In some implementations the pore size of the applicator portion 24 material may be in the range of 5-35 microns and the pore size of the vent portion 26 material may be in the range of 55-100 microns. In some implementations the pore size of the applicator portion 24 material may be in the range of 10-25 microns and the pore size of the vent portion 26 material may be in the range of 65-90 microns. The materials used to form the insert 14 and variables of the manufacturing process may be selected and optimized to provide the desired pore size differential. For example, larger polymer particles may be used to achieve larger pore sizes, other properties of the polymer may be varied, sintering temperatures and durations may be adjusted, pressure may be adjusted, etc. [0054] The insert 14 may be made of sintered porous plastic or of sintered porous plastic in combination with other materials or additives, such as an elastomeric material. The sintered porous plastic material may provide rigidity and self-supporting properties to the insert 14 while the elastomeric material may provide flexibility and elasticity properties to the insert 14.

[0055] Examples of materials that may be used for insert 14 included, without limitation, polyolefins, polyamides, polyesters, rigid polyurethanes, polyacrylonitriles, polycarbonates, polyvinylchloride, polymethylmethacrylate, polyvinylidene fluoride, polytetrafluoroethylene, polyethersulfones, polystyrenes, polyether imides, polyetheretherketones, or polysulfones, and combinations and copolymers thereof.

[0056] In some implementations, a polyolefin used for the insert 14 may be a polyethylene, polypropylene, and/or copolymers thereof.

[0057] In some implementations the elastomers used in combination with plastic for the insert 14 may be thermoplastic elastomers (TPE) such as polyurethanes and thermoplastic polyurethanes (TPU), which may in some implementations may include multiblock copolymers comprising a polyurethane and a polyester or polyether. In some implementations the elastomers used for the insert 14 may include polyisobutylene, polybutenes, butyl rubber, or combinations thereof. In other implementations the elastomers may be copolymers of ethylene and other monomers such as ethylene-propylene copolymer, referred to as EPM, ethylene-octene copolymer, and ethylene-hexene copolymer. In other implementations, the elastomers may be copolymers of propylene and other monomers such as ethylene-propylene copolymer, referred to as EPM, ethylene-octene copolymer, and polyethylene-hexene copolymer. In other implementations, the elastomers may be chlorinated polyethylene or chloro-sulfonated polyethylene. In still other implementations, the elastomers may be ethylene vinyl acetate (EVA).

[0058] In some implementations the insert 14 may be manufactured by providing polymeric particles (by themselves or in combination with other materials and/or additives) into a mold cavity and sintering the polymeric particles. In some implementations both the applicator and the vent portions of the insert 14 may be formed in the same mold cavity and sintering process. In other implementations the applicator and vent portions of the insert 14 may be formed in separate mold cavities and separate sintering processes, and latera assembled into a completed insert 14. [0059] In some implementations particles used to form insert may have average sizes ranging from about 1 pm to about 1 mm, or may have average sizes ranging from about 10 pm to about 900 pm, from about 50 pm to about 500 pm, or from about 100 pm to about 400 pm. In still other implementations, particles have average sizes ranging from about 200 pm to about 300 pm. In still other implementations, particles have average sizes less than about 1 pm or greater than about 1 mm.

[0060] In some implementations particles are sintered at a temperature ranging from about 94° C. to about 370° C. In other implementations, particles are sintered at a temperature ranging from about 150° C. to about 260° C. In other implementations, particles are sintered at a temperature ranging from about 165° C. to about 205° C. The sintering temperature may be dependent upon and selected according to the identity of the particles.

[0061] Particles may be sintered for a time period ranging from about 30 seconds to about 30 minutes. In other implementations, particles are sintered for a time period ranging from about 1 minute to about 15 minutes or from about 5 minutes to about 10 minutes. In some implementations, the sintering process comprises heating, soaking, and/or cooking cycles. Moreover, in some implementations, sintering of particles is administered under ambient pressure (1 atm). In other embodiments sintering of polymeric particles is administered under pressures greaterthan ambient pressure.

[0062] One of ordinary skill in the art knows to vary the sintering temperature and duration depending on the size of the object and the material.

Fibrous Inserts

[0063] In some implementations the insert 14, including the applicator portion 24 and the vent portion 26, may be formed of fibers rather than sintered particles. The applicator portion 24 may have fibers at a first fiber density. The vent portion 26 may have fibers at a second fiber density. The fiber density of the applicator portion 24 may be lower than the fiber density of the vent portion 26. The fiber density differential between the applicator portion 24 and vent portion 26 cause similar differential capillary forces to be exerted by the applicator portion 24 and vent portion 26 on the free liquid 18 in a similar fashion to the differential capillary forces caused by differential pore sizes as discussed above.

[0064] The foregoing description of certain examples, including illustrated examples, has been presented only for the purpose of illustration and description and is not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Numerous modifications, adaptations, and uses thereof will be apparent to those skilled in the art without departing from the scope of the disclosure.

Claims

1. A free liquid applicator comprising:

(a) a housing comprising an interior containing a free liquid and a dispensing opening extending from the interior to an exterior of the housing;

(b) an insert secured in the dispensing opening of the housing, the insert comprising an applicator portion configured to apply the free liquid from the interior onto a surface, the insert further comprising a vent portion configured to equalize pressure between the interior of the housing and an external environment, wherein:

(i) the applicator portion exerts a first capillary force on the free liquid, the vent portion exerts a second capillary force on the free liquid, and the first capillary force is higher than the second capillary force; and

(ii) both the applicator portion and the vent portion of the insert extend through the dispensing opening from the interior of the housing to the exterior of the housing.

2. The free liquid applicator of claim 1 wherein the applicator portion comprises an interior surface exposed to the interior of the housing and an exterior surface exposed to the external environment; and wherein the vent portion comprises an interior surface exposed to the interior of the housing and an exterior surface exposed to the external environment.

3. The free liquid applicator of claim 2 wherein the applicator portion and the vent portion physically contact each other along an entire length of the dispensing opening.

4. The free liquid applicator of claim 2 wherein the applicator portion is a porous polymer portion comprising a first pore size, wherein the vent portion is a porous polymer portion comprising a second pore size, and wherein the first pore size is smaller than the second pore size.

5. The free liquid applicator of claim 4 wherein the first pore size is 60% or less than the second pore size.

6. The free liquid applicator of claim 5 wherein the first pore size is 35% or less than the second pore size.

7. The free liquid applicator of claim 4 wherein the first pore size is in the range of 5-35 microns and the second pore size is in the range of 55-100 microns.

8. The free liquid applicator of claim 4 wherein the first pore size is in the range of 10-25 microns and the second pore size is in the range of 65-90 microns.

9. The free liquid applicator of claim 4 wherein the applicator portion and the vent portion comprise sintered polymer particles.

10. The free liquid applicator of claim 9 wherein the applicator portion and the vent portion comprise an assembly of individual components.

11. The free liquid applicator of claim 9 wherein the applicator portion and the vent portion comprise a unitary component.

12. The free liquid applicator of claim 2 wherein the applicator portion is a fibrous portion comprising a first fiber density, wherein the vent portion is a fibrous portion comprising a second fiber density, and wherein the first fiber density is lower than the second fiber density.

13. The free liquid applicator of claim 2 wherein:

(a) the interior surface of the applicator portion comprises a first surface area exposed to the interior of the housing;

(b) the interior surface of the vent portion comprises a second surface area exposed to the interior of the housing;

(c) the insert comprises a total surface area exposed to the interior of the housing; (d) the first surface area is in the range of 35% - 65% of the total surface area; and

(e) the second surface area is in the range of 35% - 65% of the total surface area.

14. The free liquid applicator of claim 13 wherein:

(a) the first surface area is in the range of 45% - 55% of the total surface area; and

(b) the second surface area is in the range of 45% - 55% of the total surface area.

15. The free liquid applicator of claim 1 wherein the insert is configured such that when the applicator portion dispenses the free liquid ontothe surface, the applicator portion draws at least some of the free liquid from vent portion as the vent portion allows a gas to move into the interior from the external environment through the vent portion.

16. A free liquid applicator comprising:

(b) an insert secured in the dispensing opening of the housing, the insert comprising a porous applicator portion configured to apply the free liquid from the interior onto a surface, the insert further comprising a porous vent portion configured to equalize pressure between the interior of the housing and an external environment, wherein:

(i) the applicator portion comprises a first pore size;

(ii) the vent portion comprises a second pore size;

(iii) the first pore size is smaller than the second pore size; and

(iv) both the applicator portion and the vent portion of the insert extend through the dispensing opening from the interior of the housing to the exterior of the housing.

17. The free liquid applicator of claim 16 wherein the applicator portion comprises an interior surface exposed to the interior of the housing and an exterior surface exposed to the external environment; and wherein the vent portion comprises an interior surface exposed to the interior of the housing and an exterior surface exposed to the external environment.

18. The free liquid applicator of claim 17 wherein the applicator portion and the vent portion physically contact each other along an entire length of the dispensing opening.

19. The free liquid applicator of claim 16 wherein the first pore size is 60% or less than the second pore size.

20. The free liquid applicator of claim 16 wherein the first pore size is in the range of 5-35 microns and the second pore size is in the range of 55-100 microns.

21. The free liquid applicator of claim 16 wherein the applicator portion and the vent portion comprise sintered polymer particles.

22. The free liquid applicator of claim 21 wherein the applicator portion and the vent portion comprise an assembly of individual components or a unitary component.

23. The free liquid applicator of claim 16 wherein:

(f) the interior surface of the applicator portion comprises a first surface area exposed to the interior of the housing;

(g) the interior surface of the vent portion comprises a second surface area exposed to the interior of the housing;

(h) the insert comprises a total surface area exposed to the interior of the housing;

(i) the first surface area is in the range of 35% - 65% of the total surface area; and

(j) the second surface area is in the range of 35% - 65% of the total surface area.

24. The free liquid applicator of claim 16 wherein the insert is configured such that when the applicator portion dispenses the free liquid ontothe surface, the applicator portion draws at least some of the free liquid from vent portion as the vent portion allows a gas to move into the interior from the external environment through the vent portion.

25. A free liquid applicator comprising:

(a) a housing comprising an interior containing a free liquid and a dispensing opening extending from the interior to an exterior of the housing; (b) an insert secured in the dispensing opening of the housing, the insert comprising a fibrous applicator portion configured to apply the free liquid from the interior onto a surface, the insert further comprising a fibrous vent portion configured to equalize pressure between the interior of the housing and an external environment, wherein:

(i) the applicator portion comprises a first fiber density;

(ii) the vent portion comprises a second fiber density;

(iii) the first fiber density is greater than the second fiber density; and

(v)both the applicator portion and the vent portion of the insert extend through the dispensing opening from the interior of the housing to the exterior of the housing.

26. The free liquid applicator of claim 25 wherein the applicator portion comprises an interior surface exposed to the interior of the housing and an exterior surface exposed to the external environment; and wherein the vent portion comprises an interior surface exposed to the interior of the housing and an exterior surface exposed to the external environment.

27. The free liquid applicator of claim 26 wherein the applicator portion and the vent portion physically contact each other along an entire length of the dispensing opening.

28. The free liquid applicator of claim 25 wherein:

(c) the insert comprises a total surface area exposed to the interior of the housing;

(d) the first surface area is in the range of 35% - 65% of the total surface area; and

29. The free liquid applicator of claim 25 wherein the insert is configured such that when the applicator portion dispenses the free liquid onto the surface, the applicator portion draws at least some of the free liquid from vent portion as the vent portion allows a gas to move into the interior from the external environment through the vent portion.