Valve assembly for dispensers

A valve assembly for a dispenser. The valve assembly includes a valve body that extends about a longitudinal axis and defines an outer surface and an inner passageway. A valve stem extends through the inner passageway and includes an outer stem surface, an inner stem surface opposite the outer stem surface, a fin extending radially outward from the outer stem surface, and a first orifice extending from the outer stem surface to the inner stem surface. The fin operatively engages a portion of the inner passageway forming a first seal and providing controlled dispensing through the orifice. A valve seal may be joined to the valve steam. The vale seal may operatively engage a portion of the valve body forming a second seal.

FIELD

The present disclosure is directed to a valve assembly, and, in particular, to a valve assembly including a stem having one or more fins and a valve seal.

BACKGROUND

Dispensers typically comprise a container, which may act as a pressure vessel for propellant and product contained therein. Pressurized dispensing systems, such as systems used to dispense aerosol products, have conventionally included metallic (e.g., steel or aluminum) containers for containing the product under pressure before it is dispensed from the system. Examples of products that are dispensed with such systems include air fresheners, fabric fresheners, insect repellants, paints, body sprays, hair sprays, shoe or footwear spray products, whipped cream, and processed cheese. Recently, there has been increased interest in using polymeric bottles as an alternative to metallic containers in pressurized dispensing systems because polymeric bottles have several potential advantages. For example, polymeric bottles may be easier and cheaper to manufacture than metallic containers, and polymeric bottles may be made in a wider variety of shapes than metallic containers. Additionally, metal containers may be undesirable due to relatively higher cost and being relatively less sustainable.

The containers are typically, but not necessarily, axisymmetric. The container may include a closed end bottom for resting on horizontal surfaces such as shelves, countertops, tables etc. The bottom of the container may comprise a re-entrant portion or base cup. The sidewalls generally define the shape of the container and extend upwardly from the bottom to an opening at a top of the container. The opening at the top of the container defines a neck.

Typically, a valve assembly8may be joined to a container to allow for selective dispensing of a product. With reference toFIG. 1, the valve assembly8may include a metal valve cup10inserted at least partially into the neck of the container. The valve cup10is crimped against a crimp ring of a container to seal the container and prevent the escape of propellant, product, and loss of pressurization. The valve cup10may define a central opening about through which a stem may extend. Positioned between a portion of the stem14and the valve cup10may be a gasket16. The gasket16may be made from an elastomer, and traditionally, a cross linked elastomer, such as cross-linked vulcanized rubbers. The gasket16may be used to seal the interface between the valve cup10and the stem14. The stem18may extend through the central opening in the valve cup10and engage a portion of the gasket16. The portion of the stem that extends from the central opening of the valve cup towards the bottom of the outer contain may engage a housing12and a spring20. The portion of the stem14may push the spring20towards the bottom of the container to allow product to pass from the container and into the interior of the stem and out through the actuator18. Upon release of the actuator18and/or the stem14, the spring may push the stem in a direction away from the bottom of the container, which stops the release of material from inside the container to ambient. The spring20is typically made from metal. The spring20is supported by the housing12.

To selectively dispense product from an aerosol dispenser, the valve assembly includes a number of different components. These components are made from a number of different materials including metal and polymeric, which may be plastic, components. However, for producing an aerosol dispenser that is both recyclable and economical, it is generally desirable to have all the components made from polymeric materials or to minimize the number of component parts made from other than polymeric materials.

SUMMARY

In some embodiments, a valve for a container may include a valve body extending about a longitudinal axis. The valve body may define an outer surface and an inner passageway. The inner passageway includes a first passageway opening and a second passageway opening and a passageway surface extending from the first passageway opening to the second passageway opening. The valve may also include a valve stem extending through the inner passageway. The valve stem includes an outer stem surface and an inner stem surface opposite the outer stem surface. The valve stem includes a first portion adjacent to the first passageway opening, a second portion substantially surrounded by the passageway surface, and a third portion adjacent to the second passageway opening. A valve seal may be joined to the third portion of the valve stem. A fin may extend radially outward from the outer stem surface of the valve stem and an orifice may extend from the outer stem surface to the inner stem surface of the valve stem. The inner stem surface may define a channel in fluid communication with the orifice. The fin may include a root portion joined to the outer stem surface and a tip portion opposite the root portion. The tip portion of the fin may be configured to operatively engage the passageway surface to form a seal.

In some embodiments, the valve for a container may include a valve body extending about a longitudinal axis, the valve body defining an outer surface and an inner passageway. The inner passageway includes a first passageway opening and a second passageway opening, and a passageway surface extending from the first passageway opening to the second passageway opening. The valve may also include a valve stem that extends through the passageway. A first portion of the valve stem may be adjacent to the first passageway opening, a second portion of the valve stem may be substantially surrounded by the passageway surface, and a third portion of the valve stem may be adjacent to the second passageway opening. The valve stem may include an outer stem surface and an inner stem surface opposite the outer stem surface. A fin may be joined to the valve stem. The fin may be configured to operatively engage the passageway surface to form a first seal. A valve seal may be joined to the valve stem. A portion of the valve seal may be configured to operatively engage a portion of the valve body to form a second seal.

In some embodiments, a pressurizable container for dispensing a product may include a container and a valve body joined to the container. The valve body may define an outer surface and an inner passageway. The inner passageway includes a first passageway opening and a second passageway opening and a passageway surface extending from the first passageway opening to the second passageway opening. A valve stem may extend through the passageway. The valve stem may include an outer stem surface and an inner stem surface opposite the outer stem surface. A fin may extend radially outward from the outer stem surface. The fin includes a root portion joined to the outer stem surface and a tip portion opposite the root portion. The tip portion of the fin may operatively engage the passageway surface to form a first seal. A valve seal may be joined to the valve stem and the valve seal may be configured to operatively engage a portion of the valve body to form a second seal. A product delivery device may be in fluid communication with the valve body.

DETAILED DESCRIPTION

The present disclosure is directed to a valve assembly and, more specifically, a valve assembly for a dispenser. The present disclosure describes the valve assembly used in an aerosol dispenser. However, the valve assembly may be used in a non-pressurized dispenser. An aerosol dispenser may include a container for containing a product and a propellant and a valve assembly for dispensing the product or the product and the propellant from the container. Other components may be included in the aerosol dispenser such as a nozzle for controlling the spray characteristics of a product as it is discharged from the aerosol dispenser and an actuator for selectively dispensing product from the aerosol dispenser. Products may include, but are not limited to: shave cream, shave foam, body sprays, body washes, perfumes, hair cleaners, hair conditions, hair styling products, antiperspirants, deodorants, personal and household cleaning or disinfecting compositions, air freshening products, fabric freshening products, hard-surface products, astringents, foods, paint, and insecticides.

The relatively large number of products that may be dispensed using aerosols has made aerosols a popular choice among manufacturing companies. The relative popularity of aerosol dispensers has resulted in companies considering cost cutting measures with respect to aerosol dispensers and to consider materials, at least in part, for aerosol dispensers to minimize the environmental impact. For example, an aerosol dispenser made from polymeric components may aid in the recyclability of the dispensers and help with reducing cost, such as by reducing the cost of manufacturing, eliminating expensive metal components, and reducing the cost of shipping, through weight reduction of each dispenser. The use of different materials also allows for greater flexibly in the size and shape of the dispenser. The present disclosure is directed to a valve that includes a valve assembly that may be accepted into a single recycling stream, such as the PET (polyethylene terephthalate) recycling stream, and safely vents at relatively excessive temperatures and/or pressures. Further, the valve assembly relatively minimizes the number of components used to seal product and/or propellant within the dispenser and to selectively dispense product and/or propellant.

With reference toFIGS. 2A, 2B, 3A, and 3B, an aerosol dispenser30may include a container32, a valve assembly52(also referred to herein as a valve), a product delivery device56, an actuator46, and a nozzle60. The container32may include a base cup48joined thereto and indicia50disposed on, for example, the sidewalls36of the container32. The valve assembly52may be joined to a portion of the container32. The term joined includes directly or indirectly joined. The term joined includes removably joined and fixedly joined. The term joined includes both mechanical attachment, such as by screws, bolts, interference fit, friction fit, welding, and integrally molding, and chemical attachment, such as by adhesive or the adhesive properties inherent in the materials being attached. The valve assembly52may be joined to the container such that a portion of the valve assembly52is disposed within the container. The product delivery device56may be joined to at least one of a portion of the container32and a portion of the valve assembly52and the product delivery device may be in fluid communication with the actuator46and the nozzle60.

The base cup48may be joined to the bottom portion, which is opposite the valve assembly52, of the container32and may be used, for example, to aid in positioning the dispenser on flat surfaces and to reinforce the bottom34of the aerosol dispenser. The container32may be configured to hold product and/or propellant. The product delivery device may be disposed at least partially within the container and the valve may be joined to the container32and may be in operative communication with the product delivery device. The product and/or the propellant may be stored in the container32. Upon being dispensed, the product and/or propellant may travel from and/or through the product delivery device56and through the valve assembly52.

The valve assembly52may be in fluid communication with a nozzle60. The nozzle60directs product out of the aerosol dispenser and into the environment or onto a target surface. The nozzle may be configured in various different ways depending upon the desired dispensing and spray characteristics. The actuator46may be engaged by a user and is configured to initiate and terminate dispensing of the product and/or propellant. Stated another way, the actuator provides selective dispensing of the product and/or propellant. The actuator46may be depressible, operable as a trigger, push-button, and the like, to cause release of a product and/or propellant from the aerosol dispenser30. The actuator46may include a connector such as a male or female connector, snap-fit connector, or the like to secure the actuator to the container. It is to be appreciated that to dispense product, the aerosol dispenser does not need to include an actuator and a nozzle. The product and/or propellant may be dispensed from the stem.

The container32may be used to hold product and/or propellant. The container32may be any shape that allows product and/or propellant to be held within the interior of the container. For example, the container may be peanut-shaped, oval-shaped, or rectangular-shaped. It is to be appreciated that the container32may be molded, which allows for any number of shapes to be used. The container32may be longitudinally elongate such that the container has an aspect ratio of a longitudinal dimension to a transverse dimension, such as diameter. The aspect ratio may be greater than 1, equal to 1, such as in a sphere or shorter cylinder, or an aspect ratio less than 1. The containers32may be cylindrical.

The container32may include a closed bottom34, one or more sidewalls36, and a neck40. The one or more sidewalls36may extend between the closed bottom34and the neck40. The sidewalls36define the shape of the container32. A shoulder42may be included between the neck40and the one or more sidewalls36. The neck40of the container32may define an opening38. The opening38may be opposite the bottom34of the container32. The neck40and/or shoulder42may have a uniform or varying thickness and/or crystallinity in order to achieve a desired strength in these regions of the container32.

The bottom34of the container32may be configured for resting on horizontal surfaces such as shelves, countertops, tables etc. The bottom34of the container32may include a re-entrant portion or base cup48. The base cup48may be joined to the bottom34of the container32and may aid in reinforcement of the bottom34and/or may allow the container to rest on horizontal surfaces. The container32may not include a base cup and may be configured to sit on at least a portion of the bottom34. Suitable shapes of the bottom34include petaloid, champagne, hemispherical, or other generally convex or concave shapes. Each of these shapes of the bottom34may be used with or without a base cup48. The container32may have a generally flat base with an optional punt.

The container32may be polymeric. The container32may include polyethylene terephthalate (PET), polyethylene furanoate (PEF), polyester, nylon, polyolefin, EVOH, or mixtures thereof. The container may be a single layer or multi-layered. The container32may be injection molded and/or blow molded, such as in an injection-stretch blow molding process or an extrusion blow molding process.

The container32may be axisymmetric as shown, or, may be eccentric. The cross-section may be square, elliptical, irregular, etc. Furthermore, the cross section may be generally constant as shown, or may be variable. For a variable cross-section, the container may be, for example, barrel shaped, hourglass shaped, or monotonically tapered.

The container32may range from about 6 cm to about 60 cm, or from about 10 cm to about 40 cm in height, taken in the axial direction. The container32may have a cross-section perimeter or circumference, if a round cross-section is selected, from about 3 cm to about 60 cm, or from about 4 cm to about 10 cm. The container may have a volume ranging from about 40 cubic centimeters to about 1000 cubic centimeters exclusive of any components therein, such as a product delivery device56.

At 21° C., the container32may be pressurized to an internal gauge pressure of about 100 kPa to about 1500 kPa, or from about 110 kPa to about 1300 kPa, or from about 115 kPa to about 490 kPa, or about 270 kPa to about 420 kPa using a propellant. An aerosol dispenser30may have an initial propellant pressure of about 1500 kPa and a final propellant pressure of about 120 kPa, an initial propellant pressure of about 900 kPa and a final propellant pressure of about 300 kPa, or an initial propellant pressure of about 500 kPa and a final propellant pressure of 0 kPa.

The propellant may include hydrocarbons, compressed gas, such as nitrogen and air, hydro-fluorinated olefins (HFO), such as trans-1,3,3,3-tetrafluoroprop-1-ene, and mixtures thereof. Propellants listed in the US Federal Register 49 CFR 1.73.115, Class 2, Division 2.2 may be acceptable. The propellant may be condensable. A condensable propellant, when condensed, may provide the benefit of a flatter depressurization curve at the vapor pressure, as product is depleted during usage. A condensable propellant may provide the benefit that a greater volume of gas may be placed into the container at a given pressure. Generally, the highest pressure occurs after the aerosol dispenser is charged with product but before the first dispensing of that product by the user.

The product delivery device56may be used to contain and/or provide for delivery of product and/or propellant from the aerosol dispenser30upon demand. Suitable product delivery devices56comprise a piston, a bag24, or a dip tube26, such as illustrated inFIGS. 3A and 3B. The product delivery device56may include polyethylene terephthalate (PET), polypropylene (PP), polyethylene furanoate (PEF), polyester, nylon, polyolefin, EVOH, or mixtures thereof. The container may be a single layer or multi-layered. The bag24may be disposed within the container32and be configured to hold a product therein, such as illustrated inFIG. 3A. Propellant may be disposed within the container32and/or between the container and the bag24. A portion of the bag24may be joined to at least one of the container32and a portion of the valve assembly52, such as the valve body54. The bag24may be positioned between the container32and the valve body54. The bag24may be inserted into the container32and subsequently joined thereto. The bag24may be joined to the valve body54, and the valve body54may be subsequently inserted into the container32.

As illustrated inFIG. 3B, the dispenser may include a dip tube adaptor64and a dip tube26. The dip tube adaptor64may be disposed within the container32. The dip tube adaptor64may engage a portion of the neck40. The dip tube26may be joined to the dip tube adaptor64and extend from the dip tube adaptor64toward the bottom34of the container32. It is to be appreciated that the dip tube26may be attached directly to a portion of the valve assembly, such as the valve body54. The dip tube26and/or the dip tube adaptor64may be attached to the valve body54prior to being disposed within the container. The dip tube26and/or the dip tube adaptor64may be disposed within the container and then subsequently joined to a portion of the container and/or the valve body54.

The product delivery device56may include a metering device for dispensing a pre-determined, metered quantity of product. The product delivery device56may include an inverting valve such as a valve including a ball therein to alter the path of product flow. The product delivery device56may include a dip tube disposed in a bag. The product delivery device56may be polymeric.

Referring toFIGS. 3C-3E, the product delivery device56may include a dip tube26and a bag24. The bag24may be attached to a portion of the dip tub26and the dip tube may be disposed within the bag24. The dip tube26may include one or more orifices through which product may flow. A portion of the dip tube26may be joined to a portion of the valve assembly52. A portion of the dip tube26may be joined to a portion of the valve body54. The dip tube26may be joined to a portion of the valve body54by friction fit, snap fit, chemical attachment, such as by adhesive, or mechanical attachment, such as by a weld, screw, or nail. Prior to the valve assembly52, the dip tub26, and the bag24being joined to the container32, the bag24may be wrapped about the dip tub26, such as illustrated inFIG. 3D, or collapsed in some other manner such that the bag24does not interfere as the dip tube26and bag24are inserted into the container32. Once the bag24and dip tube26are disposed within the container32, the bag24may expand within the container.

The container32, and/or the product delivery device56may be transparent or substantially transparent. This arrangement provides the benefit that the consumer knows when product is nearing depletion and allows improved communication of product attributes, such as color, viscosity, etc. Also, indicia disposed on the container, such as labeling or other decoration of the container, may be more apparent if the background to which such decoration is applied is clear. Labels may be shrink wrapped, printed, etc., as are known in the art.

The container32may include a neck40. The neck40may define an opening38and be configured to receive a valve assembly52. The valve assembly52may be disposed on or inserted, at least partially, into the opening38of the neck40of the container32, such as illustrated inFIGS. 3A, 3B, and 3C. The valve assembly52may include a valve body54, a valve stem62, and a resilient member58. At least a portion of the valve assembly52may be movable in relationship to the balance of the aerosol dispenser in order to open and close the aerosol dispenser for dispensing product and/or propellant. The valve assembly52may be opened due to movement of the valve stem62which may be through use of an actuator46or through manual or other mechanical movement of the valve stem62. When the valve52is opened, for example, by way of the actuator46, a flow path is created for the product to be dispensed through a nozzle60to ambient or a target surface. The valve assembly52may be opened, for example, by selective actuation of the actuator46by a user.

A portion of the valve body54may be sealed to the neck of the container32, such as illustrated inFIGS. 3A, 3B, and 3C, to prevent the escape of product and/or propellant. The valve body54may be sealed to the container32utilizing a press fit, interference fit, crimping, solvent welding, laser welding, sonic welding, ultrasonic welding, spin welding, adhesive, or any combination thereof, so long as a seal adequate to contain the product and/or to maintain the pressure results. The valve body54may be joined to the container32such that at least a portion of the valve body54is disposed within the container32. The valve body54may be joined to the container32such that the valve body54is joined to the opening of the neck.

As illustrated inFIG. 4, the valve body54may extend about a longitudinal axis70. The valve body54may include an outer surface72and define an inner passageway74. The inner passageway74may include a first passageway opening76and a second passageway opening78and a passageway surface80extending from the first passageway opening76to the second passageway opening78. The passageway surface80may substantially surround the longitudinal axis70.

A valve stem62may extend through the inner passageway74of the valve body54. The valve stem62provides a product flow path from the interior of the container to the nozzle60and operatively joins the actuator46to the valve assembly52. The valve stem62may be positioned with respect to the valve body54such that a first portion86of the valve stem62may be adjacent to the first passageway opening76of the valve body54, a second portion88of the valve stem62may be substantially surrounded by the passageway surface80, and a third portion90of the valve stem62may be adjacent to the second passageway opening78of the valve body54. The valve stem62may be positioned with respect to the valve body54such that a first portion86of the valve stem62extends through the first passageway opening76of the valve body54, a second portion88of the valve stem62may be substantially surrounded by the passageway surface80, and a third portion90of the valve stem62extends through the second passageway opening78of the valve body54. The valve stem62may be moveable with respect to the valve body54. Thus, the valve stem62may be positioned in other configurations as the valve stem62moves. The valve stem62may include an outer stem surface92and an inner stem surface94opposite the outer stem surface. The inner stem surface94may define a channel95through which product and/or propellant may flow. The valve stem62may include a fin96extending radially outward from the outer stem surface92.

The valve assembly52may include a resilient member58. The resilient member58may operatively engage a portion of the valve stem62. More specifically, a portion of the resilient member58may engage a portion of the valve stem62. The resilient member58may operatively engage a portion of the valve body54. The resilient member58may be any compliant member that provides resistance to the movement of the valve stem62, such as when the valve stem62is moved to a dispensing configuration or a filling configuration, and returns the valve stem62to a sealing configuration. The resilient member58may be made from at least one of a metal and a polymer. For example, the resilient member58may be made from a thermoplastic elastomer, silicone, rubber, or other polymeric material. The resilient member58may be any shape such that the resilient member58operatively engages the valve stem and/or controls the movement of the valve stem. The resilient member58may generally have a cross-sectional shape of a circle, square, rectangle, ellipse, trapezoid, parallelogram, triangle, gear, or any other shape that fits with the valve body and delivers the desired control over the movement of the valve stem. The resilient member58may include one or more notches and apertures.

The resilient member58may be made from a resilient polymeric material such as a thermoset material, a thermoplastic material, or a plastomer. The resilient polymeric material may include a non-cross-linked material. The resilient polymeric material may include a melt-processible material. The thermoplastic material may contain cross-linked polymer chains that remain melt processible. The resilient member may be made entirely from one or more non-cross-linked resilient polymeric materials. The resilient member may be made entirely from one or more melt-processible resilient polymeric materials. The resilient polymeric material may be modified such as by means of additives or by foaming to alter its properties.

The resilient member may comprise one or more thermoplastic elastomers (TPE). The thermoplastic elastomer may include styrenic block copolymers (TPS), thermoplastic polyolefin elastomers (TPO), thermoplastic elastomer vulcanizates (TPV), thermoplastic polyurethane elastomers (TPU), thermoplastic copolyester elastomers (TPC), thermoplastic polyamide elastomers (TPA), non-classified thermoplastic elastomers (TPZ), and combinations thereof.

To aid with recyclability of the container, the resilient member may include at least one of a non-cross-linked material and a melt-processible material or the resilient member may be made entirely from one or more non-cross-linked, melt-processible materials. Further, the resilient member58may have a density that would allow the resilient member58to be float-separable during a recycling process. The resilient member58may have a density less than 1.0 g/cc.

The valve stem62may include one or more fins96, such as illustrated inFIGS. 4, 5A-5D. The fin96may be joined to the outer stem surface92. More specifically, each fin96may include a root portion98and a tip portion100, which is opposite the root portion98. The root portion98may be joined to the outer stem surface92and the tip portion100may be positioned outward, such as radially outward, from the outer stem surface92. The fin96may have a fin length FL measured along the surface of the fin as the shortest distance between the point where the root portion engages the outer stem surface92to the outermost point of the tip portion100. The fin length FL may be any length such that a seal is formed between a portion of the fin96, such as a tip portion100or an intermediate portion99of the fin96, and the passageway surface80of the valve body54. The fin length FL may be from about 0.1 mm to about 15 mm or from about 0.5 mm to about 12 mm or from about 1 mm to about 10 mm, including all 0.1 mm within the recited ranges and all ranges formed therein or thereby. The fin96may have a uniform thickness or varying thickness along the fin length FL. For example, the root portion98may be thicker than the tip portion100. The root portion98may have a greater thickness than the tip portion100to accommodate the forces exerted on the fin96when the tip portion100operatively engages the passageway surface80forming a seal therebetween.

The fin96may be made from one or more materials. For example, the root portion98of the fin96may be made from a first material and the tip portion100may be made from a second material. The first material and the second material may be different. The tip portion100of the fin96may be coated with a material and this coating material may be the same or different than the materials used for the other portions of the fin96, such as the first and second materials. Stated another way, an additional material may be disposed on the tip portion100of the fin96. The material coating the tip portion100may be used to increase or decrease friction between the tip portion100and the passageway surface80as the fin96moves with respect to the valve body54. The material coating the tip portion100may be added to reduce wear and thus, prolong the life of the fin96. Materials that may be used to coat the tip portion100may include, but are not limited to: elastomers, polymers, greases, oils, silicones, and lubricants. The tip portion100may also be treated to affect the friction between the tip portion100and the passageway surface80. Treatments may include, but are not limited to, polishing, crystallization, corona-treatment, or cross-linking.

The valve stem62may be manufactured, such as by molding, with one or more fins96. The valve stem62may be manufactured with the fin96at a pre-engagement angle α measured clockwise from the outer stem surface92to the surface of the fin96, as illustrated inFIGS. 5A-5C. The pre-engagement angle α may be from about 5 degrees to about 179 degrees or from about 10 degrees to about 145 degrees or from about 15 degrees to about 120 degrees or from about 45 degrees to about 115 degrees or from about 65 degrees to about 95 degrees or from about 75 degrees to about 90 degrees, including all 0.1 degrees within the recited ranges and all ranges formed therein or thereby. For example, as illustrated inFIGS. 5A-5C, the pre-engagement angle α may be about 90 degrees. The pre-engagement angle α may be determined, in part, based on the material(s) of the fin96and the clearance between the valve stem62and the valve body54.

The valve stem62may include any number of fins96necessary to maintain a seal between the valve stem62and the valve body54. For example, a valve stem62may include a first fin102and a valve seal116or a valve stem62may include a first fin102, a second fin104, and a valve seal. The second fin104may be positioned between the first fin102and the valve seal116. As illustrated inFIGS. 5A and 5B, a valve stem62may include a first fin102and a valve seal116.

The valve stem62may include a third portion90, opposite the first portion86. The third portion90of the valve stem62may include a retaining member110. The retaining member110may be joined to the third portion90or the retaining member110may be formed with the remainder of the valve stem62. The retaining member110may be formed from the same material as the other portions of the valve stem62or with a different material. For example, the retaining member110may be formed with a first material and the remainder of the valve stem62may be formed with one or more other materials that are different than the first material. The first material may have a melting point or a glass transition temperature (Tg) that is lower than the one or more other materials to allow the first material of the retaining member110to soften and deflect at a given temperature that is lower.

The retaining member110may extend outward, such as radially outward, beyond the outer stem surface92and may be configured to engage a portion of the valve body54. The retaining member110may work in cooperation with the resilient member58to position the valve stem62in a sealing configuration. The retaining member110may be any shape such that a portion of the retaining member110may operatively engage a portion of the valve body54. The shape of the retaining member110may be such that the retaining member110maintains the position of the valve stem62during safe operating conditions and aids in retaining the valve stem so as to safely vent the container during adverse operating conditions, such as relatively elevated temperatures and/or over pressurization of the aerosol dispenser.

The valve stem62may include one or more orifices108. The orifices108may be used for filling the container with product and/or propellant and/or dispensing product and/or propellant from the container. The one or more orifices108may be any shape or size so long as product and/or propellant may be filled and/or dispensed through such orifices. For example, the one or more orifices may be circular, oval, rectangular, square, or any other shape. For a valve stem62including two or more orifices, each of the orifices may be the same or different shapes and may be the same or different sizes. The orifice108may extend from the outer stem surface92to the inner stem surface94. The orifice108may be in fluid communication with the channel95defined by the inner stem surface94such that product and/or propellent may flow through the orifice and into the channel95. The product and/or propellant may flow from the container, through the orifice, and into the channel95. The product and/or propellant may also flow through the channel, through the orifice, and into the container.

The valve assembly52may include a valve seal116. As illustrated inFIG. 5A-5D, the valve seal116may be joined to a portion of the valve stem62. For example, the valve stem62may include a fin96joined to the outer stem surface92and a valve seal116joined to the outer stem surface92. The valve seal116may be joined to one of the first portion86, the second portion88, or the third portion90of the valve stem62. For example, the valve seal116may be joined to the valve stem92such that the valve seal116is disposed on the third portion90of the valve stem62. The valve seal116may be molded into position or attached, such as through the adhesive-like properties of the material of the valve seal116or the valve seal116may be separately manufactured and subsequently inserted such that it is joined to at least a portion of the valve stem62. The valve seal116may be made from any material that provides a seal between the valve seal116and the valve body54. The valve seal116may be made from one or more materials including thermoplastic elastomers (TPE), silicone, rubber, or polymers, which may be foamed. For increased sustainability, the valve seal116may be made from a material such that when the aerosol dispenser is processed for recycling, the valve seal116separates from the valve stem62. The valve seal116may be positioned such that the valve seal116forms a second seal with a portion of the valve body54. The valve seal116may be configured to move with the valve stem62.

As previously discussed, a retaining member110may be joined to the valve stem62. The valve seal116may be positioned between the valve stem62and the retaining member110, such as illustrated inFIGS. 5A and 5B. A portion of the valve seal116may extend beyond the upper surface of the retaining member such that the valve seal116may operatively engage a portion of the valve body54to form a second seal. Alternatively, the retaining member110or at least a portion thereof may be joined directly to the valve stem62. The valve seal116may then be joined to at least one of the outer surface of the valve stem and a surface of the retaining member110. The valve seal116may be disposed on a portion of the retaining member110.

The fin96and/or the valve seal116may be positioned such that the release of product and/or propellant through the one or more orifices108is controlled. To control the release of fluid, such as product and/or propellant, from the container through the orifice108, a seal is formed that isolates the orifice and the product and/or propellant. Stated another way, a seal is formed between the fluid and the orifice108. The orifice108may be positioned between the first portion86of the valve stem62and a fin96, such that the fin creates a seal with the passageway surface. Stated another way, the one or more orifices108may be positioned such that at least one fin is located between the orifice and the third portion90of the valve stem62to prevent product and/or propellant from freely flowing from the container and through the orifice. The fin positioned between the orifice and the third portion prevents product and/or propellant from flowing to the orifice prior to the valve stem being moved to a dispensing configuration. When the valve stem is in a sealing configuration, the fin prevents product and/or propellant from accessing the orifice and contains the product and/or propellant within the container. A second fin may be located between the orifice and the first portion86of the valve stem to prevent product and/or propellant from freely flowing through the inner passageway74and out the first passageway opening76as product and/or propellant flow through the orifice.

Further, the orifice108may be positioned between the fin96, such that the fin creates a seal with the passageway surface, and the valve seal116, such that the valve seal creates a seal with a portion of the valve body54. Stated another way, the one or more orifices108may be positioned such that the valve seal116is located between the orifice and the product and/or propellant, which prevents the product and/or propellant from freely flowing from the container and through the orifice. The valve seal prevents product and/or propellant from flowing to the orifice prior to the valve stem being moved to a dispensing configuration. When the valve stem is in a sealing configuration, also referred to herein as a sealed configuration, the valve seal prevents product and/or propellant from accessing the orifice and contains the fluid, which may include product and/or propellant, within the container. The fin may be located between the orifice and the first portion86of the valve stem to prevent product and/or propellant from freely flowing through the inner passageway74and out the first passageway opening76as fluid flows through the orifice. The valve seal116may prevent fluid from reaching the orifice108in the sealing configuration, and the fin96may be used to prevent fluid from passing beyond the portion of the valve stem with the orifice and/or the portion of the valve stem with the fin96when the valve stem is in the dispensing configuration.

One or more orifices may be positioned between the fin96and the valve seal116. Similarly, one or more orifices may be positioned between a second fin and the fin96. Positioning the orifices between seals, created either by a fin or a valve seal, may provide a more robust seal and may allow for selective filling and/or dispensing of the product and/or propellant, as will be described in detail herein.

The valve stem62may be inserted into the valve body54. The valve stem62may be inserted into the valve body54in the direction shown by arrow A, as illustrated inFIG. 6. Prior to the valve stem62being inserted into the valve body54, the one or more fins96may be oriented at a pre-engagement angle α, such as previously discussed. The pre-engagement angle α may be the same for two or more fins or may be different for two or more fins. As the valve stem62is inserted into the valve body54, a portion of the fin96operatively engages the passageway surface80of the valve body54. The distance from the longitudinal stem axis112to the tip portion100of the fin96may be greater than the distance from the longitudinal stem axis112to the passageway surface80of the valve body54before the valve stem62is inserted into the valve body54. It is to be appreciated that the radial distance from the longitudinal stem axis112to the tip portion100of the fin96may be substantially equal to the radial distance from the longitudinal stem axis112to the passageway surface80of the valve body54as long as a seal may be formed upon operative engagement of the fin96and the passageway surface80.

The fin96, including the fin tip portion100, may have any shape. As previously discussed, the fin96may be tapered so that the root portion98is thicker than the tip portion100. The taper from the root portion to the tip portion100may be linear or non-linear. The cross-section of the fin96may be concave or convex. The tip portion100and/or intermediate portion99may be shaped to increase contact between the portion of the fin96and the passageway surface80. The tip portion and/or the intermediate portion99may include a taper-angle so that the cross-section of this portion is non-continuous. The taper-angle may be selected such as to maximize contact between the upper fin surface and the passageway surface when the fin is engaged with the passageway surface.

The fin96may deflect as the valve stem62is inserted into the valve body54. The fin96may deflect in a direction opposite to the direction of insertion of the valve stem62into the valve body54. For example, the valve stem may be inserted into the valve body in a direction indicated by arrow A and the fin96may deflect in a direction indicated by arrow D, as illustrated inFIG. 7. The tip portion100of the fin96operatively engages the passageway surface80of the valve body54to form a seal. The seal is configured to prevent escape of propellant and/or product through the valve assembly52. When the valve stem62is positioned such that the fin96is operatively engaged with the passageway surface80of the valve body and forms a seal therebetween and the valve seal116operatively engages a portion of the valve body and forms a seal therebetween, the valve stem62is in a sealing configuration, such as illustrated inFIG. 7. In the sealing configuration, the retaining member110of the valve stem62may engage a portion of the valve body54. It is to be appreciated that the seal formed by the valve seal116and the valve body prevents product and/or propellant from accessing the orifice.

It is to be appreciated that the amount of deflection of the fin96may result in other portions, in addition to the tip portion100, of the fin96operatively engaging the passageway surface80. For example, the intermediate portion99between the tip portion100and the root portion98may operatively engage the passageway surface80. The tip portion100and the intermediate portion99of the fin96may operatively engage the passageway surface80.

FIGS. 8A and 8Billustrate a valve stem62after insertion into the valve body54. The fin96deflects against the passageway surface80. The amount of deflection may be due, in part, to the distance between the valve stem62and the passageway surface80, the fin length, and the material(s) used to construct the fin96. Upon insertion into the valve body54, a fin96may have a post engagement angle β. The post engagement angle β may be measured clockwise from the outer stem surface92adjacent the root portion98to the fin96. The post engagement angle β may be from about 5 degrees to about 180 degrees or from about 8 degrees to about 175 degrees or from about 10 degrees to about 145 degrees or from about 15 degrees to about 120 degrees or from about 45 degrees to about 115 degrees, including all 0.1 degrees within the recited ranges and all ranges formed therein or thereby. For example, as illustrated inFIGS. 8A and 8B, the post engagement angle β may be about 175 degrees. The post engagement angle β may be greater than about 90 degrees. It is to be appreciated that the pre-engagement angle α and the post engagement angle β may be the same or different. The pre-engagement angle α may be substantially equal to the post engagement angle β or the pre-engagement angle α may be less than the post engagement angle β.

It is to be appreciated that the fin96may deflect such that permanent deformation occurs and the fin96may remain in a substantially deflected position after removal of the valve stem62from the valve body54. It is also to be appreciated that the fins96may return fully to their original position or partially to a position between their original position and the deflected position upon removal from the valve body54.

Aerosol dispensers are pressurized, such as with propellant. Thus, the internal pressure of the container may aid in forming the seal between the passageway surface80and the fin96and the seal between the valve body54and the valve seal116.

To dispense product and/or propellant from the container, a user may directly or indirectly, such as by use of an actuator, engage the valve stem62causing the valve stem62to move. Upon engagement, the valve stem62may move along the passageway surface80in a direction toward the interior44of the outer container. The valve stem62may move from a sealing configuration to a dispensing configuration. A sealing configuration is formed when fluid is prevented from flowing through the one or more orifices on the valve stem. A dispensing configuration is formed when fluid may flow through the one or more orifices on the valve stem. In a sealing configuration, the valve stem62is positioned such that a seal is maintained between the fluid and the orifice. In a dispensing configuration, the valve stem62is moved such that the seal formed between the fluid and the orifice on the valve stem is broken. For example, in a dispensing configuration, the seal formed by valve seal116, which is positioned between the fluid and the orifice108, is broken. Stated another way, the valve stem62may be moved such that the valve seal116loses engagement with the valve body54by being moved away from the valve body54. Propellant and/or product may then flow through the orifice and into the channel95. Upon disengagement of the valve stem62, the valve stem62may move and the valve seal116may re-engage the valve body54to once again form a seal between the valve seal116and the valve body54. Upon re-engagement of the seal, the valve stem is in a sealing configuration and, thus, fluid, such as product and/or propellant, may no longer flow to the orifice108. It is to be appreciated that the dispensing configuration may also be used for filling.

As previously discussed, the valve stem62may include two or more fins96and one or more orifices positioned between each of the fins96. As illustrated inFIGS. 5C and 5D, for example, the valve stem62may include a first fin102and a second fin104. The first fin102may be positioned on the first portion86of the valve stem62or the second portion of the valve stem88and the second fin104may be positioned between the first fin102and the valve seal116disposed on the valve stem62. One or more orifices108may be positioned between the first fin102and the second fin104and one or more orifices108may be positioned between the second fin104and the valve seal116. In the sealing configuration, the first fin102, the second fin104, and the valve seal116are operatively engaged with the valve body54, such as the passageway surface80, such that a seal is formed between the valve body54and each of the first fin102, the second fin104, and the valve seal116. It is to be appreciated that the valve stem may include a single fin.

As previously discussed, the valve stem62may move to allow product and/or propellent to be dispensed from or to be introduced to the container. The seal or lack thereof controls the introduction and dispersal of product and/or propellant. The amount of movement of the valve stem62may result in one or more of the seals between the fins and the passageway surface and the valve seal and the valve body breaking. More specifically, the valve stem62may be moved in a direction toward the interior of the container, such as indicated inFIG. 7by arrow D, or in any direction that allows for the one or more seals to be broken. The valve stem62may be moved such that the second fin104becomes disengaged with the passageway surface80, which breaks the seal between the second fin and the passageway surface. The disengagement may be due to the valve stem62extending beyond the second passageway opening78of the valve body54such that the second fin104no longer maintains a seal with the passageway surface80.

The internal structure of the passageway surface80of the valve body54may also be such that the second fin104no longer maintains a seal with the passageway surface80. The internal structure of the passageway surface80may include, for example, one or more grooves extending into the passageway surface80or one or more ridges protruding from the passageway surface80to interrupt the engagement of the fin and the passageway surface. The shape of the grooves and ridges may provide for gradual or abrupt flow of product and/or propellant. For example, the grooves and ridges may be tapered to, for example, gradually allow for increasing flow of product and/or propellant.

It is to be appreciated that the valve stem62may only be moved such that the valve seal116longer maintains a seal with the valve body, but the second fin and the first fin may maintain engagement with the passageway surface80and, thus, maintain a seal. Disengagement of the valve seal116, allows product and/or propellant to flow into the orifice positioned between the valve seal116and the second fin104. This position of the valve stem62may be referred to as a dispensing configuration. Product and/or propellant may not flow through the orifice positioned between the second fin104and the first fin102. The second fin104and the first fin102may maintain engagement with the passageway surface80and, thus, no product and/or propellant may flow through the orifice positioned between the second fin104and the first fin102.

The valve stem62may be positioned in a dispensing configuration upon the actuator being engaged by a user. Thus, the force required to move the valve stem62from a sealing configuration to a dispensing configuration is that typically provided by a user. It is to be appreciated that the valve stem62may include one or more orifices for dispensing product. However, in some embodiments, additional orifices may be included in the valve stem62for filling the container or dispensing product at a different rate. Due to the placement of these additional orifices being closer to the first portion86of the valve stem62a greater force and/or a greater displacement is required to move the valve stem62to a position such that product and/or propellant may flow through these additional orifices.

The valve stem62may be moved further in the direction of the interior of the container, such as in the direction indicated by arrow D inFIG. 7. The valve stem62may be moved such that both the valve seal116and the second fin104are no longer sealed with the passageway surface80. Stated another way, the valve stem62may be moved such that the valve seal116and the second fin104becomes disengaged with the valve body54and passageway surface80, respectively, which breaks the seals. The disengagement may be due to the portion of the valve stem62, including the valve seal116and second fin, extending below the valve body54. It is to be appreciated that the internal structure of the passageway surface, such as one or more grooves protruding from the passageway surface80or a change in diameter of the passageway surface, may be used to interrupt the engagement between the fin and the passageway surface or to break the seal between the valve seal and the valve body. The valve stem62may be moved such that the valve seal116and the second fin104no longer maintain a seal, but the first fin102may still maintain engagement with the passageway surface80and, thus, maintain a seal.

Disengagement of the second fin104and the valve seal116, allows product and/or propellant to flow into the orifice positioned between both the valve seal116and the second fin104and the second fin104and the first fin102. This position of the valve stem62may be referred to as a filling configuration. The filling configuration may be used, for example, to introduce product and/or propellant into the container during manufacture of the aerosol dispenser. Allowing product and/or propellant to be introduced through multiple orifices may relatively shorten manufacturing times by filling the container more quickly. Also, by having orifices that are positioned between different pairs of fins, the orifices may be different sizes and those sizes may be selected for the particular function of the dispenser. For example, the orifice positioned between the valve seal116and the second fin may be sized to allow for product dispensing and the orifice positioned between the second fin and the first fin may be sized to allow for filling of the dispenser. For example, the orifice for product dispensing may be smaller than the orifice for filling the dispenser. It is to be appreciated that the filling configuration may also be used for dispensing. For example, a dispenser may have a first dispensing rate when the stem is positioned in the dispensing configuration and a second dispensing rate, which may be greater than the first dispensing rate, when the stem is positioned in the filling configuration.

The valve assembly may be configured such that to fill the container, product and/or propellant may pass through one or more orifices defined by the valve stem and/or around the outer stem surface92. Thus, product and/or propellant may flow into the container through the channel95and orifices108of the valve stem and/or around the outer stem surface92of the valve stem. Allowing product and/or propellant to be filled through multiple pathways through the valve assembly and into the container may provide for relatively faster filling of the container. For example, the filling configuration may not require an orifice in the valve stem62in fluid communication with the product delivery device56, but rather may include the condition that the product delivery device56be in fluid communication, by way of the passageway74, with a filling apparatus sealed radially about the passageway.

It is to be appreciated that product and/or propellant may flow through any orifice below which the seal between the valve body and the stem has been broken. It is also to be appreciated that product and/or propellant may pass through the orifices in either direction. Product and/or propellant may flow from the container, through the orifice and into the channel95or may flow from the channel95, through the orifice and into the container. The channel95may be in fluid communication with each of the orifices positioned about the valve stem62. The valve stem62may include any number of orifices, fins, and valve seals.

The valve stem62may extend through the inner passageway74of the valve body54, such as illustrated inFIGS. 9A and 9B. The valve stem62may extend through the inner passageway74such that the first portion86of the valve stem62is adjacent to the first passageway opening76, the second portion88of the valve stem62is substantially surrounded by the passageway surface80, and the third portion90of the valve stem62is adjacent to the second passageway opening78. The first portion86of the valve stem62may extend beyond the first passageway opening76and the third portion90of the valve stem62may extend beyond on the second passageway opening78.

The valve assembly52may include an engagement member68. The engagement member68may be joined to a portion of the valve stem62such that the engagement member68moves as the valve stem62moves. The engagement member68may extend from the outer stem surface92towards the outer surface72of the valve body54, such as illustrated inFIGS. 9A and 9B. The engagement member68may be axisymmetric or non-axisymmetric. The engagement member68includes an engagement surface69, such as illustrated inFIG. 9C. The engagement surface69is configured to operatively engage a portion of the resilient member58. The resilient member58may be positioned between the engagement surface and a portion of the valve body54. When the valve stem62is in a sealing configuration, the engagement surface69may operatively engage the resilient member58such that the resilient member58is placed under a desired amount of compression which biases the valve stem62to remain in a position such that a seal is maintained. When the valve stem62is in a dispensing configuration, a user or other mechanical device may overcome a force of the resilient member to move the valve stem62from the sealing configuration to the dispensing configuration or the filling configuration. As the valve stem62moves from the sealing configuration to the dispensing configuration, the engagement member68compresses the resilient member58.

The engagement surface69of the engagement member68may include one or more force concentrators124. The one or more force concentrators124may be joined to the engagement member68. The one or more force concentrators124may be integrally molded with the engagement member68or later added to the engagement member68. The one or more force concentrators124may extend from the engagement surface69toward the resilient member58and be configured to operatively engage the resilient member58. The one or more force concentrators124concentrate the force applied to the resilient member58as the valve stem is moved by a user or other mechanical device. The one or more force concentrators may be used to optimize the force to move the valve stem and the ability of the valve stem to remain in the sealing configuration. The total surface area of the portion of the one or more force concentrators that engages the resilient member58is less than the total surface area of the resilient member58in facing relationship with the one or more force concentrators. The one or more force concentrators may apply strain to only those portions of the resilient member58that are engaged by the one or more force concentrators. The one or more force concentrators124may be any shape and size such that a desired force is achieved. For example, the force concentrators may be rectangular, square, conical or tapered, or crescent-shaped. The force concentrators may include a notch or aperture. The one or more force concentrators may extend radially outward from the longitudinal axis or circumferential to the longitudinal axis.

Referring toFIGS. 9A, 9B, and 9D, the valve body54may include one or more force concentrators124. The one or more force concentrators may be integrally molded with the valve body or later added to the valve body. The one or more force concentrators124may extend from the valve body54toward the resilient member68. The resilient member68may be disposed on the one or more force concentrators124extending from the valve body54. The one or more force concentrators124may be joined to any portion of the valve body54such that they operatively engage the resilient member58. For example, the one or more force concentrators124may be joined to the portion of the valve body54adjacent to the inner passageway74. Two or more force concentrators124may surround the inner passageway74adjacent to the first passageway opening76. The one or more force concentrators124concentrate the force applied to the resilient member58as the valve stem is moved by a user or other mechanical device. The one or more force concentrators may be used to optimize the force to move the valve stem and the ability of the valve stem to remain in the sealing configuration. The one or more force concentrators124may be any shape and size such that a desired force is achieved, such as previously discussed.

It is to be appreciated that one or more force concentrators124may be joined to either the engagement member68or the valve body54. Further, it is to be appreciated that one or more force concentrators124may be joined to each of the engagement member68and the valve body54.

For a configuration of the valve assembly where both of the engagement member68and the valve body54have one or more force concentrators joined thereto, the one or more force concentrators of the valve body54may be aligned or offset from the one or more force concentrators of the engagement member68. For a configuration where the one or more force concentrators of the valve body are offset from the one or more force concentrators of the engagement member, a relatively thinner resilient member may be used because the force concentrators have a greater amount of space in which to travel and act on the resilient member. By contrast, having the one or more force concentrators of the engagement member aligned with the one or more force concentrators of the valve body may require a relatively thicker resilient member to prevent the one or more force concentrators from directly engaging one another and reaching the point that the resilient member is no longer compressible, which may cause the force to move the valve stem to exceed that desired for typical consumer use.

Referring toFIG. 10, the position of the resilient member58may be such that the resilient member58is between the valve body54and the container or a dip tube adaptor64. Stated another way, the resilient member58may be positioned adjacent to the second passageway opening78of the inner passageway74of the valve body54. Similar to the above, one or more force concentrators124may be joined to the retaining member110and/or one or more force concentrators may be joined to the dip tube adaptor64. The force concentrators are configured to operatively engage the resilient member and create a desired force to move the valve stem.

The one or more force concentrators may be joined to at least one of the valve body54, retaining member110, and the engagement member68or the one or more force concentrators may be formed as a separate member and added to the valve assembly, such as illustrated inFIGS. 11A-11D. The engagement member68includes one or more force concentrators configured to operatively engage a first portion of the resilient member58and a force concentrator member126may include one or more force concentrators124configured to operatively engage a second portion of the resilient member58. The one or more force concentrators may be shaped to better position and/or hold the resilient member58. As illustrated inFIG. 11C, the one or more force concentrators124have a substantially concave shape at the portion of the force concentrator that contacts the resilient member58.

It is to be appreciated that in any of the aforementioned configurations, the one or more force concentrators may be joined to a separate force concentrator member and the member including the one or more force concentrators may be included in the valve assembly to operatively engage the resilient member.

As illustrated inFIG. 11D, the valve assembly52may be disposed within at least a portion of the container. The valve assembly52may be joined to a portion of the container, such as the neck of the container.

The aforementioned components of the aerosol dispenser30may be polymeric. By polymeric it is meant that the component is formed of a material that includes polymers, and/or particularly polyolefins, polyesters or nylons, and more particularly PET. Thus, the entire aerosol dispenser30or, specific components thereof, may be free of metal. The container32, and all other components, may comprise, consist essentially of or consist of PET, PEF (polyethylene furanoate), PEN (polyethylene naphthlate), Nylon, EVOH or combinations thereof. All or substantially all of the components of the aerosol dispenser, excluding the propellant and product, may be configured to be accepted in a single recycling stream. All such materials, or a majority of the components of the aerosol dispenser30(excluding the propellant and product) may be comprised of a single class of resin according to ASTM D7611. Particularly, the majority of the aerosol dispenser30by weight may be PET. The majority of the valve assembly52by weight may be PET.

A permanent or semi-permanent seal may be used to join any or all of the polymeric components of the aerosol dispenser30. Particularly, if the components have compatible melt indices, such components may be sealed by welding. Suitable welding processes may include sonic, ultrasonic, spin, and laser welding. For example, spin welding provides the benefit that the energy plane is generally confined to a small vertical space, limiting unintended damage of other components not intended to be welded or receive such energy. Welding may be accomplished with a commercially available welder, such as available from Branson Ultrasonics Corp. of Danbury, Conn.

Overpressurization and deformation may occur during heating, either intentionally or inadvertently, of an aerosol dispenser. This overpressurization and deformation may result in rupture of the aerosol dispenser and/or premature loss of propellant and/or product. The valve52may be designed such that the deformation is controlled and the release of product and/or propellant is controlled.

The valve stem62may be designed, in part, to aid in controlling the overpressurization and deformation of the aerosol dispenser when heated to relatively high temperatures. As previously discussed, the valve stem62may include a retaining member110. The retaining member110may be positioned at the third portion90of the valve stem62. The retaining member110may be a separate member joined to the valve stem62or may be integrally formed, such as by molding, during the manufacture of the valve stem62. The retaining member110may be configured to engage a portion of the valve body54. For example, the retaining member110may be configured to engage the portion of the valve body54that is adjacent to the second passageway opening78. The retaining member110may be configured to engage any portion of the valve body54and/or the valve seal. The retaining member110aids in positioning the valve stem62with respect to the inner passageway74and aids in preventing the valve stem62from being adversely ejected from the valve body54.

During overpressurization of the dispenser, the retaining member110may deform and allow the valve stem62to move in a direction away from the valve body and/or valve seal, but not be ejected from the valve body. The retaining member110may deform in a manner such that the valve stem62moves away from the valve body and/or valve seal to create a flow path which allows product and/or propellant to vent or be released and prevents unsafe ejection of the valve stem from the valve body54and/or unsafe discharge of product and/or propellant from the container.

The aerosol dispenser including the aforementioned components may be used to safely vent propellant and/or product when the aerosol dispenser is subject to these relatively high temperatures and/or pressures. The valve assembly is designed to allow for release of the product and/or propellant. When the aerosol dispenser is subject to relatively high temperatures, the valve body may pivot, which allows the valve body to move away from the valve stem. The valve stem may separate from the valve body and break the seals between the valve stem and the valve body so that product and/or propellant may flow from the container, through or around the retaining member, which may include one or more voids, such as apertures, slots, and notches, and be released to the environment. A flow path is created between the valve stem and the valve seal through the movement of the valve body. The movement of the valve body may be away from the container and/or outward toward the neck of the container. An aerosol dispenser including the aforementioned components may safely release product and/or propellant. The valve stem62may move to or from any one of a dispensing configuration, a sealing configuration, a filling configuration, and a venting configuration.

As illustrated inFIGS. 12A-14C, the valve assembly52may be configured such that the valve stem62does not extend above at least one of the upper portion of the neck or the upper portion of the valve body. Thus, at least one of the upper portion of the neck or the upper portion of the valve body protects the valve stem during manufacture and transport of the partially assembled dispenser. More specifically, when the valve stem extends beyond the upper surface of the neck and/or the upper surface of the valve body and prior to an actuator being joined to the valve stem, the valve stem may be inadvertently engaged allowing product and/or propellant to be dispensed or a portion of the valve stem may get damaged. Alternatively, by positioning the valve stem below the upper portion of the neck and/or the upper portion of the valve body, the valve stem may be protected from inadvertent damage or dispensing.

It is also to be appreciated that the resilient member58may be positioned in a number of locations with respect to the valve body. These positions are discussed herein in reference to a valve stem that does not extend beyond the upper portion of the valve body. However, it is to be appreciated that these resilient member positions may also be used with a valve stem that extends beyond the valve body.

Referring toFIGS. 12A, 12B, and 12C, as previously described, the container32includes a neck40and the neck40defines an opening38. The opening38is defined, at least in part, by an upper neck portion118. The upper neck portion118may extend about a longitudinal axis70. The valve body54may be inserted into a portion of the neck40. The valve body54may include a first upper valve portion120and a second upper valve portion122, such as illustrated inFIGS. 12A-12C. It is to be appreciated that the valve body54may include a single upper valve portion or any number of upper valve portions. The upper valve portion may be the portion of the valve body that is farthest from the bottom of the container. The upper valve portion120,122may extend about at least a portion of the longitudinal axis70.

The valve stem62may be positioned such that a portion of the valve stem62extends through the inner passageway74of the valve body54, as previously described. The valve stem62includes a first portion86which is configured to extend beyond the first passageway opening76of the inner passageway74. However, the first portion86does not extend beyond at least one of the upper valve portion120,122and the upper neck portion118. The upper valve portion120,122and/or the upper neck portion118aid in protecting the valve stem62prior to, for example, adding an actuator. The valve stem62may include an outer stem surface92and an inner stem surface94. A portion of the outer stem surface92may be in facing relationship with the passageway surface80.

The outer stem surface92may be joined to a portion of the resilient member58. The resilient member58may be joined to the outer stem surface92such that the resilient member58moves in response to movement of the valve stem62. A portion of the resilient member58may engage the valve body54. The valve body54is stationary and, thus, the valve body54opposes the movement of the resilient member58. More specifically, a first portion of the resilient member58is joined to the outer stem surface92and a second portion of the resilient member58engages the valve body54. As the valve stem62moves, the resilient member58compresses against the stationary valve body54.FIG. 12Aillustrates the resilient member58in an uncompressed configuration andFIG. 12Billustrates the resilient member58in a compressed configuration. The resilient member58is what causes the valve stem58to return from a dispensing/filling configuration to a sealing configuration. As the valve stem62is moved, the resilient member58compresses and biases the valve stem in the opposite direction. When the force causing the valve stem62to move is removed, the resilient member58causes the valve stem62to return to the sealing configuration.

The resilient member may be any compliant member that is configured to be joined to the valve stem and provides for return of the valve stem to the sealing configuration. The resilient member may be any shape such that the resilient member is joined to the valve stem and controls the movement of the valve stem.FIGS. 12A-12Cillustrate an annular resilient member, for example. The resilient member may be positioned between the actuator46and the valve body54.

The actuator46may be joined to the valve stem62. The outer surface of the actuator46may be joined to the inner stem surface94such as illustrated inFIGS. 12A-12C. The actuator46may be joined to the valve stem62such that when a user engages the actuator46the valve stem62moves and product and/or propellant flows through the channel95of the valve stem62, through the actuator46, and out of the nozzle60. It is to be appreciated that the actuator may be any mechanical device that allows the user to engage it and for product and/or propellant to be released from the container in response to the engagement.

Referring toFIGS. 13A, 13B, and 13C, as previously described, the container32includes a neck40and the neck40defines an opening38. The opening38is defined at least in part by an upper neck portion118. The upper neck portion118may extend about a longitudinal axis70. The valve body54may be inserted into a portion of the neck40. The valve body54may include a first upper valve portion120and a second upper valve portion122, such as illustrated inFIGS. 13A-13C. It is to be appreciated that the valve body54may include a single upper valve portion or any number of upper valve portions. The upper valve portion may be the portion of the valve body that is farthest from the bottom of the container. The upper valve portion120,122may extend about at least a portion of the longitudinal axis70.

The valve stem62may be positioned such that a portion of the valve stem62extends through the inner passageway74of the valve body54, as previously described. The valve stem62includes a first portion86which does not extend beyond the first passageway opening76of the inner passageway74. The first portion86of the valve stem62may be disposed within the inner passageway74of the valve body54. The first portion86does not extend beyond at least one of the upper valve portion120,122and the upper neck portion118. The upper valve portion120,122, the upper neck portion118, and/or the inner passageway74aid in protecting the valve stem62prior to, for example, adding an actuator. The valve stem62may include an outer stem surface92and an inner stem surface94. At least a portion of the outer stem surface92may be in facing relationship with the passageway surface80.

The actuator46may be joined to the valve stem62. The outer surface of the actuator46may be joined to the inner stem surface94such as illustrated inFIGS. 13A-13C. The actuator46may be joined to the valve stem62such that when a user engages the actuator46the valve stem62moves to a dispensing configuration and product and/or propellant flows through the channel95of the valve stem62, through the actuator46, and out of the nozzle60.

The actuator46may be joined to a portion of the resilient member58. The resilient member58may be joined to the actuator46such that the resilient member58moves in response to movement of the actuator46. A portion of the resilient member58may engage the neck40of the outer container. The neck40is stationary and, thus, the neck40opposes the movement of the resilient member58. More specifically, a first portion of the resilient member58is joined to the actuator46and a second portion of the resilient member58engages the neck40. As the actuator46moves, the resilient member58compresses against the stationary neck40.FIG. 13Aillustrates the resilient member58in an uncompressed configuration andFIG. 13Billustrates the resilient member58in a compressed configuration. The resilient member58is what causes the valve stem58to return from a dispensing configuration to a sealing configuration. As the valve stem62is moved by engagement of the actuator46, the resilient member58compresses and biases the valve stem in the opposite direction, which may include away from the bottom of the container. When the force causing the valve stem62to move is removed, the resilient member58causes the valve stem62to return to the sealing configuration. As illustrated inFIGS. 13A-13C, the resilient member58may be positioned above the valve stem62or, stated another way, the valve stem62and the valve body54may be positioned between the resilient member58and the bottom of the container.

Referring toFIGS. 14A, 14B, and 14C, as previously described, the container32includes a neck40and the neck40defines an opening38. The opening38is defined at least in part by an upper neck portion118. The upper neck portion118may extend about a longitudinal axis70. The valve body54may be inserted into a portion of the neck40. The valve body54may include a first upper valve portion120and a second upper valve portion122, such as illustrated inFIGS. 14A-14C. It is to be appreciated that the valve body54may include a single upper valve portion or any number of upper valve portions. The upper valve portion may be the portion of the valve body that is farthest from the bottom of the container. The upper valve portion120,122may extend about at least a portion of the longitudinal axis70.

The valve stem62may be positioned such that a portion of the valve stem62extends through the inner passageway74of the valve body54, as previously described. The valve stem62includes a first portion86which does not extend beyond the first passageway opening76of the inner passageway74. The first portion86of the valve stem62may be disposed within the inner passageway74of the valve body54. The first portion86does not extend beyond at least one of the upper valve portion120,122and the upper neck portion118. The upper valve portion120,122, the upper neck portion118, and/or the inner passageway74aid in protecting the valve stem62prior to, for example, adding an actuator. The valve stem62may include an outer stem surface92and an inner stem surface94. At least a portion of the outer stem surface92may be in facing relationship with the passageway surface80.

The actuator46may be joined to the valve stem62. The outer surface of the actuator46may be joined to the inner stem surface94such as illustrated inFIGS. 13A-13C. The actuator46may be joined to the valve stem62such that when a user engages the actuator46the valve stem62moves and product and/or propellant flows through the channel95of the valve stem62and through the actuator46and out of the nozzle60.

A resilient member58may be positioned opposite the actuator46. The resilient member58may be positioned such that the valve stem62is positioned between the actuator46and the resilient member58. The resilient member58may be joined to the dip tube adaptor64. The resilient member58may extend from the dip tube adaptor64toward the valve stem62such that the valve stem62engages a portion of the resilient member58. The resilient member58moves in response to movement of the valve stem62. The dip tube adaptor64is stationary and, thus, the dip tube adaptor64opposes the movement of the resilient member58. More specifically, a first portion of the resilient member58is joined to dip tube adaptor64and a second portion of the resilient member58engages the valve stem64. As the actuator46moves, the valve stem62moves and engages the resilient member58which compresses against the dip tube adaptor64.FIG. 14Aillustrates the resilient member58in an uncompressed configuration andFIG. 14Billustrates the resilient member58in a compressed configuration. The resilient member58is what causes the valve stem58to return from a dispensing configuration to a sealing configuration. As the valve stem62is moved by engagement of the actuator46, the resilient member58compresses and biases the valve stem in the opposite direction. When the force causing the valve stem62to move is removed, the resilient member58causes the valve stem62to return to the sealing configuration. As illustrated inFIGS. 14A-14C, the resilient member58may be positioned below the valve stem62or, stated another way, the valve stem62and the resilient member58may be positioned between the valve body54and the bottom of the container.

As illustrated inFIGS. 15A and 15B, the valve stem62may be configured such that the valve stem62does not extend beyond the upper portion of the valve body54. This configuration may protect the valve stem during manufacturing processes and/or shipping. Similar to the above, an actuator may be joined to the valve stem62to control the movement of the valve stem.