Aerosol actuation systems and methods for making the same

An aerosol actuation system may include an aerosol actuator formed of a first molded component including a housing, a manifold connected to the housing and a button in communication with the manifold, and a molded cap. The aerosol actuator may be assembled with an aerosol container.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Embodiments of the present invention relate to spray systems and more particularly to aerosol actuation systems, actuation mechanisms, and methods for making such systems.

2. State of the Art

Aerosol spray systems are well known. A traditional aerosol spray system may include an aerosol container, a valve, and an actuator. A product and gas contained within an aerosol container may be released by pressure exerted on the actuator, opening the valve and allowing the product and gas to escape as an aerosol. In many instances, the actuator is a button or cap having a fluid flow path therein which attaches to the valve of the aerosol system. When a user applies pressure to the button or cap, the valve opens allowing a product and gas to pass through the fluid flow path and exit the aerosol container.

The awkward ergonomics required to actuate some aerosol systems has led to the development of alternative actuation processes. For example, some aerosol systems are now actuated with elaborate trigger systems such as those disclosed and described in U.S. patent application Ser. No. 10/429,629 (Published as US 2004/0222246), now abandoned. Other trigger actuated systems have also been used. These systems, however, often use multiple parts, requiring multi-stage assembly processes. The increased part count and complicated assembly processes associated with these systems often increases the costs associated with producing aerosol actuation systems.

Therefore, it is desirable to develop improved aerosol actuation and spray systems and lower cost aerosol actuation and spray systems.

BRIEF SUMMARY OF THE INVENTION

According to certain embodiments of the invention, an aerosol actuation system may include an aerosol actuator attached to an aerosol container having a valve system. The aerosol actuator may include two or more molded pieces.

In some embodiments of the invention, an aerosol actuator may include a first molded component assembled with a second molded component. The first molded component may include a housing, a manifold, and a button. The second molded component may include a cap which may be attached to the first molded component. The first and second components may be made of similar or dissimilar materials. The first and second molded components may also have similar or dissimilar coloring.

According to other embodiments of the invention, a third component, such as an orifice cup, may be assembled with an aerosol actuator including a housing, a manifold, a button and a cap. An orifice cup may be used to alter the spray pattern of an aerosol actuator.

According to various embodiments of the invention, a button of the aerosol actuator may be connected or in communication with the manifold such that when a force is applied to the button, the manifold is moved and actuates a valve of an aerosol container to release a product or an aerosol from the aerosol container.

According to still other embodiments of the invention, a trigger and manifold used in an aerosol actuation system may be molded as a single part. In other embodiments, a trigger, manifold, and orifice cup or discharge orifice may be molded in a single part or as a unitary piece.

DETAILED DESCRIPTION OF THE INVENTION

According to particular embodiments of the invention, an aerosol actuation system100may include an aerosol actuator110and an aerosol container102as illustrated inFIG. 1. The aerosol actuator110may be connected to the aerosol container102using any conventional means, methods, or connection systems. The aerosol container102may be of any size and may contain, or be adapted to contain, a product which can be dispensed from the aerosol container102. For example, the aerosol container102may contain any product typically dispensed using traditional aerosol systems.

FIG. 2illustrates a cross-sectional view of an aerosol actuator110according to various embodiments of the invention. The aerosol actuator110may include a housing120, a cap130, a manifold140, and a button150or trigger.

The housing120may include one or more attachment mechanisms for attaching the aerosol actuator110to an aerosol container102. For example, as illustrated inFIG. 2, the housing120may include one or more protrusions122configured to hold the aerosol actuator110on an aerosol container102. The one or more protrusions122may snap under a lip or flange of an aerosol container102thereby attaching the aerosol actuator110to the aerosol container102. The housing120may also be configured with one or more protrusions122configured to mate with recesses in an aerosol container102. In some embodiments, the housing may also be configured with one or more supports124as illustrated inFIG. 2. The one or more supports124may rest on a portion of the aerosol container102. The supports124may provide strength to the housing120or improve the amount of loading forces that may be applied to an aerosol actuation system100. The supports124may also facilitate the connection between the aerosol actuator110and an aerosol container102.

According to embodiments of the invention, the housing120of an aerosol actuator110may be formed in any desired shape and size. For example, the aerosol actuator110illustrated inFIG. 2may be configured to fit on large aerosol containers102or small aerosol containers102. The dimensions of the housing120and other components of the aerosol actuator110may be scaled according to the desired use and to the desired aerosol container102size.

In various embodiments of the invention, a cap130may be connected to the housing120. For example, the cap130illustrated inFIG. 2may be snap-fitted to the housing120along an upper edge of the housing120and an edge138of the cap130. The housing120and cap130may include complementary fittings or other features allowing a cap130to be snap-fitted or otherwise connected to the housing120. In other embodiments, the housing120and cap130may include complementary surfaces allowing the cap130to rest against the housing120or be supported by the housing120.

In some embodiments of the invention, the housing120may include one or more housing support structures126. A cap130may include one or more complementary cap support structures136. The one or more housing support structures126and cap support structures136may fit together to connect the cap130to the housing120. For example, as illustrated inFIG. 2, the housing support structures126may mate, fit in, or otherwise connect with the cap support structures136to hold the cap130on the housing120. While particular housing support structures126and cap support structures136are illustrated inFIG. 2, it is understood that other such structures or connective parts may be used. For instance, the cap support structures136may include snap-fit hooks which may snap into snap-fitments in the housing120to secure the cap130to the housing120.

Additional support structures or connective elements may also be used to connect a cap130to a housing120according to embodiments of the invention. For example, the aerosol actuator110illustrated inFIG. 3includes a cap connection post137and a housing connection support127. The cap connection post137may snap into the housing connection support127to help secure the cap130to the housing120. In other embodiments, the cap connection post137may fit with or be secured to the housing connection support127in any other desired manner. Similarly, the housing120may include a housing connection post which mates with or connects with a cap connection support (not shown) to secure or support a connection between the cap130and the housing120.

A housing120according to embodiments of the invention may also include a discharge orifice160as illustrated inFIG. 2. The discharge orifice160may be molded with the housing120and may define a passage through which a product and/or an aerosol are ejected from the aerosol actuator110in an aerosol actuation system100. The discharge orifice160may include any desired shape or size and may be customized to produce particular spray patterns.

In some embodiments of the invention, an orifice cup170may be assembled with the discharge orifice160as illustrated inFIG. 3. An orifice cup170may provide an aerosol actuation system100with a particular spray pattern. For example, if a broad spray pattern is desired, an orifice cup170configured to produce such a spray pattern may be assembled with the housing120in the discharge orifice160to provide such a pattern. If an alternative pattern is desired, a different orifice cup170could be assembled or inserted into the discharge orifice160to provide the desired pattern. In this manner, the spray patterns produced by an aerosol actuation system100according to embodiments of the invention may be customized to the desired use for the aerosol actuation system100or to the product that will be dispersed by the aerosol actuation system100.

According to certain embodiments of the invention, the manifold140, the button150, or the manifold140and the button150may be integral with the housing120or integrally formed with the housing120. For example,FIG. 4illustrates a cross-sectional view of a housing120according to embodiments of the invention wherein the manifold140and the button150have been integrally molded with the housing120. The manifold140may be connected to the housing120in any desired manner. In some embodiments, connections between the manifold140and the housing120may be molded to allow the manifold140to flex. In other embodiments, connections between the manifold140and housing may hold at least a part of the manifold140in a rigid position. The manifold140may include a valve connection142having an opening configured to mate with a valve of an aerosol container102. A passage through the manifold140may lead from the valve connection142to the discharge orifice160. Product may flow through the passage from a valve of an aerosol container102and out the discharge orifice160.

According to some embodiments of the invention, the button150may be connected to the manifold140by an actuation connection152. The actuation connection152may be any shape and may connect the button150with the manifold140in one, two, or more locations. For instance, the actuation connection152illustrated inFIG. 4includes an arm connecting one side of the button150with one side of the manifold140. An arm on the other side of the button150, not shown in the cross-sectional view, would connect a second side of the button150to the manifold140. Other connections between the manifold140and button150may be used as desired.

The button150may also be integral with or connected to the housing120. The button150may be molded to include one or more button connections154to the housing120. The button connections154may be configured so that the button connections154are permanent or so that the button connections154break-away or separate from the housing120or button150. When the button connections154are permanent, the button connections154may flex or allow the button150to flex when a force is applied to the button150such that the force applied to the button150is at least partially transferred to the manifold140, for example, through an actuation connection152. The force applied to the manifold140may move the manifold140and a valve of an aerosol container102attached to the valve connection142. If sufficient force is applied, the movement of the valve connection142may open the valve of an aerosol container102allowing a product and/or an aerosol to escape the aerosol container102through the manifold140and out the discharge orifice160.

In various embodiments of the invention the button connections154may be configured to break or separate from the housing120upon activation of the button150. In such embodiments, the actuation connection152may connect the button150to the manifold140. When a force is applied to the button150, the button150may move the actuation connection152and the manifold140. When the manifold140is moved a sufficient distance, the manifold140may open a valve of an aerosol container102connected to the manifold at the valve connection142. When the force being applied to the button150is reduced or removed, the spring forces or rigidity of the manifold140may allow the manifold140to relax back into its original position wherein the valve of the aerosol container102is closed. The relaxation of the manifold140may also move the button150close to its original position. Thus, the manifold140may act as a spring to return the button150to a position within the housing120.

While the button connections154are illustrated in a particular location inFIG. 4, it is understood that the button connections154may be located in any desired position about the button150or in contact with the button150. In addition, the button connections154may be formed as an integral spring or force resisting structure such that when a force being applied to the button150is released or reduced, the button connection154may return the button150to a starting position or a position where sufficient force is not being applied to the manifold140to open a valve of an aerosol container102and allow product to escape.

According to some embodiments of the invention, an aerosol actuation system100may include a button150, manifold140, and housing120formed as a single component as illustrated inFIG. 23. A cap130may enclose the interior of the aerosol actuation system100. The button150and manifold140of the aerosol actuation system100illustrated inFIG. 23may move upon actuation of the button150such that the discharge orifice160moves in response to actuation of the button150.FIG. 24illustrates the aerosol actuation system100shown inFIG. 23.

Another embodiment of an aerosol actuation system100according to embodiments of the invention is illustrated inFIGS. 25 and 26. The cross-sectional view of the aerosol actuation system100shown inFIG. 25illustrates the button150, manifold140and housing120which are formed from a single piece of material, such as a molded plastic material. As the button150is actuated or pushed, the manifold140moves in response to the button150movement and disperses a product from a container. The discharge orifice160, including an orifice cup if desired, may move in response to forces applied to the button150.FIG. 26illustrates the aerosol actuation system100shown inFIG. 25.

In still other embodiments of the invention, the button150may be connected to the manifold140through one or more actuation connections152but not to the housing120. For example, the aerosol actuator illustrated inFIG. 5does not include any connections between the button150and the housing120. When a force is applied to the button150, the actuation connections152move the manifold140, which may activate or open a valve of an aerosol container102. When the force is released, the manifold140or a spring force integral with the manifold140may move the manifold140back to an original position, closing the valve and moving the button150back to a pre-actuation position.

According to embodiments of the invention, the aerosol actuator110components illustrated inFIGS. 4 and 5may be molded in a single piece or component. For instance, the housing120, manifold140, and button150assemblies illustrated inFIGS. 4 and 5may be formed by injection molding polypropylene or other resin or plastic material in a mold assembly. The molded housing120, manifold140, and button150may then be assembled with a cap130and connected to an aerosol container102to form an aerosol actuation system100according to embodiments of the invention.

In other embodiments of the invention, as illustrated inFIG. 6, the manifold140may be integral with the housing120. The manifold140may include one or more button connectors152wherein a button150or an actuation connection152may be connected to the manifold140and housing120assembly. For example, the button150and actuation connection152illustrated inFIG. 6may be molded as a single piece and the manifold140and housing120may be molded as a second piece. The button150and actuation connection152may be snap-fit or otherwise assembled or connected to the manifold140at the button connectors142on the manifold140. In other embodiments, the actuation connection152may be molded with the manifold140and a button150may be snap-fit or otherwise assembled or connected to the actuation connection152. In these particular embodiments, the housing120and manifold140may be molded as a first piece and the button150or button150and actuation connection152as a second piece from polypropylene or other plastic or resin material. The two pieces may then be assembled with a cap130to produce an aerosol actuator110according to embodiments of the invention.

According to still other embodiments of the invention, the button150may be integral with the housing120as illustrated inFIG. 7. The button150may be molded with the housing120and may include one or more button connections154connecting the button150to the housing120. The actuation connections152may also be formed or molded with the button150. However, the manifold140may be molded as a separate piece and then inserted, assembled, or otherwise connected to the housing120. For example, as illustrated inFIG. 7, the manifold140may be snap-fit to the housing120with a manifold snap-fitment146which may be molded with the housing120. In such embodiments, the housing120and button150may be molded and then assembled with a manifold140molded separately. The manifold140may be secured with the housing120using any desired methods. A cap130may then be attached to the assembly to form an aerosol actuator110according to embodiments of the invention.

As illustrated inFIG. 7, the button150and the actuation connections152may not actually connect with the manifold140according to some embodiments of the invention. The button150and the actuation connections152may be configured such that actuation of the button150or the application of force to the button150moves the actuation connections152such that the actuation connections152engage the manifold140. The engagement of the manifold140and the actuation connections152may move the manifold140and actuate a valve of an aerosol container102.

According to certain embodiments of the invention, an aerosol actuator110may be assembled from two parts. For example, a housing120molded with a manifold140, a button150, and a discharge orifice160may be assembled with a separately molded cap130. The assembled aerosol actuator110may be snap-fitted onto an aerosol container102having a valve. The valve may mate with the manifold140, providing a ready-to-use aerosol actuation system100.

A method for making an aerosol actuator110according to various embodiments of the invention is illustrated inFIG. 8. According to certain embodiments of the invention, a method for making an aerosol actuator110may include the molding of a first aerosol actuator component205and the molding of a second aerosol actuator component210. The first aerosol actuator component may include a housing120, a manifold140and a button150according to embodiments of the invention. The second aerosol actuator component may include a cap130. The first aerosol actuator component and the second aerosol actuator component may be assembled together 220 to form an aerosol actuator110according to embodiments of the invention. The aerosol actuator110and an aerosol container102may be assembled together 230 to form an aerosol actuation system100according to embodiments of the invention. The aerosol container102may be filled prior to, during, or after assembly with the aerosol actuator110. The assembled aerosol actuator110may also be shipped to a filling line or warehouse where aerosol actuator110may be assembled with aerosol containers102.

According to other embodiments of the invention, an aerosol actuator110may be assembled from three parts. A housing120molded with a manifold140and a button150may be assembled with a cap130as illustrated inFIG. 2. An orifice cup170may be assembled or attached to the discharge orifice160as illustrated inFIG. 3.

FIG. 9illustrates a method for making an aerosol actuator110according to other embodiments of the invention. A first aerosol actuator component is molded300; a second aerosol actuator component is molded310; and a third aerosol actuator component is molded315. The first, second, and third aerosol actuator110components may then be assembled320to form an aerosol actuator110. The aerosol actuator110may then be assembled with an aerosol container102prior to, during, or after filling of the aerosol container102. In some embodiments of the invention, where the third aerosol actuator component is an orifice cup170, the assembly of the third aerosol actuator component may be undertaken after the assembly of the aerosol actuator110with the aerosol container102.

According to various embodiments of the invention, the different components of an aerosol actuator110may be formed from different colored materials. For example, an aerosol actuator110may include a housing120having a first color and a cap130having a second, different, color. In some embodiments of the invention, various components of a single molded component may also have different colors. For instance, a button150may be molded to a housing120using a bi-injection molding process wherein the button150is molded with a different colored material than the rest of the housing120. Bi-injection molding processes may also be used with embodiments of the invention to form aerosol actuators110having different material components.

An assembled aerosol actuator110according to various embodiments of the invention is illustrated inFIGS. 10 through 17.FIG. 10illustrates a perspective view of an aerosol actuator110according to embodiments of the invention.FIG. 11illustrates a top view of an aerosol actuator according to embodiments of the invention.FIG. 12illustrates a bottom view of an aerosol actuator according to embodiments of the invention.FIG. 13illustrates a side view of an aerosol actuator according to embodiments of the invention.FIG. 14illustrates a front view of an aerosol actuator according to certain embodiments of the invention.FIG. 15illustrates a rear view of an aerosol actuator according to certain embodiments of the invention.FIG. 16illustrates a bottom perspective view of an aerosol actuator according to certain embodiments of the invention.FIG. 17illustrates a rear cross-sectional view of an aerosol actuator according to certain embodiments of the invention.

An aerosol actuator according to other embodiments of the invention is illustrated inFIGS. 18 through 21. As illustrated inFIG. 18, an aerosol actuator210according to embodiments of the invention may include an integrated button or trigger250, manifold240, and discharge orifice260. A front view of the aerosol actuator210is illustrated inFIG. 19. A cross-sectional view of an aerosol actuator210according to certain embodiments of the invention is illustrated inFIG. 20. As illustrated inFIG. 20, the manifold240, trigger250, and discharge orifice260may be molded as a single piece or component that may be used in or with an aerosol actuation system200. The molded component may be molded from a resin, plastic, composite, metal, or other material.

FIG. 21illustrates a cross-sectional view of an aerosol actuator210according to certain embodiments of the invention. The aerosol actuator210may include a single component manifold240, trigger250, and discharge orifice260fitted or otherwise situated in a housing220with a cap230. Activation of the trigger250may move the manifold240which may activate a valve of a container202to release a gas, a liquid, both a gas and liquid, or an aerosol product from the container202through the manifold240and discharge orifice260. According to embodiments of the invention, a one-piece trigger250, manifold240, and discharge orifice260component of an aerosol actuator210may be used in place of a multi-component trigger and manifold configuration in order to reduce the component count of an aerosol actuator210or aerosol actuation system200.

According to embodiments of the invention, an aerosol actuator210may be constructed or assembled by attaching or resting a one-piece trigger250, manifold240, and discharge orifice260in a housing220. A cap230placed over the housing220, or otherwise attached or snap-fitted to the housing220, may enclose the one-piece activation component within the housing220such that the trigger250portion is accessible. Activation of the trigger250may move the manifold240which may activate a valve on a container202. For example, the aerosol actuation system illustrated inFIG. 22may be activated to disperse a gas, liquid, both liquid and gas, or an aerosol from the container202by activating the trigger250of the aerosol actuator210.

According to other embodiments of the invention, the discharge orifice260may be fitted with one or more orifice cups to customize the spray from the aerosol actuator.

While various embodiments of the invention have been described with respect to particular aesthetic designs illustrated in the Figures, it is understood that aerosol actuation systems according to embodiments of the invention may include other aesthetic designs. It is also understood that portions of the aerosol actuation systems according to embodiments of the invention may be incorporated with other aerosol actuation systems.

In addition, aerosol actuation systems according to embodiments of the invention are not limited to actuation buttons or triggers on the front of the aerosol actuator. An aerosol actuator may include an actuation button, buttons, trigger, or triggers on the side of the aerosol actuator or the rear of the aerosol actuator, or any combination thereof.

Having thus described certain particular embodiments of the invention, it is understood that the invention defined by the appended claims is not to be limited by particular details set forth in the above description, as many apparent variations thereof are contemplated. Rather, embodiments of the invention include within their scope all equivalent devices or methods which operate according to the principles of the invention as described.