Abstract:
A spray cap ( 20; 300; 400; 600 ) for a spray can ( 22 ) has a body comprising: a sidewall ( 140 ) having a lower portion for mounting to a body of the spray can; and a button ( 36 ). The button has: an upper surface ( 164 ) for user engagement; a downwardly projecting sleeve ( 38 ) for receiving an outlet stem ( 240 ) of the can; and a forwardly-open compartment ( 42 ). An insert ( 34; 302 ) is within the compartment. A nozzle member ( 32 ) is mounted across the compartment to contain the insert within the compartment.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    Benefit is claimed of U.S. Patent Application No. 61/950,243, filed Mar. 10, 2014, and entitled “Modular Spray Cap”, the disclosure of which is incorporated by reference herein in its entirety as if set forth at length. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The invention relates to pressurized spray containers. More particularly, the invention relates to spray dispensing of personal care compositions (e.g., deodorants, antiperspirant, and the like) and household chemicals (e.g., cleaners, air fresheners, and the like). 
         [0003]    A typical spray container or bottle takes the form of a metallic can having a top-mounted valve assembly. Exemplary valve assemblies are actuated by depressing a spray nozzle mounted at the top of the valve assembly to open the valve and create a pathway for contents of the can to exit under pressure. In some containers, the contents are contained within a bag and the pressurant is within the can surrounding the bag. In some containers, the valve inlet is formed as or connected to a dip tube which extends down into a body of liquid in the can. In bag-less variations, the headspace of the can above the liquid contains the pressurant in normal use. Common valve assemblies include male type and female type. In a male valve assembly, a stem extends upward from the valve and is received in the nozzle. Depression of the nozzle acts to depress the stem to open the valve. In female valve assemblies, the nozzle includes a stem which is received in the valve assembly and similarly actuates spraying. 
         [0004]    In a traditional spray nozzle, the user depresses a top of the nozzle with the user&#39;s index finger and sprays discharge from a lateral outlet in the nozzle. More recently, ergonomic caps have been developed that provide for a broader area for actuation and may facilitate a more ergonomic use, for example, of the thumb instead of the index finger. U.S. Pat. No. 6,161,736 issued Dec. 19, 2000 and entitled “Dispenser Apparatus” discloses a system wherein a modified conventional pushbutton nozzle is received within an overcap which has a broad finger-actuatable portion hinged relative to a main body mounted to the can. Another variation on such a system is shown in U.S. Pat. No. 7,530,476 issued May 12, 2009 and entitled “Locking Aerosol Dispenser” which contains a more complex arrangement of pieces. 
       SUMMARY OF THE INVENTION 
       [0005]    One aspect of the disclosure involves a spray cap for a spray can. The spray cap has a body comprising: a sidewall having a lower portion for mounting to a body of the spray can; and a button. The button has: an upper surface for user engagement; a downwardly projecting sleeve for receiving an outlet stem of the can; and a forwardly-open compartment. An insert is within the compartment. A nozzle member is mounted across the compartment to contain the insert within the compartment. 
         [0006]    A further embodiment may additionally and/or alternatively include the spray cap in combination with the can, the can including a valve having the outlet stem. The sidewall lower portion is mounted to the body of the spray can and the sleeve receives an upper portion of the outlet stem. 
         [0007]    A further embodiment may additionally and/or alternatively include the valve having an open condition and a closed condition; the button is depressable from a first position to a second position; a lower rim of the sleeve being spaced apart from a shoulder of the valve in the first position; the lower rim contacting the shoulder in the second position; and depressing of the button from the first position to the second position bringing the lower rim into contact with the shoulder to depress the shoulder and shift the valve from the closed condition to the open condition. 
         [0008]    A further embodiment may additionally and/or alternatively include the can being a metallic can containing a body of the product to be dispensed. 
         [0009]    A further embodiment may additionally and/or alternatively include a method for using the combination. The method comprises depressing the button from a first position to a second position. A lower rim of the sleeve is spaced apart from a shoulder of the valve in the first position. The lower rim contacts the shoulder in the second position. The depressing of the button from the first position to the second position brings the rim into contact with the shoulder to depress the shoulder and shift the valve from the closed condition to the open condition to discharge a spray of the product from the nozzle. 
         [0010]    A further embodiment may additionally and/or alternatively include the product flowing upward to the sleeve and passing forwardly along perimeter channels in the insert to a chamber between a forward end of the insert and the nozzle. 
         [0011]    A further embodiment may additionally and/or alternatively include the body further comprising a living hinge between the button and the sidewall. 
         [0012]    A further embodiment may additionally and/or alternatively include the body being unitarily molded as a single piece. 
         [0013]    A further embodiment may additionally and/or alternatively include the body consisting of a single piece plastic molding, the nozzle consisting of a single piece plastic molding, and the insert consisting of a single piece plastic molding. 
         [0014]    A further embodiment may additionally and/or alternatively include the body compartment comprising a forwardly-projecting pin, and the insert having a compartment receiving the pin. 
         [0015]    A further embodiment may additionally and/or alternatively include the body compartment comprising a blind rear end and the insert having an end received in the blind rear end. 
         [0016]    A further embodiment may additionally and/or alternatively include the insert comprising a plurality of longitudinal grooves. The nozzle member has: a transverse web having a nozzle aperture; and a collar extending aft from the transverse web and received in the compartment. The insert has an end received by an inner diameter surface of the collar and abutting an aft surface of the web. 
         [0017]    A further embodiment may additionally and/or alternatively include the insert having a central recess in the end. 
         [0018]    A further embodiment may additionally and/or alternatively include a method for using the spray cap, the method comprising: depressing the button to discharge a spray of the product from the nozzle. 
         [0019]    A further embodiment may additionally and/or alternatively include flow of the product passing through channels along the insert. 
         [0020]    A further embodiment may additionally and/or alternatively include a method for assembling the spray cap. The method comprising inserting the insert into the compartment and assembling the nozzle member to the body to capture the insert. 
         [0021]    A further embodiment may additionally and/or alternatively include a plurality of identical bodies used with a plurality of differing inserts and/or differing nozzle members. 
         [0022]    The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0023]      FIG. 1  is a view of a spray cap and can combination with can partially cutaway. 
           [0024]      FIG. 2  is a top view of the combination. 
           [0025]      FIG. 3  is a front view of the combination. 
           [0026]      FIG. 4 . is a side view of the combination. 
           [0027]      FIG. 5  is a central vertical longitudinal sectional view of the combination with can schematically shown in profile. 
           [0028]      FIG. 5A  is an enlarged view of a nozzle region of the combination of  FIG. 5 . 
           [0029]      FIG. 6  is a central vertical longitudinal sectional view of a main body of the cap. 
           [0030]      FIG. 6A  is an enlarged view of a portion of the body of  FIG. 6 . 
           [0031]      FIG. 7  is a view of an underside of the cap body. 
           [0032]      FIG. 8  is a view of a nozzle or outlet element of the cap. 
           [0033]      FIG. 9  is a side view of the outlet element. 
           [0034]      FIG. 10  is a central longitudinal sectional view of the outlet element taken along line  10 - 10  of  FIG. 9   
           [0035]      FIG. 10A  is an enlarged view of a nozzle opening region of the outlet element of  FIG. 10 . 
           [0036]      FIG. 11  is a view of a flow metering insert for the cap. 
           [0037]      FIG. 12  is a side view of the insert. 
           [0038]      FIG. 13  is a first end view of the insert. 
           [0039]      FIG. 14  is a second end view of the insert. 
           [0040]      FIG. 15  is a central longitudinal sectional view of the insert taken along the line  15 - 15  of  FIG. 13 . 
           [0041]      FIG. 16  is a central vertical longitudinal sectional view of a combination of a second cap with the can. 
           [0042]      FIG. 16A  is an enlarged view of a nozzle region of the second cap. 
           [0043]      FIG. 17  is a view of a second insert for use with the second cap. 
           [0044]      FIG. 18  is a side view of the second insert. 
           [0045]      FIG. 19  is a first end view of the second insert. 
           [0046]      FIG. 20  is a second end view of the second insert. 
           [0047]      FIG. 21  is a longitudinal sectional view of the second insert taken along line  21 - 21  of  FIG. 19 . 
           [0048]      FIG. 22  is a view of a third spray cap. 
           [0049]      FIG. 23  is an interior view of the third spray cap. 
           [0050]      FIG. 24  is a top view of the third spray cap. 
           [0051]      FIG. 25  is a front view of the third spray cap. 
           [0052]      FIG. 26  is a side view of the third spray cap. 
           [0053]      FIG. 27  is a bottom view of the third spray cap. 
           [0054]      FIG. 28  is a central vertical longitudinal sectional view of the third spray cap taken along line  28 - 28  of  FIG. 24 . 
           [0055]      FIG. 28A  is an enlarged view of a nozzle region of the third spray cap of  FIG. 28 . 
           [0056]      FIG. 29  is a central vertical longitudinal sectional view of a fourth spray cap. 
       
    
    
       [0057]    Like reference numbers and designations in the various drawings indicate like elements. 
       DETAILED DESCRIPTION 
       [0058]      FIG. 1  shows a cap (cap assembly)  20  on a container (cutaway)  22 . The exemplary container comprises a metallic can having a central vertical axis  500  ( FIG. 5 ). The exemplary can comprises any of a number of prior art or yet-developed can configurations. However, other configurations may be used. The exemplary can configuration ( FIG. 5 ) comprises a metallic sidewall  200  of nominal right circular cylindrical configuration (e.g., formed of sheet steel and soldered (or otherwise closed) along a longitudinal seam (not shown)). The exemplary can further comprises a single-piece bottom/base  202  formed of a metal (e.g., stainless steel) stamping and crimped (at an annular joint or crimp  204 ) to a lower rim portion of the sidewall. The exemplary bottle further comprises a top  206 . The exemplary top is formed of a multi-piece assembly comprising an outer member  208  and an inner member  210  (formed as a valve cup—discussed below). Both exemplary outer and inner members are metal (e.g., stainless steel) stampings with the outer member secured at its outer periphery to an upper rim portion of the sidewall  200  at an annular joint or crimp  212 . At its inner periphery (inner diameter or ID) the outer member  208  is secured to an outer peripheral (outer diameter or OD) portion of the valve cup  210  at an annular joint or crimp  214 . The various crimps may, themselves, be soldered or otherwise sealed/secured in addition to the mechanical interlocking provided by the crimping action. 
         [0059]    A valve assembly  220  may be mounted to the top  206  (e.g., to the valve cup  210 ) within the can. In various implementations, a dip tube  222  may extend into the can from the valve assembly. A lower end of the dip tube extends within a body  224  of the liquid product to be dispensed when the container is upright. An upper end portion of the dip tube may mate directly or indirectly with the valve structure. The dip tube may be within a bag or replaced by a bag (not shown) containing the body  224  of liquid contents (e.g., a personal care product such as deodorant and/or antiperspirant or a household maintenance product such as air freshener), surface cleaner or the like) to be dispensed. Other configurations may eliminate the dip tube. 
         [0060]    The exemplary valve is shown as a conventional spring-biased male valve having an upwardly projecting outlet stem  240  having a central passageway  242  ( FIG. 5A ) coaxial with the can axis  500  and extending to an upper rim  244 .  FIG. 5  shows a closed/extended condition of the valve stem. The valve stem  240  is depressible against spring (not shown) bias into a depressed/opened condition (discussed below) to establish communication from the body of container contents through the nozzle. 
         [0061]    As is discussed further below, the exemplary cap assembly  20  comprises a combination of a main body  30  ( FIG. 6 ), a nozzle or outlet member  32  ( FIG. 8 ), and an insert  34  ( FIG. 11 ).  FIG. 6A  shows a region or section  36  (receptacle) of the cap main body that receives the outlet member and insert.  FIG. 5A  shows the outlet member  32  and insert  34  installed in associated section  36  of the cap main body. As is discussed below, the section  36  serves as a button. 
         [0062]    The section  36  comprises a downwardly-extending collar or sleeve  38  having a central passageway  40  sharing the vertical axis  500  in the initial condition and extending downward to a lower rim  42 . A lower portion of the collar  38  receives an upper portion  245  of the outlet stem  240 . As is discussed further below, a depressing of the section  36  lowers the collar  38  to progressively receive more of the stem  240 . Eventually, the rim  42  contacts a shoulder  250  ( FIG. 5 ) of the outlet stem whereafter further depressing of the section  36  depresses the outlet stem to actuate the valve to open the valve. Closing the valve is via opposite movement driven by the valve spring. 
         [0063]    With the valve open, flow up through the passageway  242  ( FIG. 5A ) enters the passageway  40  (having an axis  501 ) which intersects a compartment  42 . The compartment  42  has an axis  502  (e.g., intersecting the axis  500  at a right angle) receives the insert  34 . The flow passes around/through the insert (discussed below) and then out the nozzle opening or outlet (hereafter simply nozzle)  44 . Exemplary nozzle  44  is a central longitudinal aperture in a transverse web  46  of the outlet member  32 . The exemplary outlet member  32  includes an annular collar-like sidewall  48  extending to a rim  50 . 
         [0064]    Turning to  FIG. 10 , the collar  48  has an axis  504  (coincident with  502  when installed), an inboard or inner diameter (ID) surface  52 , and an outboard or outer diameter (OD) surface  54 . An annular barb  56  extends from the surface  54  for locking the outlet member  32  in place (discuss below). The web  46  has a longitudinally outboard or outer surface  58  and an inboard surface  60 . A central portion of the inboard surface  60  cooperates with the ID surface  52  to receive an adjacent end portion  70  ( FIG. 5A ) of the insert  34 . A radially outboard portion of the surface  60  acts as a stop, engaging an abutting rim surface (rim)  90  of the section  36 .  FIG. 6A  shows the compartment  42  having a junction  92  with the channel  40  and extending to an opening  94  surrounded by the rim  90 . A lateral surface  96  of the compartment includes a forward radially-outwardly extending channel or groove  98  near the opening  94  to receive and capture the aforementioned barb  56 . 
         [0065]    The exemplary compartment  42  comprises an aft wall  100  having an inner surface  102 . An aft or base portion  104  of the compartment is of reduced transverse dimension (diameter) relative to a remaining portion to receive and register an associated aft portion  72  ( FIG. 5A ) of the insert  34 . 
         [0066]      FIG. 11  shows further details of an exemplary insert  34 . The exemplary insert is formed as a modified circular cylinder (having lateral longitudinal axis  506  coincident with  502  when installed) extending between a first end  76  and a second end  77  and having a segmented circular cylindrical outer surface  78  circumferentially segmented by longitudinal grooves or channels  79 . Each of the ends  76  and  77  has a shallow central recess  80 . Recess  80  is open to the adjacent ends of channels  79  to help pass fluid, as is discussed below. Thus, except for the exemplary ends of the exemplary channels  79  and the recesses  80  the exemplary ends  76 ,  77  have flat circular surfaces. 
         [0067]    In the installed condition of  FIG. 5A , one of the insert ends (e.g.,  77 ) abuts the surface  102  of wall  100  and the cylindrical surface portions of the adjacent portion  72  contact the inner surface  105  of the compartment base portion  104 . Forward, along the main portion of the compartment, the surface  78  is spaced apart from the interior lateral surface of the compartment to create a gap  120 . The flat surface of the other end  76  abuts the underside  60  of the flange  46  and the section  70  is similarly received by the ID surface  52 . A flowpath  520  for contents of the container thus extends up through the outlet tube into the passageway  40  to the junction  92  and passes forward through the gap  120  and the channels  79 . With the rim  50  of the outlet member blocking the gap  120 , the flow then proceeds through terminal portions of channels  79  into the recess  80  of the end  76  and then out the nozzle  44 . 
         [0068]    Exemplary cap body, outlet member, and insert materials are molded plastic (e.g., polypropylene). 
         [0069]    The use of the outlet member  32  and insert  34  may have a number of advantages over alternative configurations. If the nozzle were to be molded as part of the cap main body, this would impose molding complications. For example, it would be difficult to precisely mold a very narrow front-to-back passageway intersecting a vertical passageway such as  40 . This would involve fine tooling and has increased risk of flash blocking the junction. Long narrow passageways are also potentially more subject to plugging from contents being dispensed. Passageway  40  and compartment  42  may thus be molded much more easily. 
         [0070]    Other advantages attend engineering and manufacturing. For example, a given cap main body configuration may be used with variations on the outlet member  32  or insert  34  to accommodate different liquids being dispensed. Because the cap main body is the most complicated part, economies of scale in its manufacture may outweigh any additional costs of the other components. Additionally, engineering of new configurations may be eased because one can easily manufacture different prototype versions of the outlet member  32  and/or insert  34  (e.g., by 3-d printing or machining) to test different options. One might very quickly be able to manufacture hundreds of different alternative outlet member and insert combinations for testing whereas similar effort would yield only a few options of a one-piece system. 
         [0071]    Other details of the cap main body may be similar to a number of known or yet-developed configurations of such caps that have large hinged buttons. Turning to  FIG. 6 , the exemplary cap main body comprises a sidewall  140  extending upward from a lower rim  142 . The sidewall has respective generally inner and outer surfaces  144  and  146 . A lower portion of the sidewall may be configured to mate with the can. The exemplary configuration has an internal inwardly-directed shoulder  148  positioned to abut a rim of the crimp  212  of  FIG. 5 . Between the shoulder  148  and the rim  142  the inner surface  144  may have plurality of inwardly-directed projections  150  for capture by an annular channel  230  between the crimp  212  and a main portion of the sidewall  200  to retain the cap against extraction. 
         [0072]    The sidewall  140  extends upward to a segmented upper rim  160  ( FIG. 1 ) having a gap  162  through which a button surface  164  is exposed. The button surface  164  is formed along a top of the section  36  of  FIG. 5A . Section  166  ( FIG. 2 ) extends downward within a sidewall opening  168  formed as a continuation of the upper opening  162  ( FIG. 6 ). At its base, the section  166  is joined by a flexible living hinge  170  to the adjacent portion of the sidewall  140 . Insert depression of the surface  164  causes flexing of the hinge and a downward shifting of the section  36 . The exemplary hinge does not have a single axis but may slightly rack so that the effect is to allow the section  36  to move closer to a straight downward motion than a pure rotation. 
         [0073]    Additionally, as is known in the art, the cap may initially be molded with frangible connections  172  ( FIG. 7 ) to initially retain the cap in the open condition prior to the first dispensing. 
         [0074]      FIG. 16  shows an alternate cap assembly  300  which may use an alternate insert  302  but a similar outlet member to that described above. Rather than having the insert end simply abut a flat aft end of the compartment, the exemplary compartment has a forwardly-extending pin  320  ( FIG. 8 ) which is received in a longitudinal compartment  322  in the insert.  FIGS. 17-21  show further details of the exemplary insert. Laterally and at the forward end, the insert is otherwise similar to the insert described above. However, the aft end of the insert bears the compartment  322  for receiving the pin. Thus, the exemplary second insert may be positioned by the pin in addition to or alternative to being positioned by the lateral surface of the compartment. Thus, although the exemplary insert  34  is bidirectional, (i.e., either of the two ends could be inserted into the compartment), the second insert might be unidirectional. 
         [0075]      FIGS. 22-28A  show a spray cap  400  that may be generally similar to the cap  20 . Generally similar inserts and nozzles are used. The exemplary insert is shown slightly more elongate than the insert of the cap  20  but otherwise the same. Material, manufacture, and use details may also be similar. A shallower well along the front of the cap is associated with a slightly larger opening to allow passage of the spray through the cap sidewall in view of the greater standoff distance between the sidewall and the nozzle. Yet further variations are possible. 
         [0076]      FIG. 29  shows a spray cap  600  which has the same differences relative to the cap  400  that the cap  300  has relative to the cap  20 . 
         [0077]    One or more embodiments of the present invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, ergonomic modifications and modifications for use with particular bottles (cans) (e.g., other valves, including female valves and other can geometries) may be made. Accordingly, other embodiments are within the scope of the following claims.