Abstract:
A nozzle insert, and/or an actuator nozzle structure, for use in dispensing a material to be dispensed from an aerosol can. The nozzle insert or actuator nozzle structure divide the spray of dispensed material into two independent, simultaneously emitted aerosol streams, which may have different attributes and may be emitted in different directions. One stream may be an upwardly directed fogger stream and the other stream may be a forwardly directed, aimable stream. This permits a user to direct, for example, an insecticide at a particular target, while simultaneously more generally fogging an area of interest.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
         [0001]    Not applicable  
         STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH/DEVELOPMENT  
         [0002]    Not applicable  
         BACKGROUND OF THE INVENTION  
         [0003]    The present invention relates to aerosol dispensing devices. More particularly, it relates to nozzle inserts mountable in the outlets of overcap actuators, and, alternatively, nozzle outlet structures formed as a unitary part of an actuator, that provide multiple simultaneous sprays.  
           [0004]    Aerosol cans dispense a variety of ingredients. One or more chemicals or other active ingredients or materials to be dispensed are usually mixed in a solvent and, in any event, typically are mixed with a propellant. Typical propellants are carbon dioxide, a selected hydrocarbon gas, or mixtures of hydrocarbon gases, such as a propane/butane mix. For convenience, materials to be dispensed will sometimes be referred to herein merely as “actives”, regardless of their chemical nature or intended function.  
           [0005]    The active/propellant mixture is stored under pressure in the aerosol can. The mixture is then typically sprayed out of the can by pushing down or sideways on an activator button at the top of the can that controls a release valve mounted in the top end of the can. The sprayed active may exit in an emulsion state, single phase, multiple phase, and/or be partially gaseous. Without limitation, actives can include insect control agents (such as a repellent, insecticide, or growth regulator), fragrances, sanitizers, cleaners, waxes or other surface treatments, and/or deodorizers.  
           [0006]    In simple arrangements, pressure on a valve control stem can be provided by finger pressure on a button attached to the stem and having an internal passage way that leads can contents to an outlet on the side of the button. In response to actuation of the valve, the can contents are permitted to pass through to the outlet via the internal passage way, and thus there is created a spray that exits to the ambient environment.  
           [0007]    In some cases it is desirable to direct or aim a particular active at a known desired target. For example, a user may see a mosquito or fly in the air or resting on the floor and desire to specifically aim an aerosol spray at it. In other cases, it may be desirable to emit that same active in a fog or other less specifically aimed form, for example to fumigate a room or large space to clear it of possible insects. Herein, a “directed” or “aimable” spray will mean a spray pattern such that the sprayed particles or droplets are moving predominantly in a substantially single direction so as to allow a user to effectively point a spray at an insect or other localized target or space. In contrast, “fog” or “fogging” spray is meant to refer to an aerosol delivery that is widely dispersed and more randomly turbulent and broken up than a stream created to be aimed at a specific target such that sprayed particles or droplets are projected in a turbulent, predominantly random pattern.  
           [0008]    Moreover, users will intuitively expect an aerosol can sprayer for aimed delivery at a target to direct a flow that is essentially perpendicular to the axis of the can. In contrast, the optimal angle for fogging will typically be at an upwardly directed angle. Thus, nozzles designed for aimed spraying of insecticides at specific targets are largely non-ideal for fogging and vice versa.  
           [0009]    In some situations it is particularly desirable to have both a fogging and a targeting capability. For example, if one wanted to spray a picnic shelter one might prefer to be able to simultaneously fog the shelter and also target specific insects that might be visible at the time of spraying. One could design specific purpose nozzle inserts to be easily removable from a sprayer outlet, and provide the user with the option to replace a nozzle with a different type of nozzle when a different function is desired. However, this would require the user to store at least one replacement nozzle between uses and to undertake assembly steps that could expose the user to the active when removing a first nozzle.  
           [0010]    Analogous issues exist with respect to fragrancers and disinfectants. Spray nozzles configurations that are particularly suitable for treating an entire room are not optimal for targeting a particular location (e.g. a toilet bowl). As such, a need exists for improvements in the spraying capability of a wide variety of aerosol dispensers.  
         BRIEF SUMMARY OF THE INVENTION  
         [0011]    The invention provides a nozzle insert for an aerosol dispenser for dispensing pressurized material from a can or other container. Aerosol dispensers include actuators that deliver can contents from a valve mounted in the can, via a through conduit or passageway in the actuator, to an actuator exit, where the material to be dispensed is released to the air. The insert&#39;s inlet or upstream end is suitable to be mounted in the actuator exit, so that the dispensed material passes through the conduit and out the outlet or downstream end of the insert.  
           [0012]    The insert will preferably have an elongated body with an inlet end suitable to be mounted at the exit of an actuator for the aerosol dispenser, an outlet end, and a conduit there between. The outlet end has two separate outlets in communication with the conduit. The two outlets are so configured as to impart differing flow characteristics to the spray of material dispensed therefrom. “Flow characteristics” is defined to include but not be limited to such characteristics as angle of flow, direction or coherence of the dispensed spray, and the like. When material to be dispensed from the aerosol dispenser is delivered to the conduit, the nozzle insert will simultaneously project a first spray from one of the separate outlets and a second spray that is independent from the first at the time of exit from the other of the separate outlets.  
           [0013]    In other preferred forms the two outlets have different cross sectional profiles or other spray modifying features. For example, one can be an elongated slot that extends both radially and axially with respect to the longitudinal axis of the nozzle insert, and the other can be a generally circular outlet hole that extends axially with respect to the longitudinal axis of the nozzle insert. Alternatively, the outlets can both be such elongated slots, where the slots are at least partially directed in radial opposition to each other.  
           [0014]    In still other preferred forms the insert can be made so as to be suitable to be inserted and retained in a friction fit manner within the exit of the actuator. For example, the insert can be conical, with its diameter increasing from the inlet to the outlet end. Alternatively, the insert can be generally cylindrical, with a first upstream section of a first diameter, a collar section downstream of the first upstream section and having a diameter larger than the first diameter, and a cap section downstream of the collar having a diameter larger than the diameter of the collar. The two outlets can then be located in the cap section. When this shape of insert is used, the actuator exit can have corresponding stepping in diameters. Friction fitting inserts into actuator exits is well known in the aerosol art, and any conventional shapes and materials to accomplish friction fitting are within the breadth and scope of the invention.  
           [0015]    In another aspect the invention provides an actuator for use with a can containing pressurized material to be dispensed, typically as an aerosol. The actuator includes a receiver to engage the valve stem of an aerosol can, the receiver having a recess for receiving the valve stem and a through conduit for passing material to be dispensed from the can to an actuator exit. There is also a nozzle structure positioned at the actuator exit (which nozzle structure may, if desired, be integrally formed with the actuator or may be a separately formed insert positioned within the actuator exit). The nozzle structure has two separate exits in communication with the actuator&#39;s through conduit. If the material to be dispensed is delivered to the through conduit, the nozzle structure will simultaneously project a first spray from one of the separate exits and a second spray from the other of the separate exits.  
           [0016]    The actuator can be a part of an overcap. Such an overcap can be mounted in any conventional manner on the can. The actuator is linked, preferably via a living hinge, to an outer skirt or other part of the cap. The actuator includes a receiver for engaging the can&#39;s valve stem. Preferably, the receiver is unitarily formed with the remaining parts of the actuator, with a through passage leading to an actuator exit equipped with a nozzle having two outlets having the outlet features described above.  
           [0017]    Alternatively, the receiver can be a part of a separate structure mounted on the valve stem and simply be so engaged by the remainder of the actuator as to allow movement of the actuator to move the separate structure. The separate structure mounted on the valve stem can be, for example, an aerosol push button, as generally described above, positioned on the valve stem, with the exit of the push button configured with two outlets having the outlet features described above.  
           [0018]    In yet another form the invention provides a method of delivering a sprayable active from an aerosol container to the ambient environment. One provides an aerosol container containing sprayable material to be dispensed, the container having an exit valve. One then actuates the exit valve to deliver an exit stream of the material to be dispensed from the container, and then divides the stream into two independent streams at an outlet nozzle. At this point, the two streams are emitted from the nozzle into the ambient environment in a form in which they are independent at the time of exiting the nozzle.  
           [0019]    In a preferred form of the method of the invention one such stream is emitted into the ambient environment in the form of a fog, and one such stream is emitted into the ambient environment as a directed spray. If desired the two independent streams both can be emitted into the ambient environment as fogs, in at least partial radial opposition to one another. Alternatively, one such independent stream can be emitted in an essentially axial direction relative to the longitudinal axis of the nozzle as a more directed and aimable stream, and the other independent stream can be emitted as a fog at least partially radially directed with respect to said axis.  
           [0020]    The foregoing and other advantages of the invention will appear from the following description. In the description reference is made to the accompanying drawings which form a part thereof, and in which there is shown by way of illustration preferred embodiments of the invention. Such embodiments do not represent the full scope of the invention, and reference should therefore be made to the claims herein for interpreting the scope of the invention. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0021]    [0021]FIG. 1 is a side elevation view, partially in section, of an aerosol can having a nozzle insert and actuator constructed in accordance with the present invention;  
         [0022]    [0022]FIG. 2 is an enlarged perspective view of a first nozzle insert;  
         [0023]    [0023]FIG. 3 is a further enlarged sectional view of a portion of the FIG. 2 insert, taken along line  3 - 3  of FIG. 2;  
         [0024]    [0024]FIG. 4 is an end elevational view of the FIG. 2 insert;  
         [0025]    [0025]FIG. 5 is a sectional view (analogous to that of FIG. 3, but of the entire section) through a second embodiment;  
         [0026]    [0026]FIG. 6 is a perspective view (similar to the FIG. 2 perspective view) of a third embodiment; and  
         [0027]    [0027]FIG. 7 is a view similar to the FIG. 3 view, but of the third embodiment and taken along line  7 - 7  of FIG. 6. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0028]    Representative conventional aerosol containers and actuators, and valving used therewith, are disclosed in U.S. Pat. Nos. 5,068,099 and 6,006,957. The disclosures of these patents are hereby incorporated by reference as if fully set forth herein. It should be appreciated from the descriptions below that these structures provide examples of environments in which the nozzle inserts, and actuator nozzle outlet structures, of the present invention can be applied.  
         [0029]    A particular embodiment of such an aerosol container and actuator assembly, as constructed in accordance with the present invention, appears in FIG. 1. There an aerosol dispenser  10  includes a container  12 , such as a conventional aerosol metal (e.g. aluminum; steel) can, that defines an internal chamber  15  capable of housing under pressure material to be dispensed. Container  12  includes a cylindrical wall  14  that is closed at its upper margin by a dome  16 . The upper margin of the can wall  14  is joined to the dome via a can chime  18 . An upwardly open valve cup  20  is located at the center of the dome  16  and is crimped or otherwise joined to the dome to form a valve cup rim  22  in a conventional manner.  
         [0030]    The aerosol dispenser  10  includes a conventional aerosol valve  41  (see e.g. U.S. Pat. No. 5,068,099 for another such valve) crimped to the valve cup  20  at the valve cup rim  22  in a conventional manner. The aerosol valve  41  has a valve stem  34  that is hollow and extends axially up from the valve cup  20 .  
         [0031]    A variety of other conventional aerosol valves are well known to the art. These valves are activated by moving their valve stems downwardly and/or sidewardly. Upon such activation, pressurized material to be dispensed that is contained within the container is delivered from the valve stem.  
         [0032]    In the present invention an actuator  48  is mounted in cooperative relation to the valve stem  34 . The actuator  48  may be mounted exclusively on the valve stem  34 , in the manner of a common aerosol button, or it may be part of a overcap or other structure mounted on the chime  18  or valve cup rim  22 . Such alternative modes of mounting actuators to aerosol cans are well known in the art, and the instant invention is not limited to any particular mounting strategy.  
         [0033]    The actuator  48  has an actuator through passage  50  that extends from an actuator inlet end  52  to an actuator outlet end  58 . The actuator inlet end  52  has a receiver  53  capable of receiving the valve stem  34  in liquid-tight relation. Particularly in accordance with the present invention, a nozzle insert  60  is mounted in the actuator outlet end  58 . The nozzle insert  60  is in the form of an elongated, generally tubular body having an inlet end  61 , an outlet end  63 , and a conduit  65  communicating there between (see especially FIG. 3). The nozzle insert  60  can be made by conventional injection molding techniques and is preferably made of a resilient plastic such as polypropylene or polyethylene. When the aerosol valve  41  is activated, material to be dispensed is released to travel through the actuator via through actuator through passage  50  and be discharged to the atmosphere through the nozzle insert  60 .  
         [0034]    Referring next to FIGS. 2-4, the nozzle insert  60  can be structured so as to split the single flow of material delivered through the actuator through actuator through passage  50  into two independent output streams to be separately emitted into the ambient environment (e.g. as a directed spray in one stream, and as a fog in the other stream). In the FIG. 2 preferred embodiment, the nozzle insert  60  includes an elongated cylindrical base section  62  disposed at the inlet end  61  of insert  60 . The diameter of base section  62  is stepped outwardly to form a collar section  64  that is disposed downstream the base section. Collar section  64  is preferably, but not necessarily, integral with the base section  62 . A cap section  66  having a greater diameter than the collar section is disposed at the distal end  63  of the insert  60 . Cap section  66  is preferably, but not necessarily, integral with the base and collar sections. These sections are each preferably annular and concentric about a longitudinal axis b-b of insert  60 .  
         [0035]    Insert  60  is preferably installed into actuator through passage  50  during manufacturing by inserting base section  62  into actuator through passage  50 . The outer diameter of insert  60  is sized to be retained by friction within actuator through passage  50 . Also, base section  62  has an outer diameter that is sufficiently less than the inner diameter of actuator through passage  50  so as to enable the inlet end  61  of insert to be easily initially guided into the actuator through passage  50 .  
         [0036]    The collar section  64  has an outer diameter that is almost equal to the inner diameter of actuator through passage  50  such that as the insert  60  is further slid inwardly the collar section  64  interferes with the actuator through passage  50 . Alternatively, the inner diameter of actuator through passage  50  could be tapered or stepped to further enhance the engagement with collar section  64  as the insert  60  is further inserted. The cap section  66  has an outer diameter sufficiently greater than the inner diameter of actuator through passage  50  such that the cap section  66  abuts the outer edge of actuator through passage  50  to provide a stop when the insert  60  is fully inserted in the actuator through passage  50 .  
         [0037]    The configuration of insert  60 , and in particular the fit between collar section  64  and actuator through passage  50 , render the dispenser suitable for mass production at a relatively low cost. Furthermore, insert  60  is compatible with conventional actuator over caps, thereby further reducing cost. It should be appreciated that while the dispenser  10  is configured such that the insert  60  extends radially with respect to the direction of axial extension of the container  12 , the present insert  60  is also compatible with dispensers whose outlet extends in the same direction as the axis of container  12 .  
         [0038]    Referring now to FIG. 2 in particular, the cap section  66  includes a stepped outer radial wall  68  having an axially outer face  69 . Face  69  presents a beveled surface  70  at the intersection between the axially outer edge of wall  68  and radially outer edge of face  69  such that surface  70  faces both radially and axially outwardly from insert  60 . A cylindrical aperture  74  extends axially through surface  69  and is in fluid communication with actuator through passage  50  to form a first outlet for aerosol content when the valve  34  is actuated. Outlet  74  does not need to be centrally disposed on surface  69 , and therefore can be in a position where it is not aligned with axis b-b.  
         [0039]    Referring next to FIG. 4, outlet  74  is sized and shaped to emit aerosol content as an aimable spray, preferably to focus delivery of sprayed material on an insect, toilet bowl, corner of a room, or similarly discrete target at a convenient distance. Outlet  74  is so shaped as to emit a roughly conical spray pattern suitable for aiming at an insect or other target. It should be appreciated, however, that any aperture having a size and shape suitable to emit an aimable, directed spray is contemplated by the present invention.  
         [0040]    Elongated slot  72  extends through surface  70  to form a second outlet for material to be dispensed delivered via actuator through passage  50  and insert  60 . Outlet slot  72  may be essentially trapezoidal in cross section and is designed to emit a fog during operation. Slot  72  is orientated such that the axis of extension a-a of slot  72  in FIG. 2 is co-planar with the axis of extension b-b of insert  60 .  
         [0041]    To particularly facilitate fogging we prefer that at least some of the side walls of the slot  72  be rounded outwardly at their outer end. This may be done on all four such walls, or preferably at least on walls  77 ,  78  and  79  (see especially FIG. 2).  
         [0042]    Referring next to the FIG. 5 variant  60   a , outlet  72   a  is also an elongated slot. The cross-sectional area of outlet  72   a , at it&#39;s upstream end  71   a , is narrower than its cross-sectional area at its downstream end  73   a  to provide a widening profile with respect to the direction of aerosol flow. This configuration creates turbulence in the aerosol spray passing through outlet  72   a  which, in turn, enhances a dispersed spray pattern that is suitable for creating a fogging spray rather than a directed spray. The rounding creates a sideways turbulence into the aerosol flow to provide an even more dispersed, yet fan-shaped fogging pattern.  
         [0043]    The radially inner surface  75   a  of outlet  72   a  extends essentially parallel to axis b-b of insert  60  (but for some slight rounding), while the radially outer surface  77   a  of outlet  72   a  is tilted away from axis b-b to further accomplish the widening effect described above. It should be appreciated, however, that any aperture having a size and shape suitable to emit a fog is contemplated by the present invention.  
         [0044]    Accordingly, during operation, a user may aim the outlet  74   a  to direct a spray of material to be dispensed towards a predetermined target, while positioning outlet  72   a  towards an area of a room or the like that is to receive the material to be dispensed as a fog. When the actuator  48  is depressed and the valve  34  is thereby opened, the material to be dispensed delivered via actuator through passage  50  is split by the insert and travels through both outlets. Consequently, a first aerosol output is emitted axially outwardly (radially outwardly with respect to container  12  and user) via outlet  74   a  as a directed spray.  
         [0045]    A second aerosol output is also emitted as a fog that flows both axially and radially outwardly with respect to the insert  60   a  via outlet  72   a . Advantageously, both the directed spray and fog are simultaneously emitted away from the user when the device is operated properly.  
         [0046]    It should be appreciated that the material to be dispensed need not only be insecticides, although insecticides are a preferred material. Other known types of materials could be used as well when there is a desire to provide multiple distinct streams, particularly streams having different characteristics.  
         [0047]    [0047]FIGS. 6 and 7 illustrate a third embodiment where there is an insert  160 . It has a base section  162  and collar section  164  having the same size and shape as insert  60 . However, the cap section  166  is somewhat different. Cap section  166  has a stepped outer radial wall  168  that is integrally connected to conical surface  170  having a pair of opposing elongated slots  172  and  174  extending there through to provide a pair of outlets for insert  160 . If desired, slots  172  and  174  can be modified from the configurations shown to each have the same size and shape as slot  72  of insert  60 , so that each slot  172 ,  174  emit the material to be dispensed as a fog. This embodiment is of special use for room or other area fogging, the division of the material to be dispensed into two streams, at least initially, providing an aesthetic distinction from single stream loggers, even if they use a unified fan spray pattern.  
         [0048]    Axes of extension of slots  172  and  174  (c-c and d-d), respectively preferably are co-planar with each other and with the axis of extension e-e of insert  160 , and intersect a given line extending radially outwardly from the axis of extension e-e. Axes c-c and d-d of slots  172  and  174  are radially offset from each other by 180° with respect to surface  170  and intersect to form a 90° angle. The radial components of the independent fog streams are in opposition to each other to also enable the dispenser  10  to fog a larger volume in a lesser amount of time compared to conventional aerosol fogging devices.  
         [0049]    The nozzle slot and other exit structures described herein as being parts of inserts formed separately and positioned in actuator through passages could, alternatively, be formed as integral parts of the actuators, to affect spray patterns in the same manner as described for the inserts. However, separately formed inserts are preferred as being much more convenient to manufacture. All parts discussed may be manufactured by standard injection molding processes.  
         [0050]    The above description has been that of preferred embodiments of the present invention. It will occur to those that practice the art, however, that still other modifications may be made without departing from the spirit and scope of the invention.  
       INDUSTRIAL APPLICABILITY  
       [0051]    The present invention provides nozzle inserts and actuators useful in converting aerosol spray streams into multiple stream configurations, and methods for using them.