Patent Publication Number: US-6981616-B2

Title: Spray delivery system and method for aerosol products

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
   This application is a continuation of application Ser. No. 10/036,544, filed Jan. 7, 2002, now U.S. Pat. No. 6,595,393. 

   FIELD OF THE INVENTION 
   The present invention is directed to a spray delivery system and method of use for aerosol products. The invention is more particularly directed to a novel actuator, device and method that provides an improved and specific pattern of spray for dispensing aerosol products. 
   The invention further relates to a spray delivery system and method that contains selectively engageable automatic mechanisms for preventing accidental or unintended spraying of the aerosol product. The novel features of the present invention are particularly useful for aerosols that utilize hazardous chemicals, such as insecticides or non-lethal incapacitating agents. 
   BACKGROUND OF THE INVENTION 
   Aerosol spray containers have been well known in the art for decades. A typical aerosol container utilizes an assembly to actuate and release the pressurized materials in the canister and direct them toward an intended target. Such prior art containers have often utilized a spray through overcap consisting of a one piece housing and actuator. These containers are usually operated by directly pressing the actuator down to engage a valve stem and thereby release the pressurized material from the canister. Although devices of this type have at times been adequate to permit material to be sprayed from a pressurized canister, they have exhibited a number of drawbacks. To begin with, the spray pattern associated with such containers was generally imprecise or inconsistent. Such devices frequently exhibited a broad cone spray pattern with excessive turbulence and eddy currents. Such spray patterns have proven to be particularly troublesome in aerosol products containing hazardous or potentially irritating chemicals, particularly when used in windy or confined environments. Use of these devices frequently resulted in the spraying or contamination of unintended targets including the user. 
   In order to attempt to improve the spray characteristics of aerosols, a nozzle insert has sometimes added into the actuator. While this generally improved the spray characteristics, it still left other issues. For example, although such inserts were capable of focusing the output in a narrow stream, they did not perform well to precisely produce desired spray patterns that combined the characteristics of cone and stream type patterns. The resultant spray patterns were often so narrow that they required multiple sprays or excessive movement to cover an intended target. Likewise the force of the resultant streams was at times sufficient to cause injury upon contact with delicate areas such as the eyes. Additionally, most actuator/insert constructions did not permit one to select or modify a spray pattern of a given actuator. 
   Most of the available overcaps for aerosol products operate to dispense products in the same manner. The overcaps use an actuator to engage an aerosol valve stem to pass the pressurized product into the actuator for dispensing. A portion of the bottom of the overcap is usually attached to the outside diameter of the aerosol valve and container to render it non-removable. The pressurized product is typically dispensed by pressing the actuator into engagement with the aerosol valve stem. Typically, a spring biasing force must be overcome by the actuator in order to engage and depress the valve stem and dispense the product. Since it is desired to allow the user to dispense an aerosol product without necessitating the use of excessive force, the biasing force that must be overcome by pressing the actuator, has generally been relatively minimal. While this condition was necessary for intended operation of the aerosol container, it likewise made the undesired effect of potential unintended actuation and dispensing just as easy. This was a particular problem for any aerosols that contain active ingredients that could cause some degree of harm or discomfort to the user or surroundings. As a result, significant efforts have been directed towards making accidental dispensing of aerosol containers more difficult to occur. 
   A typical way of attempting to prevent the accidental, or otherwise unintended, dispensing of aerosol products has been to add a locking mechanism to the overcap. Most such mechanisms provide an additional piece on the aerosol overcap that requires the user to move the piece into a disengaged position in order to dispense the aerosol. Many of these devices, however, are either inconveniently located, difficult to operate with one hand or are themselves, readily unintentionally moved into engagement. An example of such a locking mechanism is a sliding lever on the side of the housing. In use, however, such a locking mechanism is often covered by the user&#39;s palm or fingers when dispensing the product from the aerosol container. Such locking mechanisms frequently exhibit an additional drawback, in that once the actuator is in an unlocked position, it remains unlocked and makes the system available for unintentional operation. The mechanism does not lock automatically after dispensing, but instead requires the user to perform an additional intentional locking action to return the lever or the like to a position where it prohibits operation of the actuator. 
   Another type of known locking mechanism utilizes an actuator that rotates into engagement with a supporting portion of the housing to prevent the user from pressing the actuator except in certain pre-designated positions. Like the mechanism described above, however, once the actuator is rotated into engagement, it remains unlocked until the user performs an additional intentional locking action as such accidental dispensing is only partly prohibited and the user again must remember to relock the system to prohibit such circumstances after use. A further problem with these systems and the previously described lever locking mechanisms, is that there is still a significant chance that the device can reach a disengaged or unlocked position due to environmental or unintentional acts, rather than the intentional act of the user thereby freely permitting accidental dispensing of product from the aerosol. 
   Some locking mechanisms that have utilized a spring-loaded system to return the device to a locked condition after dispensing have also exhibited shortcomings. Such devices have often required two hands for operation. Those devices that permit some type of single-handed operation, usually required the user to see the locking device to operate them, thus rendering them useless, for example, in the case of darkness or engaging a potentially hostile person with a non-lethal incapacitating spray. 
   Another known type of overcap uses a trigger to actuate the aerosol valve to dispense the aerosol product. The trigger usually is a separate piece or more often a number of pieces that are added into the housing of the overcap. The trigger is generally contained in the housing by undercuts or the like. Because the trigger is added to the actuator system, it can be dislodged from the housing when dropped or struck making operation of the dispensing system impossible. Other known designs have used additional parts in the assembly to lock the trigger when not in use, thereby introducing additional complexity. Such designs have still not provided the combination of a self locking action once the actuator is released into a closed position, along with the advantages of an improved spray pattern and ease of operation with one hand. In addition, many of these mechanisms have had difficulty handling submergence in water, shock and extreme operating temperatures while providing quiet and consistent use. 
   In view of the above, it is apparent that there exists a need in the art for an improved aerosol spray delivery and dispensing method and apparatus that overcomes the problems and difficulties described. It is the purpose of this invention to fulfill the above described needs in the art, as well as other needs apparent to the skilled artisan from the following detailed description of this invention. 
   SUMMARY OF THE INVENTION 
   The spray delivery system of the present invention permits the dispensing of aerosol products in an improved, precise and specific pattern of spray. The spray of this delivery system, likewise selectively provides hybrid type spray patterns in a device and method that contains (i.) A first locking feature that prevents accidental or unintended dispensing of the product during shipment and prior to initial use that can be visually detected and must be removed in order to make use of the device; (ii.) A second locking mechanism that requires the user to depress a locking spring and the actuator in order to dispense product and automatically returns the device to a locking position after dispensing; (iii.) An override system force that the second locking mechanism that provides user with a means to disarm the second locking means for unencumbered use of the system; and (iv.) Offers a precise pre-selected spray pattern emanating from the actuator. These advantages are all provided in an easy to assemble spray delivery system that is compact and can be easily carried in the pocket of a user, can be operated with one hand, does not require user to be able to see the system to operate and has further safeguards to minimize the possibility of any of the material dispensed from the aerosol container through the system of coming into contact with the user. 
   This invention fulfills the above described needs in the art, and provides these and other advantages in a spray delivery system and method for aerosol containers, the system comprising: 
   a shell having a first wall with first and second apertures therein, a second wall, and a housing extending outwardly from said shell and surrounding said first aperture; 
   a lock having a first end with a depressible button and a second end with a spring, said button extending through said second aperture of said shell, said remainder of said lock being within said housing and movable from a first position wherein said button extends through said second aperture and outwardly from said shell an axial distance less than said housing, to a second position wherein said button is depressed and a substantial portion thereof is contained within said shell and said spring is compressed against said second wall of said shell and exerts a biasing force on said lock to automatically return it to said first position when said button is released; and 
   an actuator having a top, a nozzle and at least one projection extending downwardly from said top and slideably engaging a portion of said lock, said nozzle being contained and vertically movable within said housing, said projection further contacting said portion of said lock so that it is thereby prohibited from vertical movement when said lock is in said first position and being capable of vertical movements when said lock is in said second position. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention has various configurations, constructions in operation will be best further described in the following detailed description, taken in conjunction with the accompanying drawings in which: 
       FIG. 1  is an exploded view of the main parts of one embodiment of the present invention. 
       FIG. 2  is a rear plan view of one embodiment of the present invention. 
       FIG. 3  is a top plan view of an overcap construction of the present invention. 
       FIG. 4  is a bottom plan view of an actuator construction in accordance with an embodiment of the present invention. 
       FIG. 5A  is a top plan view of a spring lock of one embodiment of the present invention. 
       FIG. 5B  is a front view of the spring lock mechanism of the present invention illustrated in  FIG. 5A . 
       FIG. 6  is a cross-sectional view of one embodiment of a spray nozzle insert, taken along section  6 — 6  of  FIG. 1   
       FIG. 7A  is a top view of one embodiment of the spring lock of the present invention inserted into an overcap in an unactuated condition. 
       FIG. 7B  is a top view of one embodiment of the embodiment of the spring lock illustrated in  FIG. 7A  in an actuated position. 
       FIG. 8A  is a cross-sectional of one embodiment of the embodiment of the spray delivery system illustrated in  FIG. 2  in a condition prior to any use of the device. 
       FIG. 8B  is a cross-sectional view of an embodiment of the invention taken along section  8 — 8  of  FIG. 2  with the actuator partially depressed. 
       FIG. 8C  is a cross-sectional view of an embodiment of the invention taken along section  8 — 8  of  FIG. 2  with the actuator fully depressed. 
       FIG. 8D  is a cross-sectional view of an embodiment of the invention taken along section  8 — 8  of  FIG. 2  with the spring lock in a disable mode. 
       FIG. 9A  is a side view of one embodiment of an actuator and a spring lock of the present invention in a locked or up position. 
       FIG. 9B  is a side view of the actuator and spring lock illustrated in  FIG. 9A  in an enabled or down position. 
       FIG. 10  is a side plan view of one embodiment of the present invention having a content level indicator. 
   

   DETAILED DESCRIPTION OF CERTAIN PREFERRED EMBODIMENTS 
   This invention will now be described with reference to the drawing figures in which like reference numbers indicate like parts throughout the several views. It will be appreciated by those of skill in the art that the spray delivery system and device and method may be used in conjunction with virtually any type of aerosol product or container. However, the present invention is described below in an exemplary non-limiting preferred embodiment, in which it is used in conjunction with a non-lethal incapacitating aerosol, containing oleoresin capsicum. Such materials and novel solvents for use with the present invention are shown for example in the co-pending application, U.S. application Ser. No. 10/036,546 entitled “Non-lethal Temporary Incapacitation Formulation and Novel Solvent System” filed concurrently herewith, the disclosure of which is hereby incorporated by reference. 
   The present invention is shown in the several embodiments of  FIGS. 1–10 , for use in connection with conventional aerosol containers having depressible valve stems. The conventional aerosol container indicated by the numeral  1 , is provided with a top  3  with a centrally located valve stem  5 , which is spring biased and which is normally maintained in its elevated or raised position to close the discharge outlet through the valve stem. When the valve stem  5  is depressed, or pushed inwardly relative to the container  1  and parallel to the axis of the container, then the aerosol material in the container is discharged through the valve stem, all of which is conventional. 
   The spray delivery system and device of the present invention, is referred to generally by the numeral  10 . The device  10 , is formed of several main components, namely, an overcap generally designated by the numeral  12 , a spring lock generally designated by the numeral  14 , an actuator generally designated by the numeral  16  and an optional nozzle insert generally indicated by the numeral  18 . All of these components are constructed of a durable material designed to handle complete submergence in water, shock, extreme operating temperatures, and resistance to chemicals while providing reliable consistent and quiet movement and performance. A variety of plastic materials have been found to be preferable in achieving this performance. Particularly preferred plastic materials meeting these criteria have been found to be Amoco Polymers ACCUTUF 3541 for the overcap, Amoco Polyproylene 3432 for the actuator and Ticona Celcon M-90 for the insert the spring lock. In order to achieve the desired performance characteristics of the device, it will be appreciated that all of the main components are substantially housed within the overcap  12 . 
   The overcap  12 , is provided with a hollow body or shell generally indicated at  20 , with the bottom or skirt portion  22  thereof having an annular shape, with an inwardly projecting annular rib  24 , that is adapted to seat on the annular rim  7  of the aerosol container to retain the device thereon in known manner. The shell body  20  of the cap  12  has a floor  26  with an aperture  28  therethrough that permits the valve stem  5  to extend into the interior of the shell  20 , and further allows the top  3  of the aerosol container  1  to seat properly on the device as illustrated, for example, in  FIGS. 8A–D . The device  10  is designed to occupy essentially the same circumferential area as the aerosol container  1  that it is mounted on for ease of operation and storage. 
   The shell body  20  has a front wall  30  that extends upwardly from the floor  26 . The front wall  30  has a central portion  32  and integral angled peripheral portions  34  and  36  respectively. Portions  34  and  36  are angled preferably between 20 to 40 degrees to assist a user in initially locating and thereafter retaining their thumb on the actuator without requiring the user to look at the device. The interior portion of each of the respective angled portions,  34  and  36  respectively, can each be provided with a ridge  38  and  40  respectively. These ridges assist in engaging and maintaining the spring lock  14  in the overcap  12  in proper alignment as will be described to follow in detail. The front wall  30  also has a vertically spaced aperture  42  extending upwardly from the skirt portion  22  to accommodate the button  44  of the spring lock  14 . The front wall  30  has an opening  46  located above the aperture  42 . The opening  46  leads to a nozzle housing  48  that extends axially from the exterior face  50  of the front wall  30 . The nozzle housing  48  accomodates and shrouds the nozzle  52  of the actuator  16  which is permitted vertical movement therein, as will be later described. The housing  48  extends axially beyond the end of the nozzle  52  in order to prevent any damage or harm to the nozzle as a result of impact or the like. 
   The housing  48  preferably has a flat lower surface  54  and preferably extends for a length greater than the thickness of an average human index finger when the button for  44  of the spring lock  14  is fully depressed. The flat surface  54  and the extended length of the housing  48  assist in both enabling a user to position his finger on the button  44  by touch alone without having to see the device  10 . Furthermore, the flat surface  50  combined with a preferred slight angle on that surface, encourage free movement of the user&#39;s finger in a sliding relation along the bottom surface  50  of the nozzle housing to operate the button  44 . 
   The shell body  20  has oppositely disposed side walls  56  and  58  respectively that extend upwardly from the floor  26  and are substantially the same height as and are integral with the angled peripheral portions  34  and  36  of the front wall  30 . Side walls  56 ,  58 , are preferably angled slightly inwardly from the back of the overcap  12  towards the nozzle housing  48  and are spaced from each other sufficient distance to accommodate the thumb of a user, whether wearing a glove or not, and urge the thumb into the proper position to depress the actuator  16  as will be described to follow. The interior of each of the side walls,  56  and  58  respectively, each contains a guide  60  preferably molded into the interior surface thereof. These guides assist in keeping the spring lock  14  aligned properly within the overcap  12 . 
   The side walls  56 ,  58  are joined at one end by a rear wall  62 . The rear wall  62  extends upwardly from the floor  26  to a height less than the side walls  56  and  58  and front wall  30 . With particular reference to  FIGS. 1 ,  2 ,  3 ,  7 A and  7 B, the rear wall  62  contains a locking aperture  64  and a retaining slot  66 . The locking aperture  64  contains two projections  68  and  70  respectively. Projections  68 ,  70  are used to contact and temporarily retain the spring lock hook  72  of spring lock  14  when it is desired to maintain the device  10  in an always armed or override condition where the button  44  of the spring lock  14  need not be depressed prior to dispensing material from the aerosol container  1 . As particularly illustrated in  FIGS. 1 ,  2  and  3 , the aperture  64  and projection  68  and  70  respectively, are preferably recessed within the rear wall  62  so that the hook  72  is unlikely to be accidentally engaged or disengaged from the projections  68  and  70  through inadvertent contact. The retaining slot  66  surrounds the outwardly protruding lug  74  of the actuator  16  and permits a limited degree of vertical movement of the lug when the actuator is depressed. The top portion  76  of the aperture  64  serves to assist in retaining the actuator within the overcap  12  by prohibiting the actuator to be raised any further vertically than the point at which the lug  74  contacts the top portion  76 . The lug  74  serves to limit downward travel of the actuator  16  in a similar manner. 
   Referring now to  FIGS. 1 ,  2 ,  5 A,  5 B,  7 A,  7 B,  8 A–D and  9 A– 9 B the spring lock  14  of the present invention is illustrated. Spring lock  14  has a main body  78  with a depressible button  44  located at one end. When the spring lock  14  is assembled in the overcap  12  the button  44  extends through the aperture  42  in the front wall  30  of the overcap  12 . The end  45  of the button  44  is preferably contoured to readily accommodate a user&#39;s index finger. The main body  78  also has upwardly extending posts  80  and  82  that are integral with the button  44  and are contained within and contact the angled peripheral portions  34  and  36  respectively of the front wall  30  of the overcap  12 . In this manner posts  80 ,  82  serve to limit the axial distance that the button  44  can project outside of the overcap  12  and further serve along with the ridges  38 ,  40  of the overcap  12  to maintain the spring lock in proper alignment within the overcap. The body  78  of the lock  14  further features a forward aperture  84  and a central valve stem aperture  86 . The valve stem aperture  86  allows the valve stem  5  of the container and the lower portion  88  of the actuator  16  to pass therethrough without restricting the vertical movement thereof. The forward aperture  84  permits any excess material that has been dispensed from the nozzle  52  that falls within the nozzle housing  48  or travels along the notch  136  to drop therethrough and be deposited through the aperture  28  onto the top  3  of the container  1 . This construction prevents the user from contacting any such material. 
   The spring lock  14  is retained vertically in position within the overcap  12  by downwardly extending hooks  90  and  92  respectively. Hooks  90 ,  92  bear against the bottom of the floor  26  at opposing edges of the aperture  28  and bias the spring lock  14  against the top surface of the floor  26  and permit axial movement of the spring lock along a portion of the aperture  28 . The hooks  90  and  92  slideably contact the floor  26  when the spring lock  14  is properly assembled in the overcap. The spring lock  14  also has vertical ribs  94  and  96  respectively. The top portion  98  of each of the ribs  94 ,  96  is preferably angled from the back to the front of the spring and has a flat surface. 
   As particularly illustrated in  FIGS. 8A–D and 9A  and  9 B the top portion  98  of the ribs  94 ,  96  serves to contact the projections  100  and  102  respectively of the actuator to support and prevent vertical movement of the actuator when the device  10  and the spring lock  14  is in a rest or unactuated position. As particularly illustrated in  FIGS. 9A and 9B , ribs  94 ,  96  thereby prevent accidental or unintended actuation of the device  10  by prohibiting downward movement of the actuator  16 . The button  44  of the lock  14  must be angled sufficiently depressed to allow the projections  100  and  102  to engage a lower part of the angled top  98  of the ribs and/or clear the ribs entirely to allow sufficient downward movement of the actuator to depress the valve stem  5  and dispense material from the container  1 . The angled top  98  of the ribs  94  and  96  serves to encourage free travel of the projections  100  and  102  thereon as the button  44  is depressed and also permits and encourages proper seating of the actuator  16  thereon. It has been found that a variety of different angles are acceptable for the top  98  of the ribs  94  and  96  but that an angle of 10 to 20 degrees, and most particularly about 13 degrees, has been shown to have particularly desirable results in operation. 
   Extending from the rear of the main body  78  of the spring lock  14  are opposed leaf springs  104  and  106  respectively and a spring lock hook  72  when the spring lock  14  is appropriately assembled within the overcap  12  the leaf springs  104  and  106  respectively contact the rear wall  62  of the overcap  12  between the locking aperture  64  and the retaining hole  66 . In a rest position when no force is applied to the button  44  the leaf springs  104  and  106  serve to bias the button into a fully extended position whereby the posts  80  and  82  of the spring lock  14  are in contact with the interior surface  31  of the front wall  30  of the overcap  12  and the spring lock hook is contained within the shell body  20 . The posts  80  and  82  each have angled top surfaces that contact the bottom of the supports  71  and  73  respectively of the actuator  16  when the button  44  is not depressed. In this position the posts  80  and  82  contact and prevent the actuator  16  from being depressed. When the button  44  is sufficiently depressed, the posts  80  and  82  move out of contact with the supports  71 ,  73  thereby permitting downward motion of the actuator to dispense aerosol material. The angle of the top posts  80 ,  82  is preferably the same as the top  98  of the ribs  94 ,  96 . 
   As particularly illustrated in  FIGS. 2 ,  7 B and  8 B–D when the user desires to dispense material from the container one must exert a sufficient axial force against the button  44  to overcome the biasing force of the springs  104  and  106 . In this condition, the spring lock hook  72  extends outside of the rear wall  62  axially beyond the projections  68  and  70 . Once pressure sufficient to overcome the bias of the springs  104  and  106  is released from the button, the springs  104  and  106  automatically bias the spring lock  14  back into its rest position where the device is protected from unintentional operation. 
   The spring lock  14  can be selectively maintained in a constantly armed condition that does not require depressing of the button  44 . In order to use the actuator  16  to dispense material from the container  1  in this condition, when the button  44  is depressed, the spring lock hook  72  is manually bent downwardly so that it is engaged in the projections  68  and  70 . In this condition, the device  10  is armed and the actuator  16  can be freely operated without requiring the user to do anything with the button  44 . The spring lock hook  72  has a built in biasing force that tends to urge the hook into a parallel alignment with the main body  78 . In the override or armed position, the hook  72  is bent downwardly. When it is desired to remove the device from this armed or override condition and back to one where the button  44  must be depressed in order to use the actuator  16 , the user need only depress the button  44  a sufficient axial distance so that the spring lock hook  72  clears the projections  68  and  70 . The lock hook  72  will automatically return to its safety or rest position wherein the lock hook  72  is substantially parallel to the main body  78 , thereafter, once the user stops exerting sufficient force against the button  44 , the spring lock  14 , will be returned to its auto-lock position where the button  44  must be depressed to enable the actuator  16  to dispense material from the device. 
   The next main component of the device  10  is the actuator  16 . The actuator  16  has a substantially hollow body  108  having a continuous outer wall  110  that closely follows the shape and dimension of the overcap  12  into which it is assembled. The outer wall  110  contains a void in the area under the nozzle  52 . The outer wall  110  is integral with and connected to a top  112 . The top features an actuating pad  114  and a finger rest  116 . The pad  114  and the rest  116  are preferably provided with a rough surface to assist the user in gripping the device whether with a hand or a glove without slipping. As particularly illustrated in  FIGS. 1 ,  2  and  8 A–D, the actuating pad  114  is preferably angled downwardly toward the front of the top  112  so that the actuator  16  has a vertical height within the overcap  12  approximately equal to the height of the sidewalls  56  and  58  at its highest point, the pad  114  extends downwardly toward the front of the top  112  such that a sufficient portion of the front wall  30  and angled peripheral portions  34  and  36  extend above the pad  114  to serve as a guide and stop for the finger of the user. This ensures proper positioning of the user&#39;s finger to depress the actuator without necessitating the user seeing the device to achieve this condition and also forms a ridge to help maintain the user&#39;s finger both axially and laterally within this position on the actuator. 
   Although it has been found that a variety of different angles are sufficient to achieve this desirable effect, angles of about 5 to 15 degrees and most preferably around 8 degrees, have been found to be particularly useful in achieving this purpose. The finger rest  116  is likewise angled but in an opposite direction to the pad  114 . This again is done to ergonomically accommodate the bend of a users thumb on the actuator and thereby ease actuation and holding of the device. It has been found that a variety of angles have been useful for the rest  116  to achieve this condition with those range of 25 to 30 degrees being most preferable. 
   The outer wall  110  of the actuator  16  is provided with a temper evident tab  118  protruding therefrom. This tab  118  prevents operation of the actuator  16  by restricting any downward movement of the actuator  16  by engaging and overlapping the top edge  63  of the rear wall  62  making it impossible to actuate the device  10  until the tab  118  is removed. The tab  118  provides another safety device for transit and shipment of the device  10  before it is used. It also provides a readily visible indication that the device  10  has not been previously used. In order to use the device  10  the user must first remove the tab  118  from the actuator  16  by twisting it off and discarding it. Actuator  16  has projections  100  and  102  respectively, and supports  71  and  73  respectively, that extend downwardly from the top  112  that are integral with the interior surface of the outer wall  110 . As previously described, the projections  100 ,  102  support the actuator  16  and can travel along the ribs  94 ,  96  of the spring lock  14 . As also previously described supports  71  and  73  support the actuator  16  and travel along the posts  80 ,  82  as the button  44  is depressed. A protruding lug  74  is located on the rear portion of the outer wall  110 . The lug  74  is journaled for vertical movement within the retaining slot  66 . The slot  66  restricts vertical movement to the range permitted by the lug  74  contacting either the top or bottom edge of the aperture  64  and further serves to maintain the actuator  16  in proper alignment. 
   The actuator  16  is further provided with a valve stem actuator  120 . The stem actuator  120  has a central chamber  122  located within a chamber wall  124 . The bottom of wall  124  terminates in a closed umbrella shaped guide  125  having an angled bottom surface  128 . The angled surface  128  tends to assist in urging and retaining proper alignment between the central chamber  122  and the valve stem  5 . Angles of about 45 degrees have been found to be particularly useful for the surface  128 . The upper end of the chamber wall  124  is integral with a nozzle wall  130  of the nozzle  52 . In similar fashion the central chamber  122  is in fluid communication with the nozzle chamber  132 . As such when the valve stem  5  is actuated by the actuator  16 , pressurized material from the container is dispensed first through the central chamber  122  and then into and out of the nozzle chamber  132  and towards an intended target. 
   It has been found that the length of the chamber  132  is important in achieving a desired spray pattern. To begin with, the nozzle chamber  132  must be of a sufficient length to allow the material to be dispensed in a uniform manner that is relatively unaffected by wind, rain or like environmental conditions. In this regard, a range of lengths of more than ¼ inch to about 1½ inches have been found to be sufficient for this intended purpose with the most preferred lengths being about one inch for the non lethal temporary incapacitation formulation and solvent system of the present invention. 
   Nozzle  52  can optionally be provided with additional features that can be particularly useful when the device  10  intended is used in connection with potentially harmful or irritating aerosol materials. A notch  136  can be provided in the bottom of the portion of the nozzle wall  130  that extends outwardly beyond the wall  110 . Alternatively the notch  136  can extend along the entire length of the nozzle  52 . As illustrated in  FIGS. 8A–D  and as previously described, in use the nozzle  52  will move vertically within the nozzle housing  48 . When the actuator  16  is released it is possible that a small amount of material from the aerosol container may remain at the end of the nozzle  52  after use. If this occurs then the notch  136  facilitates the channeling of any such material along the nozzle  52  to direct the material away from the finger of the user to the interior of the overcap  12  and into the top  3  of the container  1 . The bottom of the nozzle housing  48  may optionally also be slightly inclined toward the shell body  20  of the overcap  12  to assist this result. An angled surface  134  can further be provided at the end of the nozzle to both facilitate this action and to permit the actuator to be more easily inserted and assembled into the overcap  12  and nozzle housing  48 . 
   It has also been found that achieving a hybrid spray pattern (e.g. combination of cone and stream pattern) is facilitated by tapering the nozzle chamber  132  slightly from a larger opening at its exit end to a slightly smaller diameter opening where it contacts the central chamber  122  of the stem actuator  120 . Although a variety of tapers have been found to be sufficient, one of approximately one half degree per side has been found to produce particularly beneficial results. 
   As previously described, there is a great difference between the prior art stream and cone spray patterns when compared to the hybrid spray patterns achievable using the present invention. The stream pattern requires precise aiming and multiple actuations to cover the entire surface of the desired target. If a target is moving erratically, (e.g. during an arrest of an unruly subject by a police officer using a non-lethal incapacitating spray) there is a strong chance that the target will be missed by a narrow stream pattern, due to the difficulty in aiming at a small facial target. Additionally, if the spray pattern is too focused, it can also cause damage to the eyes of a target at close ranges due to its sharp and needle like pattern. 
   One of the advantages of the device  10  is the versatility and precision of its spray pattern. Such spray patterns can even more readily be achieved by utilizing a nozzle insert  18  in the nozzle chamber  132  of the actuator  16 . As illustrated in  FIGS. 1 and 6 , the insert  18  has a wall  138  and central orifice  140  extending along its entire length. It has been found that various inserts of different dimensions can be placed in the nozzle  52  permanently by molding or similar techniques to produce different desired spray patterns. The insert  18  may contain an optional projection  142  in the wall  138  to assist in retaining it within the nozzle chamber  132 . It was found, for example, that a nozzle insert  18  that was large at the beginning of the orifice and narrowed like a funnel at the orifice exit was particularly advantageous for the application of pepper spray. This insert  18  results in a spray pattern can also be used in any household or industrial application where a precise and focused pattern, unaffected by wind as desired, such as spraying an entire target such as a beehive or a wasp&#39;s nest. Choice of a particular insert design will also depend upon the formulation, propellant, solvent and pressure of the aerosol material and the desired characteristics of the spray pattern. 
   Extensive experimentation was conducted with the present invention to achieve advantageous hybrid spray patterns and design the particular geometries of nozzle inserts to be used in the present invention. These results and findings of this experimentation are summarized in the following example. While this example will show one skilled in the art how to operate within the scope of this invention, it is not to serve as a limitation on the scope of the invention. 
   EXAMPLE 1 
   Various tests and nozzle inserts were developed and tested to meet the following criteria when used in the present invention. 
   Spray pattern must be stable in wind. Typical spray patterns that atomize such as fog or cone are not stable and subject to wind movement. 
   At impact with the target, spray pattern must cover the entire target with one shot. Spray patterns that are solid stream in nature require multiple shots in order to cover the entire target. 
   Spray must penetrate windy conditions. Typical spray patterns that atomize, such as fog or cone, are not narrow and sharp enough to penetrate into wind and reach the target and will immediately atomize. 
   Eliminating blow back on the user. Typical spray patterns that atomize, such as fog or cone, can be blown back on user in windy conditions. 
   In order to eliminate effects on bystanders, or missing the target, the spray must not be affected by cross wind. Typical spray patterns that atomize such as fog or cone are subject to wind movement during cross winds. 
   The spray must not aerosolize and mist, and can be used indoor and in confined areas. Typical spray patterns, such as fog or cone, atomize indoor and may travel to areas other than the target, including circulation in HVAC. 
   Must reach the target even during rain. Fog or cone patterns are not narrow and sharp enough to penetrate wind and reach the target. 
   The goal was to develop nozzle inserts and resilient hybrid patterns that achieved the benefits of both solid stream and cone spray pattern. 
   A plexiglass sheet of 5 feet by 5 feet square and ¾ of an inch thick was placed vertically as a target. Digital video cameras were placed behind the glass and at a 90 degree angle to the glass. Water was used as the liquid projectile due to its molecular weight of 18.02 mw and evaporation rate 18.96 mmHg. Tests were performed at approximately 70° F. with a constant pressure of 40 PSI. Various nozzle insert orifices in accordance with the present invention, were designed in different dimensions made of polypropylene plastic as follows (dimensions are in inches): 
   
     
       
         
             
             
             
             
           
             
                 
                 
             
             
                 
               Beginning of 
               Orifice 
                 
             
             
                 
               Orifice 
               Exit 
               Orifice Shape 
             
             
                 
                 
             
           
          
             
                 
             
          
         
         
             
             
             
             
          
             
                 
               0.100 
               0.030 
               Circle 
             
             
                 
               0.090 
               0.030 
               Cylinder inserted in orifice tube 
             
             
                 
               0.090 
               0.030 
               Circle 
             
             
                 
               0.090 
               0.040 
               Circle 
             
             
                 
               0.085 
               0.040 
               Circle 
             
             
                 
               0.085 
               0.030 
               Circle 
             
             
                 
               00.80 
               0.040 
               Circle 
             
             
                 
               0.080 
               0.030 
               Circle 
             
             
                 
               0.080 
               0.010 
               4 hole shower design 
             
             
                 
               0.070 
               0.040 
               Circle 
             
             
                 
               0.070 
               0.030 
               Circle 
             
             
                 
               0.070 
               0.070 
               Rectangle 
             
             
                 
               0.060 
               0.020 
               Oval 
             
             
                 
               0.060 
               0.010 
               Oval 
             
             
                 
               0.060 
               0.020 
               Circle 
             
             
                 
               0.040 
               0.080 
               Circle 
             
             
                 
               0.030 
               0.030 
               Circle 
             
             
                 
               0.020 
               0.080 
               Triangle 
             
             
                 
               0.020 
               0.060 
               Oval 
             
             
                 
               0.020 
               0.080 
               Circle 
             
             
                 
               0.010 
               0.040 
               Circle 
             
             
                 
                 
             
          
         
       
     
   
   Water was continuously flowed through the selected orifices and videoed. The resultant impact pattern was measured and noted. The pattern and trajectory of water in flight was then evaluated and analyzed using the following procedure. 
   An industrial and customized fan approximately two feet in diameter was used to generate various wind speeds. A wind meter was used to log the speed. The fan was placed in three different pre-selected positions. In position (a) the fan was directly facing the spray and spraying into the wind. In position (b) the fan was directly behind the spray to assess tail wind. In position (c) the fan was at a 90 degree angle or cross wind to the spray to assess side wind. The fan generated speeds of 5, 10, 15, 20, 30, 40 and 45 miles per hour for each of the three positions. 
   In all test combinations up to 40 miles per hour, the liquid reached the target successfully. However, above 40 miles per hour in positions (a) and (c) 80% of spray reached the target and the remaining 20% was forced by wind to follow its route thus showing that the liquid is highly stable in windy conditions with no effect on bystanders. Similar tests were conducted using the non-lethal temporary incapacitation formulation and novel solvent system of the present invention and achieved like results. A comparison test was conducted using an isopropyl alcohol solvent where the spray was adversely impacted for all positions at fan speeds below 5 miles per hour. It was determined that spray patterns that met the criteria set forth above had the following elements in common:
         1. The beginning of the orifice of the nozzle insert must be larger than the exit orifice, the entire nozzle insert was therefore at the beginning of the orifice and narrowed like a funnel at the orifice exit. This must be in a ratio of between about 2 to 1 to 5:1.   2. The nozzle insert orifice must be a perfect circle shape throughout the entire orifice funnel, beginning, middle and end.       

   It was found that as the water entered into the large opening of the nozzle insert orifice funnel, it traveled toward the smaller exit orifice. As the water exited, it took the shape of the small circular orifice and in a solid stream fashion travels toward the target. At impact with the target, the stream opened up, taking the circular shape of the funnel at the beginning of its path. The result was a spray pattern that was a solid stream in its trajectory that opened up upon impact providing a hybrid pattern between stream and cone. The range of the stream depends primarily on the pressure and length of the nozzle. The impact pattern dimension depends on the ratio of the orifice. The larger the ratio the smaller the target coverage and vice versa. 
   In certain preferred embodiments, the device  10  of the present invention can be combined with a canister  1  having a content level indicator, generally indicated as  144  in  FIG. 10 . In prior aerosol canisters, it has not been possible to quickly detect the approximate amount of content left therein by the user. A graphical content level indicator  144  is placed on the outside of the container  1  in order to quickly determine the level of formulation in the canister. The location of the level indicator  144  on the canister  1  is determined as follows. First, empty canisters are placed in water to determine the location of the zero percent mark and additional full canisters are placed in water to determine the location of the one hundred percent mark. With these two marks, the locator marks for the twenty five, fifty and seventy five percent levels are located appropriately between the determined zero percent and one hundred percent locator marks. In order to test the content level of an aerosol canister, having a content level indicator, the following procedure is used.
         1. Fill a container or drinking cup having a diameter sufficiently large so that the outer surface of the aerosol canister does not come into contact with the container when it is in an upright condition.   2. Place the canister inside the container bottom down.   3. Gently and loosely hold and steady the unit upright inside the water. Care should be taken not to push the canister into the water, but instead to let it naturally float.   4. Observe the water line in comparison with the level indicator printed on the side of the canister to determine the level of contents.       

   The above described method has been found reliable to quickly detect the approximate amount of content left in an aerosol canister. 
   Operation 
   The operation of one embodiment of a completely assembled device  10  of the present invention will now be described with particular reference to  7 A,  7 B,  8 A–D,  9 A and  9 B. The device  10  is first illustrated in  FIG. 8A  in a configuration prior to any use thereof in a condition sufficient for shipping or the like. As can be seen in this condition, downward travel of the actuator  16  is further prevented by the vertical ribs  94 ,  96  and posts  80 ,  82  of the spring lock  14 . Any downward travel of the actuator  16  is further prevented by engagement of the tamper evident tab  118  with the top edge  63  of the rear wall  62  of the overcap  12 . In this condition, even if the button  44  of the spring lock  14  is fully depressed, the actuator still will not dispense any aerosol material from the container  1 . 
   With reference to  FIGS. 8B ,  8 C, and  9 B, the device  10  is next illustrated in a condition wherein the actuator  16  is depressed and material from the container  1  can be dispensed. It will be noted that in order to achieve this condition, the tamper evident tab  118  has been removed from the actuator  16 . Thereafter, in order to permit the actuator  16  to be depressed the user must depress the button  44  of the spring lock  14  inwardly. As the user does this, the projections  100  and  102  of the actuator  16 , travel down the angled top portions  98  of the respective vertical ribs  94  and  96 . At the same time the supports  71  and  73  of the actuator  16  travel down the angled top portions of the posts  80  and  82 . The further the button  44  is depressed, the more actuator  16  can be depressed given the angle of the vertical ribs  94 ,  96  and the posts  80 ,  82  to a point where the ribs  94 ,  96  completely clear the bottom of the projections  100  and  102  and the posts  80 ,  82  clear the bottom of the supports  71 ,  73  and do not restrict the downward travel of the actuator  16 . In this condition the material is dispensed from the container  1  through the actuator  16  and exited out of the actuator nozzle  52  and nozzle housing  48 . Similarly, in this condition depressing the actuator  16  has resulted in a change of position of the nozzle  52  to a position where the nozzle wall  130  is adjacent the bottom interior surface  146  of the nozzle housing  48 . 
   Once the user releases downward pressure on the actuator, the spring bias of the valve stem  5  will tend to raise the actuator  16  back to its original unactuated position. Additionally, once the user releases pressure on the button  44 , the spring lock  14  is automatically returned to its locked position due to the spring biasing force of the leaf springs  104  and  106 . No effort or act of the user is required to automatically return the device to this position. Once returned to the automatic locked position, the spring lock  14 , as described above, will prohibit downward travel of the actuator  16 , until and unless the button  44  of the spring lock is again depressed. 
   In the alternative, as illustrated, for example in  FIGS. 7B and 8D , once the button  44  of the spring lock  14  is depressed in order to allow the actuator to travel downward sufficiently to dispense product from the valve stem, the spring lock can be maintained in an override or constantly armed position. This is accomplished by bending the spring lock hook  72  downwardly until it is engaged by the projection  68  and  70  of the lock hook  72 . In this condition the actuator  16  can be freely depressed to dispense material from the container  1  without having to first depress the button  44 . In order to disengage this override or armed condition, the user need only further press the button  44  a slight axial distance sufficient to allow the lock hook  72  to extend beyond the projection  68  and  70 . At that point the biasing force of the hook  72  will return it to a position where it is parallel to the main body  78  of the spring lock  14  and the leaf springs  104  and  106  will urge the spring lock  14  into an automatically locked condition. 
   While the principles of the invention have been made clear in illustrative embodiments, there will be immediately obvious to those skilled in the art many modifications of structure, arrangement, proportions, the elements, materials, and components used in the practice of the invention, and otherwise, which are particularly adapted to specific environments and operative requirements without departing from those principles. The appended claims are intended to cover and embrace any and all such modifications, with the limits only of the true spirit and scope of the invention.