Patent Publication Number: US-2023148674-A1

Title: Aerosol Actuator

Description:
CROSS-REFERENCES TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Application Ser. No. 63/279,533, filed Nov. 15, 2021 and entitled “Aerosol Dispenser Cap,” which is incorporated herein by this reference. 
    
    
     FIELD OF THE INVENTION 
     The invention relates to dispensing of an aerosol product and more particularly to an improved tilt-type aerosol actuator assembly having a cap rotatable relative to a base for enabling and disabling dispensing of an aerosol product from an aerosol container. 
     BACKGROUND OF THE INVENTION 
     An aerosol dispenser comprises an aerosol container filled with an aerosol product and an aerosol propellent. The aerosol container is equipped with a tilt-valve to control the discharge of the aerosol product and propellant. An aerosol actuator assembly is an interface device typically comprising an operating cap and a base that attaches to the container and can be actuated by a user to control the flow of an aerosol product through the aerosol valve. 
     The aerosol valve includes a biasing spring which biases the valve into a closed position. A valve stem cooperates with the aerosol valve for opening the valve. An operating cap engages with the valve stem and via tilting action of the actuator, opens and closes the valve. The operating cap will typically include a spray nozzle for directing the dispensed aerosol product. 
     One problem commonly associated with tilt-type aerosol dispensers is that of accidental discharge of the contents of the container because of inadvertent tilting of the valve stem. Frequently, after the purchase of an aerosol dispenser, a protective cap that prevents inadvertent operation is thrown away and the aerosol actuator left unprotected. Subsequently, if the dispenser is packed into luggage or otherwise packed with other articles, sufficient force may be applied to the operating cap to tilt the cap and cause operation of the aerosol dispenser valve. 
     Although existing aerosol actuator assemblies have proven to be effective, there remains room for improvement in the art. What is needed is a cost effective and relatively simple aerosol actuator assembly where the operating cap can be selectively moved from a locked position which prohibits the dispensing of product to an unlocked position that allows the dispensing of an aerosol product. Prior art, selectively lockable aerosol actuator assemblies have often proven to be overly complex and too costly for mass production. 
     SUMMARY OF THE INVENTION 
     The present invention solves the problems of the prior art by providing an aerosol actuator having an operating cap and a base cap, where the operating cap interfaces with the aerosol valve of an aerosol dispenser and is rotatable between a locked position which prohibits dispensing of the aerosol product and an unlocked position that allows dispensing of the aerosol product via tilting action of the operating cap, which causes tilting or opening of the aerosol valve. The operating cap includes a plurality of fins that are rotatable over a plurality of slots and blocking surfaces disposed in the base cap. 
     In the exemplary embodiment, in the locked position, the operating cap is rotated clockwise such that the fins are positioned over the blocking surfaces which thereby prevent depression or operation of the cap. In the unlocked position, the operating cap is rotated counterclockwise such that the fins are disposed above the slots in the base cap, thereby allowing downward depression of the cap. The fins and slots are configured such that downward depression of an operating surface on one side of the operating cap causes tilting of the cap, which thereby causes tilting of the aerosol valve to which the operating cap is attached. It will be appreciated that the operating cap and base cap may be configured such that the direction of rotation for unlocking and locking of the operating cap may be reversed from that of the exemplary embodiment. The base cap is configured so as to be attachable via a press fit to either a lip of an aerosol container or to the lip of an aerosol valve cup. 
     Comprising only two components, i.e., the operating cap and the base cap, the aerosol actuator of the present invention may be manufactured from plastic materials at relatively low cost and in high volume. Being fabricated entirely from plastic materials, the aerosol actuator of the present invention is well-suited for recycling. 
     The above and other advantages of the aerosol actuator of the present invention will be described in more detail below. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1   . is a perspective view of an aerosol actuator of the present invention. 
         FIG.  1 A  is a cross-sectional view of the aerosol actuator of  FIG.  1    mounted on an aerosol container. 
         FIG.  2    is an exploded perspective view of the aerosol actuator of  FIG.  1   . 
         FIG.  3 A  is a cross-sectional view, taken along the line A-A of  FIG.  1   , of the aerosol actuator of  FIG.  1   , showing the front and rear fins of the operating cap positioned above the corresponding blocking surfaces of the base cap when the operating cap is rotated to the locked position. 
         FIG.  3 B  is a cross-sectional view, taken along the line B-B of  FIG.  1   , of the aerosol actuator of  FIG.  1   , showing the side fins of the operating cap positioned above the corresponding blocking surfaces of the base cap when the operating cap is rotated to the locked position. 
         FIG.  4 A  is a cross-sectional view, taken along the line A-A of  FIG.  1   , of the aerosol actuator of  FIG.  1   , showing the front and rear fins of the operating cap positioned above the corresponding slots of the base cap when the operating cap is rotated to the unlocked position. 
         FIG.  4 B  is a cross-sectional view, taken along the line B-B of  FIG.  1   , of the aerosol actuator of  FIG.  1   , showing the side fins of the operating cap positioned above the corresponding slots of the base cap when the operating cap is rotated to the unlocked position. 
         FIG.  5    is a cross-sectional view, taken along the line A-A of  FIG.  1   , showing the operating cap of the aerosol actuator of  FIG.  1    in the depressed position. 
         FIG.  6    is a top view, partially cut away, showing the fins of the operating cap of the aerosol actuator of  FIG.  1   , over the blocking portions of the base cap, when the operating cap is in the locked position. 
         FIG.  7    is a top view, partially cutaway, showing the fins of the operating cap of the aerosol actuator of  FIG.  1    over the slots of the base when the operating cap is in the unlocked position. 
         FIG.  8 A  is a cross section of the operating cap of  FIG.  1    taken along the line A-A of  FIG.  1   . 
         FIG.  8 B  is a cross section of the operating cap of  FIG.  1    taken along the line B-B of  FIG.  1   . 
         FIG.  9    is a bottom view of the operating cap of the aerosol actuator assembly of  FIG.  1   . 
         FIG.  10    is a top view of the base cap of the aerosol actuator assembly of  FIG.  1   . 
         FIG.  11    is a side view of the base cap of the aerosol actuator assembly of  FIG.  1   . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     With reference to  FIG.  1   , the aerosol actuator assembly  10  comprises an operating cap  12  and a base cap  14 . The operating cap  12  is rotatably attached to the base cap  14 . The base cap  14  is secured to an aerosol container  18 . The aerosol container  18  has a longitudinal axis of symmetry  8 . 
     With reference to  FIGS.  1  and  1 A , the construction and operation of a conventional aerosol container  18  is described as an aid in understanding the function of the aerosol actuator assembly  10  of the present invention. The aerosol container  18  is equipped with an aerosol valve  20  having a valve stem  22 . The aerosol valve  20  controls the flow of the aerosol product  50  through the valve stem  22 . The aerosol product  50  and the aerosol propellant (not shown) are stored within the aerosol container  18 . 
     For the purpose of this disclosure a downwards direction refers to a direction along the longitudinal axis of symmetry  8  towards a closed or bottom end  26  of the aerosol container  18  and an upwards direction refers to a direction along the longitudinal axis of symmetry  8  towards the aerosol valve  20  installed in the aerosol container  18 . 
     The aerosol container  18  has a top end  24  and the bottom end  26  with a cylindrical sidewall  28  therebetween. The bottom end  26  is closed out by an end-wall  30 . The top end  24  tapers radially inwardly to form a neck  32  terminating in a bead  34 . The bead  34  defines an opening  36  in the aerosol container  18  for receiving a mounting cup  38 . The mounting cup  38  includes a peripheral rim  40  for sealing to the bead  34  of the aerosol container  18 . The mounting cup  38  includes a turret  42  for receiving the aerosol valve  20 . 
     The aerosol valve  20  includes a valve body  44  secured to the turret  42  of the mounting cup  38 . The valve body  44  defines an internal valve cavity  46  in fluid communication with the aerosol container  18  through a dip tube  48 . The aerosol valve  20  includes a valve element  52  positioned within the internal valve cavity  46 . A biasing spring  54  biases the valve element  52  into a normally closed position to inhibit the flow of the aerosol product  50  through the valve stem  22 . 
     The aerosol valve  20  is configured such that tilting of the valve stem  22  by an external force applied to the valve stem  22  causes a gap to open between the valve stem  22  and the valve element  52 , which thereby allows aerosol product  50  to exit the aerosol container  18  through a flow passage  56  in the valve stem  22 . Upon removal of the external force from the valve stem  22 , the biasing spring  54  causes the valve element  52  to seal against the valve stem  22 , thereby preventing the aerosol product  50  from exiting the aerosol container  18 . 
     With reference to  FIGS.  1  through  11    the aerosol actuator assembly  10  of the present invention is described herein. The aerosol actuator assembly  10  comprises the operating cap  12  and the base cap  14 , which are configured such that the operating cap  12  is rotatable relative to the base cap  14  between an unlocked position (see  FIGS.  4 A,  4 B and  7   ) and a locked position (see  FIGS.  3 A,  3 B and  6   ). When the operating cap  12  is rotated to the unlocked position, the operating cap  12  is tiltable relative to the base cap  14  for actuating the aerosol valve  20  to dispense the aerosol product  50  from the aerosol container  18 . (See  FIG.  5   .) Tilting of the operating cap  12  occurs when a user presses downwardly on an actuation surface  58  of the operating cap  12 , when the operating cap is in the unlocked position. (See  FIGS.  4 A,  4 B and  7   .) When the operating cap  12  is rotated to the locked position (see  FIGS.  3 A,  3 B and  6   ), tilting of the operating cap  12  is blocked. 
     With reference to  FIGS.  1 - 7  and  10   , the base cap  14  includes an outer cylindrical sidewall  60 , a middle cylindrical sidewall  62  and an inner cylindrical sidewall  64 . The outer cylindrical sidewall  60 , the middle cylindrical sidewall  62 , and the inner cylindrical sidewall  64 , are coaxial with the longitudinal axis of symmetry  8  of the aerosol container  18 . Disposed between the middle cylindrical sidewall  62  and the inner cylindrical sidewall  64  are a plurality of buttresses  66  which are connected to the side walls and serve to stiffen the sidewalls. 
     Formed between the outer cylindrical sidewall  60  and the middle cylindrical sidewall  62  are a plurality of gusset portions  98 , which function to interconnect the outer cylindrical sidewall  60  with the middle cylindrical sidewall  62 . 
     A top surface of the middle cylindrical side wall  62  between a clockwise stop surface  92  and a counterclockwise stop surface  94  is defined as the forward shelf  68 . Formed in the inner cylindrical sidewall  64  is a rear slot  70  and side slots  72 . Each of the side slots  72  has a bottom surface  112 . (See  FIG.  2   .) The rear slot  70  has a bottom surface  114 . (See  FIG.  2   .) In the exemplary embodiment, the depth of bottom surfaces  112  of the side slots  72  and the bottom surface  114  of the rear slot  70  and are the same. For the purposes of this disclosure, the depth of bottom surfaces  112  of the side slots  72  and the bottom surface  114  of the rear slot  70  and the depth of the forward shelf  68  is defined the vertical distance, downwardly, from a plane  142  defined as being coplaner with the upper circumference of the inner cylindrical wall  64  of the base cap  12 . In the exemplary embodiment, the depth of the forward shelf  68  is less than that of the bottom surface  112  of the side slots  72  of the bottom surface  114  of the rear slot  70 . 
     Adjacent to the side slots  72  are side blocking portions  74 . Formed at an end of each side blocking portion  74  is a clockwise stop surface  84 , where the clockwise stop surface  84  limits clockwise rotation of the operating cap  12 . Formed at one of the walls defining each of the side slots  72  is a counter-clockwise stop surface  86 , where the counter-clockwise stop surface  86  limits counterclockwise rotation of the operating cap  12 . 
     Similarly, formed adjacent to the rear slot  70  is a rear blocking portion  76 . Formed at an end wall of the rear blocking portion  76  is a clockwise stop surface  88 , where the clockwise stop surface  88  functions to limit clockwise rotation of the operating cap  12 . Formed at one of the walls defining rear slot  70  is a counterclockwise stop surface  90 , where the counterclockwise stop surface  90  serves to limit counterclockwise rotation of the operating cap  12 . 
     Formed on a top surface  80  of each side blocking portion  74  and a top surface  82  of the rear blocking portion  76  are a plurality of locking protrusions  78 . The forward shelf  68  of the base cap  14  also includes a clockwise stop surface  92  and a counterclockwise stop surface  94 , where the counterclockwise stop surface  94  serves to limit counterclockwise rotation on the operating cap  12  and the clockwise stop surface  92  serves to limit clockwise rotation of the operating cap  12 . 
     The base cap  14  includes an annular projection  71  formed on an inner surface of outer cylindrical sidewall  60  and adjacent a lower edge and which extends radially inwardly. (See  FIGS.  3 A,  3 B,  4 A,  4 B and  5   .) The annular projection  71  snaps over the peripheral rim  40  (see  FIG.  1 A ) of the mounting cup  38  and thereby secures the base cap  14  to the aerosol container  18 . In other aerosol container configurations, the annular projection  71  may engage with the bead  34  of the aerosol container  18 . 
     The base cap  14  further includes a plurality of annular protrusions  106  spaced about an exterior surface of the middle cylindrical sidewall  62 . (See  FIG.  2   .) The plurality of annular protrusions  106  of the base cap  14  engage via a snap fit relationship with a plurality of mating angular protrusions  108  formed on an inner surface of the operating cap  12 . (See  FIG.  2   .) 
     With reference to  FIGS.  1 - 11    and particular reference to  FIGS.  2 ,  8 A,  8 B and  9   , the operating cap  12 , includes a generally hollow, hemispherical body  116 , a tubular portion  118  that is coaxial with the axis of symmetry  8  of the aerosol container  18 , and four equally spaced fins, i.e. front fin  120 , rear or rear fin  122  and side fins  124 , extending radially outwardly from the tubular portion  118 . 
     With particular reference to  FIGS.  1 ,  8 A and  8 B , each of the fins extends downwardly from the interior of the operating cap  12  to a specific height above a plane  146 , the plane  146  being coplanar with a bottom circumference  148  of the operating cap  12 . The front fin  120  has a height  130 . The rear fin  122  has a height  128  and the side fins  124  have a height  126 . (See  FIG.  3 B .) The height  128  of the rear fin  122  is greater than the height  130  of the front fin  120  and the height  126  of the side fins  124 . The height  126  of the side fins  124  is greater than the height  130  of the front fin  120 , but less than the height  128  of the rear fin  122 . 
     The operating cap  12  further includes a nozzle flow passage  134  which has an exit orifice  136  at one end and connects to a flow passage  138  of the tubular portion  118  at another end. (See  FIG.  8 A .) The tubular portion  118  is configured at an open end  140  to engage with an outlet end of the aerosol valve  20 . 
     As referenced, the plurality of angular protrusions  108  formed on the inner surface of the operating cap  12  snap over the plurality of annular protrusions  106  of the base cap  14 . When the operating cap  12  is snapped into place on the base cap  14 , the operating cap  12  is prevented from translating relative to the base cap  14 , but it&#39;s free to rotate relative to the base cap  14  about a longitudinal axis coincident with the longitudinal axis  8  of the aerosol container  18 . 
     As the aerosol valve  20  is spring loaded (see  FIG.  1 A ) and attached to the operating cap  12  via a press fit between the tubular portion  118  of the operating cap  12  and the valve stem  22  of the aerosol valve  20 , the operating cap  12  is biased in an upwards direction. With the operating cap  12  engaged with the base cap  14 , in the exemplary embodiment, the operating cap  12  is rotatable, relative to the base, clockwise to a locked position or counterclockwise to an unlocked position. 
     With reference to  FIGS.  2 ,  3 A,  3 B,  5  and  6   , when the operating cap  12  is rotated fully clockwise, the side fins  124  rest upon the top surfaces  80  of the side blocking portions  74  (of the base cap  14 ) (see  FIG.  3 B ) and abut the clockwise stop surfaces  84  (see  FIG.  6   ) and the rear fin  122  rests upon the top surface  82  of the rear blocking portion  76  (see  FIG.  3 A ) and abuts the clockwise stop surface  88 . (See  FIG.  6   .) The front fin  120  rests on the forward shelf  68  and abuts the clockwise stop surface  92 . In this position, downwards depression or tilting movement of the operating cap  12  is prevented. With depression or tilting of the operating cap  12  blocked, depression or tilting of the aerosol valve  20  is also blocked and consequently aerosol product  50  cannot be dispensed from the aerosol container  18 . 
     The locking protrusions  78  on the top surfaces  80  of side blocking portions  74  and the top surface  82  of rear blocking portion  76 , respectively, provide tactile feedback to a user as the operating cap  12  rotates. The locking protrusions  78  also function to prevent the side fins  124  and the rear fin  122  from inadvertently rotating counterclockwise and allowing the operating cap  12  to inadvertently move into the unlocked position. 
     With reference to  FIGS.  2 ,  4 A,  4 B and  7   , when the operating cap  12  is rotated fully counterclockwise into the unlocked position, the side fins  124  are positioned above the side slots  72  of the base cap  14  (see  FIG.  4 B ) and abut the counterclockwise stop surfaces  86  (see  FIG.  7   ) and the rear fin  122  is positioned above the rear slot  70  (see  FIG.  4 A ) and abuts the counterclockwise stop surface  90 . (See  FIG.  7   .) In the unlocked position, the front fin  120  rests upon the forward shelf  68  (see  FIG.  4 A ) and abuts the counterclockwise stop surface  94 . (See  FIG.  7   .) 
     When the operating cap  12  is in the above-described unlocked position relative to the base cap  14 , i.e. as shown in  FIGS.  4 A and  4 B , downward pressure by a user on an actuation surface  58  of the operating cap  12  causes the operating cap  12  to tilt and thereby open the aerosol valve  20 , i.e. the rear fin  122  moves downwardly in the rear slot  70  causing the operating cap to tilt and valve stem  22  of the aerosol valve  20  to tilt and thereby open the valve. Upon the removal of user pressure on actuation surface  58 , the biasing spring  54  of the aerosol valve closes the valve and drives the operating cap  12  upwards. 
     In more detail, downward pressure on the actuation surface  58  of the operating cap  12  causes the front fin  120  to contact the forward shelf  68  and the rear fin  122  to depress until it contacts the bottom surface  114  of the rear slot  70 . As the height  128  of the rear fin  122  is greater than the height  130  of the front fin  120  and the height  126  of the side fins  124 , this results in the operating cap  12  tilting upon depression of actuation surface  58 . Consequently, the tubular portion  118  of the operating cap  12  causes tilting of the valve stem  22  of the aerosol valve  20 . Upon the valve stem  22  of the aerosol valve  20  being tilted, aerosol product under pressure in the aerosol container  18 , flows through the nozzle flow passage  134  and the flow passage  138  of the operating cap  12  until it is dispensed from the exit orifice  136 . After being depressed, upon release of the operating cap  12 , the biasing spring  54  of the aerosol valve  20  biases the operating cap  12  upwardly, such that the operating cap  12  may subsequently be rotated clockwise into the locked position. 
     In the exemplary embodiment, in the unlocked position, the side fins  124  of the operating cap  12  are disposed above the side slots  72 . The height of the side fins  124  are configured such that when the operating cap  12  is depressed, the side fins  124  will not contact the bottom surfaces  112  of the side slots  72  when the rear fin  122  abuts the bottom surface  114  of the rear slot  70 . 
     In an alternative embodiment, the height of the side fins  124  may be configured such that upon downward depression of the operating cap  12 , the side fins  124  contact the bottom surface  112  of the side slots  72  before the rear fin  122  contacts the bottom surface  114  of the rear slot  70 . Upon the continued application of downward force, the operating cap  12  will rock about the side fins  124  until the rear fin  122  contacts the bottom surface  114  of the rear slot  70 . This rocking action may create a more positive “feel” or “feedback” to a user of the aerosol actuator  10 . 
     The operating cap and the base cap of the present invention may be injection molded from a wide variety of plastic materials of which polyethylene and polypropylene are two such materials. These materials are well-suited for low cost, high volume production. Other materials and methods of manufacture may also be suitable. 
     It will be appreciated that an improved aerosol actuator featuring a two-piece construction comprising an operating cap and a base cap having the ability to rotate between an open position and a closed position has been presented. While the present invention has been described with regards to a particular embodiment, it is recognized that additional variations of the present invention may be devised without departing from the inventive concept.