Abstract:
A unitary over-molded non-clogging system having mechanical breakup capability, a positive shutoff flared wall skirt, having two different overmolded materials forming a laminate combination. The soft flexible face inner portion with a flexible positive shutoff in combination, with mating sealing surface points at two distinct positions, on a conventional actuator body post, forms half of the unitary fitment. A hard portion contour forms the outer half, maintaining registration and retention of the entire overmold fitment within the actuator. This overmold combination fit provides these features without increasing the total amount of parts normally used in conventional spray actuators on pumps and aerosol systems. The actuator can employ a post with or without a mechanical breakup face while the mating surface of the inner soft interfacing portion would compliment it. This type of actuator also can be used as an outlet valve means for pumps, reducing overall cost.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a particular apparatus and method of manufacturing actuators that are suitable for use on aerosol dispensers or pumping assemblies. More specifically related to an actuator assembly that resembles the conventional types which are effective in preventing or reducing partial or total clogging through the introduction of air causing the drying or hardening of the product being dispensed within the flow channels and discharge orifice of the actuator assembly between the atomization stages or over intervals of usage. 
     2. Description of the Related Art 
     Actuator assemblies that fit on top of aerosol containers or that are used as part of a pumping system have been used for many years to dispense liquid or product under pressure through an orifice or opening. Often, the liquid or product is atomized via a (MBU) mechanical breakup means within the actuator assembly before it exits out the orifice as a fine spray using a specially configured nozzle or other mechanism. While these devices typically work well initially, they typically become partially or fully clogged as the product being dispensed dries and hardens in various flow channels and in the discharge orifice. Many of these other actuators rely on mechanical force, such as a spring or other mechanism, to open an orifice and flow channels for dispensing by withdrawing a probe or plug from the orifice and then closing the orifice after dispensing the product by moving the probe or plug back towards or into the orifice. 
     By way of example, U.S. Pat. No. 5,198,774 of Lund et al, discloses a combined lock and anti-clog actuator. The actuator is adjustable between a locked and an unlocked position. The locked position cooperates with an anti-clog member, which has a nozzle seal for inhibiting the clogging of the product within. 
     U.S. Pat. No. 5,894,964 of Barnes et al, discloses an inner actuator chamber arranged in a way designed to minimize blockage of the actuator. 
     U.S. Pat. No. 5,480,095 of Stevenson et al, shows an actuator that attenuates the accumulation of solidified sprayed fluid. 
     U.S. Pat. No. 5,687,877 of Smolen, Jr., discloses a pump dispenser with a check valve that moves forward during the pressure stroke and than closes and pulls liquid back during the suction stroke, minimizing blockage. 
     U.S. Pat. No. 5,560,544 of Merritt et al, discloses an anti-clogging atomizer nozzle. U.S. Pat. No. 5,358,149 of O&#39;Neill discloses an anti-clogging means similar to U.S. Pat. No. 5,687,877 of Smolen, Jr. 
     U.S. Pat. No. 4,982,900 of Blake discloses a trigger sprayer with several nose piece valve configurations. 
     U.S. Pat. No. 5,855,322 of Py discloses a one-way valve system that utilizes a swirl chamber with radially deformed, expandable outlet flexing valving as part of a pouched reservoir system, as an inclusive assembly. 
     Despite the efforts of such devices as shown in the forgoing patents, there remains a need for an anti-clogging actuator that can perform a rapid positive shut off. Specifically, a product that can prevent clogging from occurring by effecting a rapid shut off; that would afford an effective shut off method to prevent product build up behind the orifice at sealing surfaces and within flow channels; and that would create a positive shut off to reduce dribbling or seeping under low pressure would be most desirable, especially if the part count remains the same as with conventional actuators while employing a method of unitary overmolding of two separate materials, accomplishing the same desired equivalent features. 
     SUMMARY OF THE INVENTION 
     It is the object of the present invention to provide a method for the apparatus, that can be manufactured economically while maintaining all the features of non-clogging and positive shutoff within an actuator that does not increase in a total number of parts that are presently available. This actuator assembly will still isolate fluid within the MBU (mechanical breakup channels and orifice), preventing air from migrating back through the same. 
     It is a related object of the present invention to provide a non-clogging actuator assembly that has two diaphragms in tandem with a mechanical breakup between them, the in tandem diaphragms also provide double one-way valving with flexible movement to afford mechanical breakup and positive shutoff features that respond to a predetermined threshold pressure supplied by a number of systems in present use. 
     It is another object of the present invention to provide a means that enables the elimination of the pump outlet valve requirements when new concepts need economic relief to manufacture competitively for same uses and still work with existing pumps and dispensers that may or can utilize those needed features. 
     It is another object of the present invention to provide a non-clogging actuator that has a positive shutoff to prevent or reduce dribbling or seeping. 
     It is another object of the present invention to provide a non-clogging actuator with or without a positive shutoff feature, that is commercially advantageous by having no increase in overall part count greater than the conventional two piece systems currently being used, while easily being molded without complex actions, and adaptable for use in existing and future aerosol systems; and which lends itself to a variety of assembly modes and an assembly sequence that allows for subassembly pre-testing before final assembly. 
     Additional objects, advantages, and novel features of the invention will be set forth in part in the description that follows, and in part will become apparent to those skilled in the art upon examination of the following or may be learned by the practice of the invention. The objects and advantages may be realized and attained by means of the instrumentalities and in combinations particularly pointed out in the appended claims. 
     To achieve the foregoing and other objects and in accordance with the purposes of the present invention, as embodied and broadly described herein, an actuator assembly is provided, that addresses the above discussed clogging and pressure decreasing at end of stroke or duration of an aerosol spray system, problems. The actuator assembly according to this invention includes a overmolded and bonded laminate structure that is fabricated through a two stage overmold process producing an inserted unitary part which is of two different materials and two different durometers ie densities, that is assembled conventionally into a standard type actuator housing having a receiving pocket with a center post that has a face configuration that interfaces with the overmoled unit, and same post having a frustrum shoulder a distance down from its face that also interfaces with the overmolded unit, as the dual in tandem diaphragms-valves with MBU configuration sandwiched in between them allows each to flex in proper order, under pre-determined threshold pressures supplied by a system providing them. According to this invention, a flexible diaphragm flexes away from the first and second mating seal surfaces when product under pressure flows into contact with these flexible in tandem diaphragms. These in tandem diaphragms then resiliently springs back into abutting, biased sealing contact, shutting off the mating surfaces providing the positive shutoff feature desired. Preferably, the apparatus flexes away from the two mating surfaces at a predetermined minimum pressure, which can be set at various thresholds for various needed product categories, thereby controlling the dispensing of those products (i.e., the product is dispensed in a fairly constant pattern and then shut off rather than being very strong at the beginning of the spraying process and then dribbling out at the end or under low pressure operations). Those skilled in the art will recognize that any minimum predetermined pressure required to activate the disclosed assembly will vary with the type material and the geometry selected for the individual components. 
     Other features and advantages of the invention will become clear from the following detailed Description and drawings of particular embodiments of the actuator system and method and associated combinations and features of the present invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The accompanying drawings, which are incorporated in and form a part of the specification, Illustrate the preferred embodiments of the present invention, and together with the descriptions Serve to explain the principles of the invention. 
     In the Drawings: 
     FIG. 1 is a side sectional view of the preferred embodiment of the actuator assembly of this invention. 
     FIG. 2 is a partial sectional side view blowup of the actuator assembly of FIG.  1 . 
     FIG. 3 is a detailed sectional of the overmold from FIG. 1, showing the combined bonded laminate of the two different overmold halves as a unitary part, before assembly with a front isometric view of same. 
     FIG. 3A shows an isometric view of the overmold assembly. 
     FIG. 4 is a detailed sectional of the outer half of the overmold from FIG.  3 . 
     FIG. 4A shows an isometric view of the outer half of the outer half of the overmold of FIG.  3 . 
     FIG. 5 is a detail view looking into the bottom and showing the vortexing channels and mechanical breakup pattern detail of the inner half of the overmold from FIG.  3 . 
     FIG. 5A is a detailed sectional view of the inner half of the overmold from FIG.  3 . 
     FIG. 5B is a bottom isometric view of the overmold inner half of the overmold in FIG.  3 . 
     FIG. 6 is a detailed sectional view of the actuator housing from FIG.  1 . 
     FIG. 6A is a partial detailed blowup of the post and insert pocket of the actuator housing from FIG.  6 . 
     FIG. 6B is two isometric views of the actuator housing. 
     FIG. 7 is a detailed sectional view of another means of the overmold concept showing a simpler version with isometric top and bottom supportive views without the flared skirt utilized in the positive shutoff detail of FIG.  3 . 
     FIG. 8 is a detailed sectional view of yet another Cans of the overmold concept that shows supportive isometric views as in FIG. 8, demonstrating a further simplified version. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     With the above assembly in mind, it may now be helpful in fully understanding the inventive features of the present invention to provide in the following description a thorough and detailed discussion of specific embodiments of the invention. 
     Most generally, and referring to FIGS. 1-6, it may be seen in overview that the actuator assembly  10  according to this invention provides a flexible diaphragm face member (or inner fitment half)  16  and (outer fitment half)  17  that form an overmold unitary insert  20  with flexible diaphragms  16   d  and  16   e  that flexes away from first and second positive shutoff mating surfaces (a first mating surface at side  14   a  at point  14   e  of post  14  and a second mating surface at face  16   d  of post  14 , at the surface points  14   d  and  14   f  as shown for example in FIG. 2) when product under pressure flows into contact with the flexible diaphragm face member  16 . From viewing the figures, it may be understood that the flexible diaphragm face at points  16   e  and  16   d  then resiliently springs back into abutting, sealing contact with these shutoff mating surfaces  14   e ,  14   d , and  14   f , when the pressure has decreased. Preferably, the flexible face member  16  flexes away from the three shutoff mating surfaces at a predetermined minimum pressure and then flexes back into sealing contact when the product drops below this minimum pressure, thereby controlling the dispensing of the product (i.e., the product is dispensed in a fairly constant pattern and then shut off rather than being very strong at the beginning of the spraying process and then dribbling out at the end or low pressure operations). 
     FIG. 1 illustrates a side view of the actuator assembly  10  and FIG. 2 illustrates a partial side view blowup of the actuator assembly  10 . The actuator portion  12  is shown in FIG. 1 as a dashed circle, and this is the portion of the actuator assembly  10  that provides flow control features (i.e., anti-clogging features and anti-dribbling features). 
     As shown in FIG. 2, the actuator  12  comprises a post  14  about which product can flow in through a feed channel  15 . The actuator assembly  10  is seated (not shown) on a pump or valve stem which normally connects to a pressurizing system supplying product under pressure to the actuator assembly  10  as shown in the closed position so that product cannot exit the actuator  12 . The actuator  12  further includes a flexible diaphragm face fitment inner half of the overmold  16  which is part of the bonded compression fitment outer half of this combination, forming the two different materials of two different durometers as combined halves of a unitary part insert  20 , fabricated by the overmold process.  16  is the flexing member of the overmold insert  20 , and provides the resiliency needed for flexing away from post  14  at three positions on post, one being at the interface of the post face  14   f  another  14   d  and  14   e  being at a distance positioned down from the face  14   f , at a point  14   s  on the post shoulder and at the frustrum  14   c . When the location points  14   e ,  14   f  and  14   d  along with the feed channel  15 , reaches a predetermined minimum pressure, the flexing member  16  then returns to its original shape at the sealing contact points they interface with and the pressure is reduced below that minimum pressure. The flexible diaphragm inner half of the overmold is bonded to the compression fitment outer half  17 , which also defines the location and amount of flexing or change in shape that the flexible diaphragm fitment face  16  undergoes when under pressures above the minimum pressure. 
     As shown in FIGS. 2 and 5, the flexible diaphragm inner half  16  is constructed as shown whereas it is the resilient member that flexes away from seal points as described above. This portion of the unitary fitment  20  contains all the vortexing elements required of a mechanical breakup system. Tangentials  19  are fed by feed slots  19   s  and the product enters by way of  15  in the actuator assembly as illustrated in FIG.  2 . The product then is directed into a conical manifold  19   m  that receives the turbolated product provided by the tangential grooves  19 , and upon a predetermined threshold pressure, opens the upper diaphragm  16   d , emitting an aerosol spray pattern. The straight side wall  19   a  with vertical feed slots  19   s  of the flexible fitment inner half  16  are fitted with interference to the straight side wall of the actuator post  14 . 
     As shown in FIG. 4 the compression outer half  17  of the unitary fitment  20 , restricts the upper biased flexible diaphragm of  16   d , enabling proper movement required to respond to a predetermined threshold pressure and to facilitate the desired spray pattern.  17   b  are retention barbs or a ring that keeps the insert overmold unitary fitment in place, within the receiving pocket  12   p  within the actuator housing  12 .  17   o  is the exit opening for the spray pattern and is designed to limit impingement of same.  17   w  is the wall for the bond to  19   g  of  16 . 
     As shown in FIG. 3, unitary overmold fitment  20  is illustrating how the bonded laminate combination of  16  to  17  looks in cross section as well as a isomeric view of same, before it is inserted into the actuator pocket  12   p  of the actuator housing  12 . 
     As in FIG. 6, the actuator housing is illustrated as shown whereas a pump or valve pocket  12   v  receives a pump stem or valve stem usually part of a pump or valve system.  14  is the post that the unitary overmold insert  20  surrounds and accommodates the in tandem diaphragm-valves interface with proper fit at points  14   c  and the nipple  14   n  that facilitates flow of product under pressure by way of the mechanical breakup 16 mbu configuration positioned in the flexible diaphragm inner half, see FIG.  5 . The MBU portion 16 mbu interfaceces with the actuator hemispheric nipple  14   n  on the post face  14 , see FIG.  6 . MBU configurations are regulated through factors obtained by formulas known to those skilled in the state of the art technology. Of course, the MBU of  16  mbu can also be on the face of the actuator post  14 , surrounding the hemispheric nipple  14   n  on the post face, see FIG.  6 . The flexible diaphragm area having  16  mbu would be smooth and interface accordingly, with resulting parity. 
     To further understand the features of the invention, it may be useful to provide a quick overview of the movement of the components during operation of the actuator assembly  10 . 
     When the actuator assembly  10  is closed or shut, the flexible diaphragm fitment inner half  16  is in a biased state and “at rest” position (see FIGS. 1 and 2) in which the flared skirt of  16   e  of the flexible diaphragm inner fitment half  16  is interferenced between the actuator pocket  12   p  and post shoulder  14   s  of the actuator assembly  10 . The side walls  14   a  of the post  14  of the actuator housing and  19   w  of the flexible diaphragm fitment inner half  16  are sealably in contact with the side mating surface with the area around the vertical feeder channels  19   s  and the interfacing of  14   f  of the actuator post face to the flexible diaphragm fitment inner half floor  16   f  but not with the tangentials  19  (see FIG.  5 ). Also the upper diaphragm of the in tandem dual, is biased in sealably contacting the hemispheric nipple  14   n  as centered on the actuator housing post  14 . With the above condition, there is no path for product to follow in the biased static mode. However, when a pressure reaches the controlled threshold that overcomes the lower diaphragm seal surface-shutoff valve, product passes through the vertical feeder channel in  16 , and enters the vortexing mechanical breakup  16  mbu configuration in  16 , onto the hemispheric nipple  14   n , overcomes the upper diaphragm biased seal surface and exits the outlet orifice  16   o  as an aerosolized spray pattern. This system will also accommodate any pump that would omit an internal outlet valve device or a new concept as such. 
     FIGS. 7 and 8 are area reductions affecting the Flexible Face Inner Fitment whereas in FIG. 7, the Flared Skirt Lower Diaphragm  16   e  is eliminated leaving all the other interfacing elements in place, with  16  prime to serve as described and shown in FIG.  3 . 
     In FIG. 8, the same applies in FIG. 7 with the exception of the Flexible side wall, (see FIG. 5A 19   w ) being eliminated as well as the flared skirt  16   e  in FIG. 7 as shown and the remaining portion of  16   e  becomes  16  double prime. The function of FIG. 8 is prepared to serve as only the Non Clogging feature within the unitary overmold assembly bond. 
     In the above-disclosed embodiments, the materials of the overmolded fitment and actuator are not limiting factors in the disclosed invention and those materials durometers-densities specifically shown are presented only for the purposes of illustration. 
     Since numerous modifications and combinations of the above apparatus and method or processes in manufacturing arise out of technologies new and old, and these embodiments will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and processes shown and described above. Accordingly, resort may be made to all suitable modifications and equivalents that fall within the scope of the invention as defined by the claims which follow. The words “comprise”, “comprises”, “comprising”, “include(s)”, and “including” when used in this specification and in the following claims are intended to specify the presence of stated features or steps, but they do not preclude the presence or addition of one or more other features, steps, or groups thereof.