Abstract:
A decor-able, multiple-configuration protector for the nozzle assembly of a spray can having parts capable of absorbing, deflecting, and/or redirecting damaging force from accidental drops and bumps.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to and the benefit of the filing of U.S. Provisional Patent Application Ser. No. 61/907,771, entitled “NOZZLE PROTECTOR COVER”, filed on Nov. 22, 2013, and the specification and claims thereof are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention (Technical Field) 
     Embodiments of the present invention relate to aerosol spray can accessories, and more particularly to nozzle protectors. 
     2. Description of Related Art 
     Most ordinary spray cans comprise a cylindrical body and a top dome attached by a rolled over and sealed first joint. At its top, the dome comprises a nozzle valve cup assembly that is typically centrally disposed and recessed, and attached to the dome through a rolled over and sealed second joint. A discharge tube protrudes from the center of the valve cup, to which a nozzle, typically comprising an actuator button with an aperture, attaches to spray the contents of the can when pressed. Most spray cans comprise covers to isolate the spray nozzle from the environment and protect it and/or assist in packaging and stacking. The cover typically snaps onto/into the first joint (between the cylindrical body and the dome) or, less commonly, the second joint (between the dome and the valve plate). The cover typically stays on while the can is not being used. 
     A common problem with the spray cans of the type described above is that the discharge tube and nozzle often break off if, for example, the can is accidentally dropped. The industry has responded by providing removable nozzle protectors that may be purchased separately and attached to the dome, or by turning modified covers into nozzle protectors (e.g., cap actuators) that snap onto/into the first joint (between the cylindrical body of the can and the dome). A device that protects spray cans from damage during drops must possess several qualities. Although there are aerosol cans that cost above $20 dollars, they are in the minority, so a protector designed to protect the majority of products should be simple and inexpensive to manufacture. It should be durable enough to protect the heaviest cans, which may weigh up to 22 ounces and hit the ground with a force greater than 350 pounds when dropped, and be able to be used with confidence on the most expensive products, such as a mink oil hair spray selling for $96. The types of modified covers and nozzle removable protectors currently being used seem primarily designed to protect during shipping and display and to facilitate stacking. They are very stiff and fracture easily during impact, often resulting in damage during use, at home and in the workplace, to the actuator/valve cup assembly. 
     Embodiments of the present invention solve this problem by providing durable nozzle protectors that preferably snap onto the second joint (between the dome and the valve plate) and that are openable/closable. A user can conveniently twist a shell component of an embodiment of the present invention to switch between an open and a closed configuration, allowing the use of the spray can while an embodiment of the present invention is installed. Embodiments of the present invention can substitute other nondurable, stiff, bulkier cover/nozzle protectors that only have an open configuration. 
     BRIEF SUMMARY OF THE INVENTION 
     Embodiments of the invention comprise a protector for a nozzle actuator assembly for an aerosol spray can comprising a circular base comprising a top surface and a bottom surface, said top surface comprising at least one cylindrical upward first projection that forms one or more walls to protect said nozzle actuator assembly, said bottom surface comprising a downward cylindrical second projection at its outermost periphery that forms a lower rim, said lower rim comprising a concentric first ridge, and a shell comprising at least two opposing openings. In one embodiment, the first ridge is curved inwardly and its most inner perimeter is smaller than an outer diameter of a rolled joint of the spray can. Preferably, the shell component is detachable from the base. Preferably, the top surface of the base comprises a cylindrical upward third projection smaller in diameter than the inner diameter of the shell, and onto which the shell connects in such a way that the shell can rotate relative to the base. 
     Preferably, the top surface of the base further comprises a cylindrical upward fourth projection placed outwardly in relation to the third projection and larger in diameter than the outer diameter of the shell and comprises a first detent. Preferably the shell comprises a second and third detents that are capable of interlocking with the first detent to lock the shell in either an open or closed configuration. 
     In one embodiment, the third and fourth projections comprise a cutout portion to allow a spray to flow unrestricted. 
     In one embodiment, the shell comprises a top opening, preferably circular in shape and which is capable of accommodating decorative attachments. 
     In one embodiment, the base component clamps around the rolled joint of a spray can. 
     In a different embodiment, the shell and the base further comprise hooks to accommodate restraints. 
     In another embodiment, the shell extends downward over the base and is capable of being clamped over the rolled joint. 
     In a different embodiment, the shell is detachably connected or fixed to one or more walls to protect the nozzle assembly and is shaped as an arching bridge with enough space under it to allow the finger of a user to enter to operate the nozzle assembly on one side and to allow spray to exit the nozzle assembly unrestricted on the other side of the shell. Preferably the base and the shell are molded out of plastic. 
     In another embodiment, the shell opposing openings are sufficiently large to allow the finger of a user to enter to operate said nozzle assembly on one side and to allow spray to exit the nozzle assembly unrestricted on the other side of the shell. 
     Further scope of applicability of the present invention will be set forth in part in the detailed description to follow, taken in conjunction with the accompanying drawings, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       The accompanying drawings, which are incorporated into and form a part of the specification, illustrate one or more embodiments of the present invention and, together with the description, serve to explain the principles of the invention. The drawings are only for the purpose of illustrating one or more preferred embodiments of the invention and are not to be construed as limiting the invention. In the drawings: 
         FIG. 1  is a front view of an embodiment of the present invention disposed on the joint between the dome of a spray can and its valve plate showing the position of the nozzle assembly and the finger of a user; 
         FIG. 2  is a side view of the embodiment of  FIG. 1  disposed on the can; 
         FIG. 3  is an isometric view of the embodiment of  FIG. 1  without the spray can in the open configuration; 
         FIG. 4  is a cross-sectional view of the embodiment of  FIG. 3  in the open configuration; 
         FIGS. 5A and 5B  are left (A) and right (B) views of the embodiment of  FIG. 3  in the open configuration; 
         FIG. 6  is a front view of the embodiment of  FIG. 3  in the open configuration; 
         FIG. 7  is a rear view of the embodiment of  FIG. 3  in the open configuration; 
         FIG. 8  is an overhead view of the embodiment of  FIG. 3  in the open configuration; 
         FIG. 9  is an isometric view of the embodiment of  FIG. 3  in the closed configuration; 
         FIG. 10  is a rear view of the embodiment of  FIG. 3  in the closed configuration; 
         FIG. 11  is a left view of the embodiment of  FIG. 3  in the closed configuration; 
         FIG. 12  is a right view of the embodiment of  FIG. 3  in the closed configuration; 
         FIG. 13  is a front view of the embodiment of  FIG. 3  in the closed configuration; 
         FIG. 14  is an overhead view of the embodiment of  FIG. 3  in the closed configuration; 
         FIG. 15  is an isometric view of the base component of the embodiment of  FIG. 3 ; 
         FIG. 16  is a front view of the base component of the embodiment of  FIG. 3 ; 
         FIGS. 17A and 17B  are right (A) and left (B) side views of the base component of the embodiment of  FIG. 3 ; 
         FIG. 18  is a rear view of the base component of the embodiment of  FIG. 3 ; 
         FIG. 19  is an isometric view of the shell of the embodiment of  FIG. 3 ; 
         FIG. 20  is a rear view of the shell of the embodiment of  FIG. 3 ; 
         FIG. 21  is a right side view of the shell of the embodiment of  FIG. 3 ; 
         FIG. 22  is a front view of the shell of the embodiment of  FIG. 3 ; 
         FIG. 23  is an overhead view of the shell of the embodiment of  FIG. 3 ; 
         FIG. 24  is a left side view of the shell of the embodiment of  FIG. 3 ; 
         FIG. 25  is an overhead view of an alternate embodiment of the base showing detents in a different position; 
         FIG. 26  is a bottom view of base component of the embodiment of  FIG. 3 ; 
         FIG. 27  is a bottom view of assembly of the embodiment of  FIG. 3 ; 
         FIGS. 28A and 28B  are a cross-sectional view and a top view of an example of a possible insert accessory for the sell; 
         FIG. 29  is a cross-sectional view of an embodiment of a single piece apparatus; 
         FIG. 30  is a cross-sectional view of a different embodiment of a single piece apparatus; 
         FIG. 31  is a cross-sectional view of a different embodiment of a single piece apparatus; 
         FIG. 32  is a cross-sectional view of a different embodiment of a single piece apparatus 
         FIG. 33  is a front view of a different embodiment of the invention; 
         FIG. 34  is a right side view of the embodiment of  FIG. 33 ; 
         FIG. 35  is a back view of the embodiment of  FIG. 33 ; 
         FIG. 36  is a left side view of the embodiment of  FIG. 33 ; 
         FIG. 37  is a cross-sectional side view of the embodiment of  FIG. 33 ; 
         FIG. 38  is a perspective view of a detachable component of the base of the embodiment of  FIG. 33 ; 
         FIG. 39  is a top view of the component of  FIG. 38 ; 
         FIG. 40  is a front view of the component of  FIG. 38 ; 
         FIG. 41  is a cross-sectional side view of the component of  FIG. 38 ; 
         FIG. 42  is a cross-sectional side view of the shell of the embodiment of  FIG. 33 ; 
         FIG. 43  is a front view of a different embodiment of the invention comprising different attachments for restraints; 
         FIG. 44  is a front view of a different embodiment of the invention comprising a clamp attachment mechanism on the base component of the apparatus and holding rings; 
         FIG. 45  is a front view of an embodiment similar to that of  FIG. 44  but without holing rings; 
         FIG. 46  is a front view of an embodiment of a different embodiment of the invention wherein a clamp assembly is disposed at the base of the shell component; 
         FIG. 47  is a front view of an embodiment similar to the embodiment of  FIG. 46  but the clamp assembly comprises a detachable clamp that can be tightened with, for example, a screw; 
         FIG. 48  is a front view of an embodiment similar to the embodiment of  FIG. 47  with a clamp spun about the base of the shell; and 
         FIG. 49  is a front view of a different embodiment of the invention in which the shell component can attach to the base component through hook and loop elements. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the embodiments of the invention. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details. For instance, well known operation or techniques may not be shown in detail. Technical and scientific terms used in this description have the same meaning as commonly understood to one or ordinary skill in the art to which this subject matter belongs. 
     As used throughout this specification and claims, the term “protector” refers to fixtures that are capable of absorbing, deflecting, or redirecting force that can potentially damage, for example, the discharge tube or nozzle actuator of a spray/aerosol can, or simply cover a nozzle assembly for, for example, partial isolation from the elements, or serve as a base for additional fixtures such as holders, ornaments, etc. 
     As used throughout this specification and claims, the term “can”, as in “spray can” refers to containers to spray products that may be manufactured from any materials, including metal, plastic, etc. 
     Referring to the figures, one embodiment of the present invention comprises nozzle protector  10 , preferably manufactured of a suitable material, for example, plastic commodity resins such as PVC, PE, PS, Nylon, Rubber, Silicon, or Vinyl (but not limited thereto), but can also be made of other suitable materials such as metals, for example, aluminum, tin, etc. Nozzle protector  10  preferably comprises base component  12  and shell  14 . In one embodiment, base component  12  is formed from a relatively short cylinder with an inner diameter approximating the size of sealed joint  16  of spray can  18 . See  FIGS. 1-2 . Preferably base component  12  is manufactured of a material offering sufficient resilience to easily snap onto sealed joint  16 . Also shown are valve cup  9  (in ghost lines), discharge tube  11 , nozzle actuator button  13 , and aperture  15 . 
       FIG. 3  shows a perspective top view of the embodiment of  FIG. 1  in the open configuration without the spray can.  FIG. 4  is a cross-sectional front view of the embodiment of  FIG. 3 . In this embodiment, base  12  preferably comprises lower rim  20 . Referring to  FIGS. 3-14 , lower rim  20  preferably comprises ridge  22 , which preferably curves inward. Preferably, ridge  22  comprises a diameter slightly smaller than the outer diameter of joint  16  so that when the apparatus is installed/removed a moderate amount of force is required but base  12  does not tend to rotate about joint  16 . When properly installed, ridge  22  is preferably disposed against lower external edge  24  of joint  16  and the bottom surface of seat  26  rests on top edge  28  of joint  16 . See  FIGS. 1-2 . In a different embodiment, lower rim  20  has a diameter smaller than an outer most rolled joint of a spray can and ridge  22  projects outwardly to snap the base into place. Alternatively, lower rim  20  has a diameter larger than an outer most rolled joint of a spray can and ridge  22  curves inwardly. 
     Referring to  FIGS. 3-19 , on its opposite side (top), seat  26  preferably comprises a plurality of concentric cylindrical projections. In one embodiment one of these projections is preferably outer detent rim  30  (see  FIGS. 4, 15 ), which is preferably relatively short in height and on its inner periphery comprises one or more vertical ridges protruding inwardly, optionally at approximately 90 degrees relative to the vertical axis of detent rim  30  to serve as detents. In one embodiment detent rim  30  comprises open/close detents  32 ,  34  ( FIG. 14 ), which preferably interlock with one or more ridges  36  ( FIG. 19 ) protruding from the lower outer periphery of shell  14  to hold the shell in either an open or closed configuration. 
     Preferably, seat  26  further comprises a second upward projection  38  ( FIG. 15 ), concentric to detent rim  30  and disposed inwardly in relation to it. Preferably, projection  38  comprises outward protruding ridge  40  relatively close to its top edge. Ridge  40  preferably interlocks with ridge  44  of similar proportions disposed at the lower inner periphery of shell  14  to hold the shell in place while allowing it to revolve about. Optionally, sections of projection  38  are removed, for example, to facilitate removal from an injection mold or to fine tune the tension exerted upon shell  14  during impact to permit it to dislodge without exerting enough tension upon base  12  to dislodge base  12 . 
     Preferably, seat  26  further comprises a third upward projection  42 , concentric to the other two projections and disposed inwardly in relation to them. Preferably projection  42  comprises two deflector walls  46 , which are formed by, for example, cutting two arcs diametrically opposed to each other. Optionally, the tops of deflector walls  46  are clipped, molded, or otherwise sized to a height about or just above the height of most common nozzle actuator buttons and provide sufficient clearance for the spray path to flow uninterrupted and the user&#39;s finger to access nozzle actuator button  13 . The inner face of projection  42  is preferably flush with the inner end of seat  26  ( FIG. 4 ), which approximates, in turn, the inner most diameter of seal  16 . In one embodiment, deflector walls  46  are preferably built to protect the nozzle actuator assembly during secondary impacts, e.g., when shell  14  is dislodged during a primary impact and/or to shield the nozzle actuator assembly when shell  14  is rotated into the closed configuration ( FIG. 9 ). 
     Optionally, shell  14  is easily removed by the user in instances when the spray pattern needs to be greater than that allowed when shell  14  is in place. In that case, base  12  can be used alone and still provide protection for the nozzle actuator assembly when such clearance is necessary because walls  46 , which are part of base  12 , are capable of deflecting impacts. Optionally the projections protruding upward from seat  26  are carved out at the front end of base  12  (indentation  27 ) to decrease interference with the spray pattern (see e.g.,  FIGS. 6, 8, 16, and 26 ). 
     Referring to  FIGS. 19-24 , shell  14  is preferably a single piece component comprising a relatively small, centrally disposed, optional hole  48  at its top end and two openings  50 , preferably oval in shape, at its front and back ends wherein the size and shape is sufficiently large to accommodate the finger of a user moving in and out to access the nozzle actuator button and permit unobstructed flow of the contents of the can when sprayed. As discussed above, the lower inner face of shell  14  comprises inward facing ridge  44 . In one embodiment, ridge  44  is segmented to facilitate installation/removal from base  12 . Ridge  44  preferably snaps onto projection&#39;s  38  outward protruding ridge  40  during installation allowing shell  14  to revolve around a vertical axis. 
     Decorative elements may be attached to the shell, for example, at hole  48 . Preferably, such elements are made from a resilient material and/or do not fill hole  48  so that its ability to collapse during an impact is not disrupted. For example, a decorative element such as the one illustrated in  FIGS. 28A and 28B  fits in hole  48 . Many variations of the shell&#39;s design are possible as long as all they work similarly. The shell which has attached to it another piece or pieces which rotate, flap, slide, or otherwise work to cover the openings must take all of these factors into account. A decorative element may alternatively be integrally formed with shell  14 . 
       FIG. 25  shows an alternative embodiment of base  12  comprising, for example, segmentations and alternative locations for detent ridges. 
       FIGS. 29, 30, and 31  show cross-sectional views of embodiments of single piece protectors (i.e., base and shell are fused) with optional reinforcement elements illustrated in ghost lines. These embodiments preferably fit over and snap onto sealed joint  16 . The embodiment of  FIG. 31  further comprises wing structures  60  on the sides of the shell for reinforcement against impacts. 
       FIG. 32  shows a cross-sectional view of a different embodiment of a nozzle actuator assembly protector comprising an outer shell component  62  (delineated with ghost lines) that revolves to provide open and closed configurations and preferably fits over and snaps onto sealed joint  16 . 
     In one embodiment, hole  48  is not provided. In another embodiment, shell  14  is not provided. In another embodiment, detent rim  30  is not provided. In a different embodiment, deflector walls  46  are not provided. In another embodiment, indentation  27  is not provided. 
     Referring now to  FIGS. 33-42 , there is shown nozzle protector  100  preferably comprising base component  112 , which comprises one or more base hooks  113 , and shell component  114 , which comprises one or more shell hooks  115 . Preferably, base hooks  113  and shell hooks  115  allow a restraint, for example, an O-ring  117  (shown in ghost lines in  FIGS. 33-34 ), to further secure a connection between base component  112  and shell component  114 . Preferably the restraint helps to position and prevent shell  114  from accidentally separating from the protector, and to lessen the effect of the forces acting to remove the base from the can during angled drops and bumps. These restraints can be, but are not limited to, any type of elastic type o-ring, band, strap, coil spring, or molded in component, such as a hook and loop (see e.g.,  FIG. 49 ), whose composition, mounting, and dimensions can be varied to give the desired results, with the restraint being either permanently deformed after a drop or re-useable. In the case of an O-ring, preferably it is made of a stretchy material in a size that preferably allows a user to dispose over base hooks  113  and shell hooks  115  with ease. Optionally, lower rim component  120  is detachable from base  112 . See  FIGS. 38-41 . 
     Referring to  FIG. 43 , there is shown a different embodiment of the invention wherein nozzle assembly protector  200  comprises base  212  and rotating shell  214 . Preferably, base  212  comprises hooks  213  and rotating shell  214  comprises hooks  215  that preferably line up with each other when rotating shell  214  is set to an open configuration so that a restraint can be employed, for example, O-ring  217 . 
     Referring to  FIG. 44 , in a different embodiment, nozzle assembly protector  300  comprises clamp assembly  327  in which base  312  is, for example, split to slip over a spray can&#39;s rolled joint and can then be adjusted to a tight fitting by placing screw  340  through holes  329  and tightening. Preferably, base  312  comprises lower rim  320  with ridge  322 , detent rim  330 , upward projection  338 , and walls  346 . Optionally, holders  335  are added to lower rim  320 . Preferably, one or more connectors  339  are disposed on top of walls  346  for the user to optionally place overarching bridge cover  314 , which preferably curves sufficiently to allow the user&#39;s finger to interact with the nozzle&#39;s actuator to be pressed down and spray unrestricted.  FIG. 45  shows and embodiment similar to the one in  FIG. 44  but without holders on the lower rim. 
     Referring to  FIG. 46 , there is shown a different embodiment of the invention in which nozzle assembly protector  400  comprises shell  414  disposed on base  412 . Preferably, shell  414  further comprises clamp assembly  427  comprising, for example, holes  429  in which screw  440  is inserted and tightened to secure protector  400  onto, for example, the rolled joint of a spray can. 
     As illustrated in  FIGS. 47-48 , optionally, nozzle assembly protector  500  preferably comprises clamp  510 , which is disposed at the base of shell  514  to secure protector  500  onto, for example, the rolled joint of a spray can. Preferably, clamp  510  comprises clamp assembly  527  with, for example, holes  529  for screw  540  to be inserted and tightened. 
     In a different embodiment, nozzle assembly protector  600  comprises shell  614  with hook and loop components  617 . 
     INDUSTRIAL APPLICABILITY 
     The invention is further illustrated by the following non-limiting examples. 
     Example 1 
     Several issues arose in trying to make a one piece protector, either one that extended just above the nozzle-button, or one that fully covered it. For example, during low angle drops, too much stiffness led to damage of either the protector, due to brittle fracture, or the can, primarily at the valve cup/dome interface, leading to leakage, or both. When softened, the one piece protector collapsed partially and absorbed energy, thus preventing damage to the can during low angles, but this softness became an issue during high angle drops, also resulting in damage to can/protector. Too much stiffness led to a spring loading effect that sent the one piece protector flying upon impact and also caused the can to bounce wildly. Many attempts were made to alter the shape, and plastic composition, of one piece designs in order to provide both high angle impact stiffness and low angle impact absorption, including the attachment of impact absorbing materials. During high angle drops it was noticed that the single piece protectors had a tendency to dislodge and slide across the face of the valve cup, directly damaging the nozzle assembly. Because single piece designs were found to be less effective, a two piece embodiment was developed instead. 
     A base component was fabricated to firmly attach to the outer lip of the seal between the valve cup and the dome. The base component comprised deflector walls. A cover component attached to the base by a short mount that allowed the cover to revolve about the long axis while holding firmly to the base to permit an opening and closing action. The cover attachment to the base was designed to release before that of the base/can attachment so that the base remained on the can for a possible secondary impact as the cover was moving out of the way. In order to arrest the lateral movement of the cover during impact and force the cover to pivot about the point of contact, an outer retaining wall was added to the base component, and/or restraints were added, and/or the clamp. The corners of the deflectors of the base component were relieved and the thickness and composition adjusted to allow the cover component to pivot over them without significant interference, while still providing sufficient protection during secondary impacts. 
     It was observed during testing that for effective protection at low angle drops, the cover component had to simply absorb the impact without deflecting too much and contacting the actuator. At higher angles, in contrast, the cover component made contact with the surface and had to begin absorbing energy, while at the same time imparting a certain amount of force upon the can in order to slightly start increasing the can&#39;s angle of impact as the cover component began pivoting. This absorption and re-direction lessened the forces received by the base component when it came in contact with the surface. Many times, higher initial angles resulted in enough cover component imparted re-direction of the can for the base component to avoid contact with the surface. Thus, a secondary impact was shifted to the shoulder of the can. A hole in the top of the shell was added to slow down this absorption and re-direction phase, thereby increasing their effect. 
     The preceding examples can be repeated with similar success by substituting the generically or specifically described components and/or parameters of this invention for those used in the preceding examples. Note that in the specification and claims, “about” or “approximately” means within twenty percent (20%) of the numerical amount cited. 
     Although the invention has been described in detail with particular reference to these preferred embodiments, other embodiments can achieve the same results. Variations and modifications of the present invention will be obvious to those skilled in the art and it is intended to cover in the appended claims all such modifications and equivalents. The entire disclosures of all references, applications, patents, and publications cited above are hereby incorporated by reference.