Patent Description:
Spray caps with a locking member to prevent accidental activation of an actuator are known and are readily available for use with an aerosol container. An aerosol container may be defined as a container adapted to contain a payload and a propellant which are to be expelled from the container through a dispensing mechanism; thereby forming an aerosol. Typically the container for such aerosol applications is found to be a metal cylinder, though containers made of glass and/or other shapes are also conceivable. The expelled aerosol may pertain to e.g. a hairspray, a deodorant or another similar product. In practice the dispensing mechanism on aerosol containers tends to comprise a valve stem. Pressing on the valve stem opens an associated valve and releases the aerosol from the container into the spray channel.

Such a spray cap with a locking member to prevent accidental activation of an actuator is for example known from <CIT>. In this document a spray cap is disclosed with a hinging nozzle locking member with two projections. One of these projections, when engaged with an actuator recess internal to the spray cap, prevents activation of the actuator, as a result of which pressing down on the actuator does not lead to discharge of the aerosol. The nozzle locking member is attached to a cap body by means of a hinge, such that the locking member itself can easily be inserted or removed from the cap body.

This known solution has the effect of preventing accidental discharge during e.g. transport of the aerosol containers, which may be either in a commercial or a personal capacity. However, the known spray caps with such locking members are currently complex products which require multiple parts and/or elaborate assembly procedures, like for example the locking member of <CIT> which is a separate part connected to the spray cap. In producing large quantities of spray caps, this may pose a problem for facilities in that multiple production lines or e.g. complex multi-cavity moulds for said multiple parts, and/or elaborate assembly lines would be required.

Additionally, the known solution of <CIT> provides a challenge for the consumer in that they have to open or close the locking mechanism before and after every use of the product. For everyday use this may be considered an unnecessary act, as then it is unlikely that one would need to prevent accidental discharge on a continuous basis. Hence it may be annoying for the consumer to have to repeatedly perform this act.

<CIT> shows in Fig. <NUM> thereof a rotatable cap member having receiving parts with which a mode can be selected. The receiving parts determine the depressible depth of the actuator. One of the receiving parts forms a locking member associated with a lock mode and corresponds to blocking a depression of the actuator.

<CIT>, on which the preamble of claim <NUM> is based, discloses a spray cap having a blocking member that is pivotably connected to an annular base part.

It is an object of the invention to provide a spray cap that offers the advantage of preventing accidental discharge, yet in a manner simple and elegant for the manufacturer and/or the consumer.

This object is achieved by a spray cap for an aerosol container according to claim <NUM>.

The spray cap according to the invention is monolithically formed, thus in one piece, including the locking member and the actuating member, wherein the locking member directly and solely engages with the actuating member to restrict movement of said actuating member, thereby preventing accidental discharge of the dispensing mechanism on the container.

The cap body comprises a snap member to hold the locking member when it is in its releasing position. This characteristic provides support to the locking member in its releasing state, which prevents the locking member from needlessly moving about. In addition it aids in the ease of operating the locking member in that it (<NUM>) provides a reliable feel on the locking member and (<NUM>) defines two distinct positions of the locking member either being engaged, or disengaged. In a more specific embodiment the snap member may be formed as a holding protrusion to hold the locking member when it is in its releasing position. This embodiment still providing an element simple to produce.

As a result of the one-piece spray cap no separate parts are needed for the actuating or locking mechanisms. This is advantageous in that only one part will have to be produced, and that no further assembly of the spray cap itself would be required. Only one single mould would be required for injection moulding the spray cap.

Also is noted that for the current one-piece solution there would not be any separate small plastic parts that could result in environmental pollution, as the consumer does not have to discard the locking member after first releasing it from its locking position. The spray cap according to the current invention hence has an advantage over a spray cap using e.g. a tear-off tamper-evident or otherwise expendable locking mechanism.

Another advantage is that the locking member is directly connected to the actuating member to restrict movement thereof. The spray nozzle can only be in fluid communication with the interior of the container when the actuating member is activated through pressing downward on the actuating member. As such, no further mechanisms or parts, like for example a cap or a lid for the spray nozzle, would be required to prevent accidental discharge.

In a possible embodiment, the spray nozzle and the first flexible connection are located on one side of the spray cap, and the locking member engages with the actuating member substantially on an opposite side of the spray cap. This provides the advantage of the locking member, when in its locking position, having to withstand the smallest possible moment with respect to a downward pressing motion applied on the actuating member. This leads to a sturdy locking feature, even if the spray cap is made of a plastic material.

The first flexible connection may be a connection that is also elastic and/or resilient, thereby allowing the actuating member to not only pivot, but also to spring back once the consumer releases the actuating member after use.

In yet another possible embodiment, the engagement between the locking member and the actuating member is formed as a latching mechanism. This yields a locking engagement easy to operate and simple to produce, whilst also providing a sturdy engagement for potential repetitive use. Alternative embodiments may use e.g. a male-female connection or a snap connection.

In a further practical embodiment, the locking member is formed as a flap having a curved tongue. This leads to a structure with increased bending stiffness, which prevents deflection of the locking member due to the application of a downward pressing motion when operating the actuating member in the locking position. Other embodiments may include tongues with other suitable geometries, e.g. a straighter beam or a latch of a more round nature, provided that these tongues may be received within a latching recess of the latching mechanism.

In another practical embodiment, the actuating member defines a latching recess, such that the recess can receive the curved tongue, in a latching manner.

In an embodiment, the tongue has a tip region which - in the locking position of the locking member - is in engagement with an interior wall member extending downwardly from an upper side of the actuating member, such that bending of the tongue is counteracted. This provides additional stiffness to the structure in the locked position.

In another embodiment, the curved tongue has a summit region such that in receiving the curved tongue in a latching manner the summit region, at the tip region, forms a pre-guiding surface during movement of the tongue through the recess from the releasing position to the locking position.

In yet another embodiment, at an end of the flap an abutment ridge is formed, wherein the abutment ridge abuts - in the locking position of the locking member - a rear side surface of the actuating member above the recess such that a force of the locking member on the actuating member is perpendicular to the pushing-down direction of the actuating member. The rear side surface thus forms a stop for the swivelling movement of the locking member in a plane parallel to the axial movement of the spray tube and the stem. Thereby, if the locking member is pushed further inward, the force of the locking member on the actuating member will be perpendicular to the pushing-down direction of the actuator, such that the actuator member will not be pushed down and inadvertent operation of the dispensing mechanism of the aerosol container is prevented, while locking the spray cap assembly.

In a practical embodiment the locking member comprises an exterior surface, which, when the locking member is in its locking position, is flush with - or lying recessed with respect to - an outer contour of the cap body. This is advantageous in that the locking mechanism cannot easily be affected - e.g. accidentally opened - by potential contact of the spray cap with other items during transport.

Similarly, in another embodiment, the actuating member is advantageously flush with - or lies recessed with respect to - an outer contour of the cap body. This may lead to preventing accidental pressure on the actuating member when e.g. stacking multiple aerosol containers with spray caps during transport.

In another embodiment the spray cap comprises a second flexible connection, formed between the locking member and the cap body, such that the locking member is able to pivot relative to the cap body.

In a further possible embodiment, the second flexible connection is formed as a living hinge. This is advantageous as it allows the locking member to be monolithically formed with the cap body, whilst also being simple to produce.

In a practical embodiment of the spray cap according to the invention, the spray cap is made by injection moulding from a plastic material, or another suitable material.

The invention also relates to a method for manufacturing the spray cap as described in the above, wherein he spray cap is injection moulded from a plastic material, in particular a thermoplastic resin comprising PE and/or PP.

These and other aspects of the invention will be more readily appreciated as these become better understood by reference to the following detailed description and considered in connection with the accompanying figures. In these figures like reference symbols designate like parts.

In <FIG> is shown a one-piece spray cap <NUM> mounted on an aerosol container <NUM>. The aerosol container <NUM> in this specific embodiment is formed as a cylinder <NUM> with a tapered area <NUM> at the top. However other cross-sections and/or shapes of the aerosol container <NUM>, such as rectangular, elliptical or spherical, may also be conceivable.

The spray cap <NUM> comprises a cap body <NUM>, an actuating member <NUM> that is monolithically formed with the cap body <NUM> and a spray nozzle <NUM>.

The cap body <NUM> comprises a skirt <NUM> and two radially opposing spaced apart side cheeks <NUM>, <NUM>. The side cheeks <NUM>, <NUM> are integral with the skirt <NUM> and extend upwardly therefrom. The side cheeks <NUM>, <NUM> define between them a space which is shielded laterally by the side cheeks <NUM>, <NUM> and which is open at a front and rear side of the cap body <NUM>.

The skirt <NUM> and the side cheeks <NUM>, <NUM> define an outer contour of the cap body <NUM>. The actuator member <NUM> is arranged in the space between the side cheeks <NUM>, <NUM> in such a manner that the actuator member does not extend beyond the outer contour of the cap body <NUM>. Thereby the risk that the actuator member <NUM> is unintentionally operated, during transport for example, is reduced. The actuator member <NUM> thus does not extend beyond the upper side of the side cheeks <NUM>, <NUM>. Furthermore, the actuator member <NUM> has a front side 135A and a rear side 135B, which do not extend beyond front and rear edges of the side cheeks <NUM>, <NUM>.

The spray nozzle <NUM> is arranged in the actuator member <NUM> at a front side thereof. In the embodiment shown in the figures the nozzle <NUM> is arranged in an upper end region <NUM> of the front side 135A of the actuator member <NUM>.

It should be noted that the spray nozzle <NUM> does not necessarily have to be located at the upper end region <NUM> of the front side 135A. It may equally be located elsewhere along front side 135A.

In <FIG> is shown a cross-section through the spray cap <NUM> of <FIG>. As can be seen in these figures, and also in <FIG>, the spray cap <NUM> comprises a locking member <NUM> that is monolithically formed with the cap body <NUM>. The locking member <NUM> is formed as a flap <NUM> having a tongue <NUM> protruding from a flap inner side 161A.

The spray cap <NUM> has a first flexible connection C1 that is located between the cap body <NUM> and the front side 135A of the actuator member <NUM>, and a second flexible connection C2 that is located between the locking member <NUM> and the cap body <NUM>.

The side cheek <NUM> of the cap body <NUM> has an inner side <NUM>, on which a holding protrusion <NUM> is formed. The holding protrusion <NUM> is located on the same side of the spray cap <NUM> as the locking member <NUM>. The holding protrusion <NUM> is shown to be of a shape with a top part <NUM> of the holding protrusion <NUM> extending further outward from the cap body <NUM> in comparison with a bottom part <NUM> of the holding protrusion <NUM>. It should be noted that many shapes, such as a rectangular, triangular, a rounded or an L-shaped protrusion may be conceivable.

The actuating member <NUM> includes a latching recess <NUM> formed at a rear side <NUM> of the actuating member <NUM>. The latching recess <NUM> extends vertically from a lower edge <NUM> of the actuating member <NUM> upwardly and extends transverse thereto over a larger part of the width of the rear side <NUM> of the actuating member <NUM>.

The actuating member <NUM> comprises an extra structural interior wall member <NUM> extending downwardly from the upper side of the actuating member <NUM> as can be seen in <FIG>.

A spray tube <NUM> is integrally formed on an inner side of the actuator member <NUM>. The spray tube <NUM> partially extends, at least at a lower end thereof, coaxially with the centre axis of the skirt <NUM>. In an upright position of the container <NUM>, the spray tube <NUM> extends downwardly in a substantially vertical direction from the inner surface of the curved front side 135A of the actuator member <NUM>.

The aerosol container <NUM> has a dispensing mechanism arranged at an upper end <NUM> of the container <NUM>. The dispensing mechanism includes a commonly known valve stem <NUM>. The lower end portion of the spray tube <NUM> is arranged in a fitting and sealing manner over an upper end portion <NUM> of the valve stem <NUM> when the spray cap is mounted on the aerosol container. The spray tube <NUM> defines a spray channel <NUM> which is in fluid communication with the spray nozzle <NUM> arranged at an upper end <NUM> of the spray channel <NUM>.

The aerosol container <NUM> comprises a rim <NUM>, arranged at an upper end <NUM> of the container <NUM>. In the mounted state the skirt <NUM> of the cap body <NUM> is arranged over the rim <NUM> as is visible in <FIG> and engages the rim <NUM> from an outer side. At least at a front side of the cap body <NUM> an inner skirt portion <NUM> is formed which engages an inner side of the rim <NUM>. The cap body <NUM> is at least fixed to the upper end <NUM> of the container <NUM> by one or more locking ribs <NUM> formed in the circumferential direction on the inner side of the skirt <NUM>, which rib or ribs <NUM> engage under the rim <NUM> when the cap body <NUM> is pushed on the top side of the container <NUM>. The rib or ribs <NUM> prevent easy removal of the cap body <NUM> from the container <NUM>.

The first flexible connection C1 in <FIG> is shown to comprise a connection wall <NUM> extending in a substantially lateral direction in between the inner skirt portion <NUM> and an inwardly extending rib <NUM> formed on the actuator member <NUM>. The inner skirt portion <NUM> and the rib <NUM> provide a reinforcing effect on both ends of the connection wall <NUM>, whereby, when the actuator member <NUM> is pressed down by a user, all or at least a major part of the deformation takes place in the connection wall <NUM> which thereby functions as a well-defined hinge. The actuator member <NUM> pivots with respect to the cap body <NUM> around this hinge, as depicted in the operated state in <FIG>. Alternatively this first flexible connection C1 could also be formed as a living hinge, or another suitable flexible connection.

The second flexible connection C2 in <FIG>, i.e. the connection between the locking member <NUM> and the cap body <NUM> is formed as a living hinge. Alternatively this could be another suitable flexible connection. The locking member <NUM> is pivotally attached to the cap body <NUM> by means of the second flexible connection C2 between the locking member <NUM> and the cap body <NUM>, on a side opposite to the spray nozzle <NUM>, thus on the rear side of the spray cap <NUM>. The locking member <NUM> has two distinct positions between which the locking member <NUM> can pivot with respect to the cap body <NUM> which may be explained with reference to <FIG>: a releasing position and a locking position.

In <FIG> the locking member <NUM> is shown in the releasing position in which the flap <NUM> lies on an exterior surface <NUM> of a rear wall portion <NUM> of the cap body <NUM>. It is noted that there are embodiments conceivable in which the flap <NUM> does not lie flat on the exterior surface <NUM>, but is maintained in another position. This forms an elegant embodiment of the releasing position. The rear wall portion <NUM> is inclined with respect to the skirt <NUM> and extends inwardly therefrom. When the flap lies flat on the surface <NUM> the locking member <NUM> does not extend beyond the cap body contour as determined by the skirt <NUM>, when it is in the releasing position. This forms a practical and elegant solution, wherein a user is as less as possible hindered by the locking member <NUM> in the releasing position when he operates the actuator member <NUM>.

Here, the locking member <NUM> is shown to be kept in its releasing position relative to the cap body <NUM> by the holding protrusion <NUM>. The locking member <NUM> is clamped between the holding protrusions <NUM>, or alternative may snap behind it in the releasing position. Multiple protrusions may also be used to keep the locking member <NUM> in its relative position with respect to the cap body <NUM>, e.g. protrusions extending from the cap body <NUM> on either side of the locking member <NUM> when considering its horizontal direction. Alternatively, any other suitable snap member could be used.

In <FIG> the locking member <NUM> is shown in the locking position. The tongue <NUM> of the locking member <NUM> engages the latching recess <NUM>. In the locking position at least a part of the upper side of the tongue <NUM> engages an upper edge of the latching recess <NUM>, whereby movement of the actuator member <NUM> in the downward direction is blocked without any play, such that actuating of the stem valve is prevented.

An exterior surface <NUM> of the locking member <NUM> in this embodiment is advantageously flush with the cap body <NUM>, which gives the cap <NUM> a smooth visual appearance when it is in the unused state, which may make the combination of container and cap more attractive, e.g. when it is on display in retail. In another preferred embodiment the exterior surface <NUM> may also lie recessed with respect to cap body <NUM> in the locking position. In another possible embodiment the exterior surface <NUM> may extend outward from the contour as determined by the cap body <NUM> in the locking position.

The actuating member <NUM> is pivotably attached to the cap body <NUM> by means of the first flexible connection C1, such that the actuating member <NUM> can pivot relative to the cap body <NUM>. The actuating member <NUM> can pivot with respect to the cap body <NUM> may be explained with reference to <FIG> and <FIG>.

In <FIG> the actuating member <NUM> is shown in a neutral state in which the actuating member <NUM> is unaffected and arranged such that the spray tube <NUM>, extending from an inner side of the actuating member <NUM>, does not press down on the valve stem <NUM>.

In <FIG> is shown a cross-section through the spray cap of <FIG> mounted on an aerosol container, in an operated state. The locking member <NUM> is in its releasing position. The actuating member <NUM> is shown in an operated state in which it is pressed down. In this operated state the actuating member <NUM> is pivoted relative to the cap body <NUM> - at and by means of the first flexible connection C1 - by applying a downward pressing force P1 on the relatively flat operating surface of the actuating member <NUM>. As a result the actuating member <NUM> and the spray tube <NUM> are displaced downwardly, i.e. in the direction of the aerosol container <NUM>. The spray tube <NUM> then presses down the valve stem <NUM>, which opens a valve in the dispensing mechanism of the aerosol container and releases the aerosol in a commonly known manner through the valve stem <NUM>. The valve stem <NUM> dispenses the aerosol from the aerosol container <NUM> into the spray channel <NUM>, and subsequently into and outward from spray nozzle <NUM>.

Due to the actuating member <NUM> pivoting relative to the cap body <NUM> by means of the first flexible connection C1 the spray tube <NUM>, the actuating member <NUM> and the inner portion <NUM> can be seen to tilt with respect to the cap body <NUM>. This is in addition to the downward displacement. It should be appreciated that the tilting movement is not a necessary feature to operate the dispensing mechanism <NUM>.

The interior wall member <NUM> provides additional stiffness which prevents that the actuator member will deform itself too much instead of that the deformation takes place at the connection C1. Moreover, the additional stiffness facilitates that when the actuator member <NUM> is locked by the locking member <NUM>, and the actuating member <NUM> is inadvertently pressed down, the spray tube <NUM> does not move down, due to deformation of the actuating member <NUM> itself, to an extent in which it operates the valve stem <NUM>.

In the locking position shown in <FIG> the engagement between the locking member <NUM> and the actuating member <NUM> is formed as a latching mechanism. The actuating member <NUM> defines the latching recess <NUM>, such that the recess <NUM> can receive the curved tongue <NUM> of the locking member. It should be noted that this is only one embodiment for a latching mechanism. It is also conceivable for the locking member <NUM> to define a latching recess for the actuating member <NUM> to latch on to. Alternatively, other such connections, e.g. male-female connections or snap connections, may also be used to engage the locking member <NUM> and actuating member <NUM>.

In an embodiment not shown a holding recess is provided at an upper end of the inner side <NUM> of the cheek <NUM> and/or at an upper end of the inner side of the cheek <NUM> such that the locking member <NUM> can snap into the holding recess. Thereby, the snap connection between the locking member <NUM> and the holding recess retains the locking member in its distinct locking position relative to the cap body <NUM>. This snap connection may be used in addition to a latching mechanism as shown in <FIG>.

In the releasing position shown in <FIG> the locking member <NUM> and actuating member <NUM> can be seen to be disengaged. This allows movement of the actuating member <NUM> relative to the cap body <NUM>, from the neutral state to the operated state.

In the locking position shown in <FIG> the locking member <NUM> engages with the actuating member <NUM>. This restricts movement of the actuating member <NUM> relative to the cap body <NUM>. In the current embodiment the locking member <NUM> engages with the actuating member <NUM> on a side opposite to the spray nozzle <NUM>.

In this specific embodiment of the spray cap <NUM> the latching mechanism is located most remotely from the flexible connection C1. This leads to the locking member <NUM> having to withstand the smallest force possible, should the actuating member <NUM> accidentally be operated when in the locking position. It should be noted that this is not essential with respect to restricting movement of the locking member <NUM> when in the locking position. It should be appreciated that this location can be varied along the circumference of the cap body <NUM>.

In <FIG> is shown a view in perspective of a spray cap <NUM> according to the invention, for which the locking member <NUM> is in its releasing position. The locking member <NUM> is shown to be formed as a flap <NUM> having a curved tongue <NUM> extending from an inner side of the flap. The curved geometry of the tongue <NUM> leads to increased bending stiffness, which prevents deflection of the tongue <NUM> due to the application of a downward pressing motion P1 on the actuating member <NUM> while the locking member <NUM> is in the locking position. This increased rigidity of the tongue <NUM> prevents, or at least limits, deformation of the tongue <NUM> when in a locked position the actuating member <NUM> is pressed down. This prevents that through deformation of the tongue <NUM> the actuating member <NUM> would still be able to operate the valve stem <NUM> and cause a release of the aerosol. Although the curved shape of the tongue is considered a simple and elegant solution to increase the rigidity of the locking member <NUM>, also other features are conceivable which increase the rigidity of the locking member <NUM>.

At an end of the flap <NUM> an abutment ridge <NUM> is formed. This abutment ridge <NUM> abuts, in the locking position of the locking member <NUM>, the rear side surface <NUM> of the actuating member <NUM> above the latching recess <NUM> as can be seen in <FIG>. The rear side surface <NUM> thus forms a stop for the swivelling movement of the locking member in a plane parallel to the axial movement of the spray tube <NUM> and the stem <NUM>. Thereby, if the locking member <NUM> is pushed further inward, the force of the locking member <NUM> on the actuating member <NUM> will be perpendicular to the pushing-down direction of the actuator, such that the actuator member <NUM> will not be pushed down and inadvertently operation of the dispensing mechanism of the aerosol container <NUM> is prevented, while locking the spray cap assembly.

Claim 1:
A spray cap (<NUM>) for an aerosol container (<NUM>) having a dispensing mechanism (<NUM>) at the top of the container, the spray cap comprising:
- a cap body (<NUM>) adapted to be mounted on the aerosol container;
- a duct defining a spray channel (<NUM>) and having a spray nozzle (<NUM>) at one end, and when the spray cap is mounted on the aerosol container, connected with the dispensing mechanism of the aerosol container;
- an actuating member (<NUM>) coupled with the duct, such that operation of the actuating member, when the cap body is mounted on the container, activates the dispensing mechanism to release the aerosol into the spray channel and towards the spray nozzle, wherein the actuating member (<NUM>) is monolithically formed with the cap body (<NUM>), and wherein the actuating member (<NUM>) is pivotably attached to the cap body (<NUM>) by means of a first flexible connection (C1), such that the actuating member (<NUM>) is able to pivot relative to the cap body (<NUM>), and
- a locking member (<NUM>) pivotably attached to the cap body, which locking member has a locking position in which it restricts movement of the actuating member relative to the cap body and a releasing position in which it allows movement of the actuating member relative to the cap body, wherein the locking member (<NUM>) is monolithically formed with the cap body (<NUM>), wherein, in the locking position, the locking member (<NUM>) and the actuating member (<NUM>) are in engagement, and in the releasing position the locking member (<NUM>) and actuating member (<NUM>) are disengaged,
characterised in that
- the cap body (<NUM>) comprises a snap member to hold the locking member (<NUM>) when it is in its releasing position.