Patent Description:
Various volatile material dispensers are known in the prior art and generally include a housing with a refill inserted therein. The refill generally includes a container for holding a volatile material therein. In some dispensers, the volatile material is passively emitted therefrom. In other dispensers, a diffusion element is utilized to facilitate the dispensing of the volatile material. Examples of diffusion elements include heaters, piezoelectric elements, fans, aerosol actuators, and the like. Regardless of the manner in which the volatile material is emitted, once the volatile material has been expended from the refill, the refill is removed by a user and replaced with a new refill.

One type of volatile material dispenser, referred to herein as a plug-in dispenser, includes a housing and a heater disposed within the housing. A refill for use with a plug-in dispenser generally includes a container with a volatile material therein and a wick in contact with the volatile material and extending out of the refill. Upon insertion of the refill into the dispenser, at least a portion of the wick is disposed adjacent the heater such that volatile material that moves through the wick is volatilized by the heater. The volatile material dispenser typically includes a plug assembly having electrical prongs extending outwardly from the housing. The electrical prongs are inserted into a standard electrical outlet and thereafter supply electrical energy to the volatile material dispenser.

A volatile material dispenser is known from document <CIT> consists of a volatile material container with a cylindrical neck. A generally flat wick extends from volatile material in the container up the neck and out through an opening at the top of the neck. The wick is supported in the opening by a cage consisting of vertical supports and horizontal fins which extend from the wick to the wall of the opening. The cage is an interference fit in the opening allowing the wick to be pulled up to allow exposure of a desired length of the wick above the opening. The gap between fins is selected to minimize the chance of a person touching the bare wick.

The invention provides a refill as defined in claim <NUM> below. Optional features of the invention are set out in the dependent claims.

Other aspects and advantages of the present invention will become apparent upon consideration of the following detailed description, wherein similar structures have like or similar reference numerals.

The present disclosure is directed to volatile material dispensers. While the present invention may be embodied in many different forms, several specific embodiments are discussed herein with the understanding that the present disclosure is to be considered only as an exemplification of the principles of the invention, and it is not intended to limit the invention to the embodiments illustrated.

Referring to the drawings, <FIG> depict a first embodiment of a volatile material dispenser <NUM>. The dispenser <NUM> generally includes housing <NUM> comprised of top and bottom portions <NUM>, <NUM> that are joined to form the housing <NUM>. The housing <NUM> could optionally be made of any number of pieces. As best seen in <FIG> and <FIG>, the housing <NUM> generally includes a discontinuous oval-shaped wall <NUM> with a front surface <NUM>, a rear surface <NUM>, and first and second opposing curved side surfaces <NUM>, <NUM>. A bottom of the wall <NUM> is not enclosed, thereby forming a cavity <NUM> for insertion of a refill <NUM>, as seen in <FIG>. A gap <NUM> is formed between edges <NUM>, <NUM> of the wall <NUM>, wherein a groove is formed within the gap <NUM>. The housing <NUM> further includes an inset top surface <NUM> connecting the front, rear, and side surfaces <NUM>, <NUM>, <NUM>, <NUM>, wherein an emission aperture <NUM> is formed within a central portion of the top surface <NUM>.

Referring to <FIG>, an insert <NUM> is detachably attached within the inset top surface <NUM> and the gap <NUM>. In particular, the insert <NUM> includes a top wall <NUM> that curves into a side wall <NUM> that is generally perpendicular to the top wall <NUM>. The top wall <NUM> includes first and second latches <NUM> with outwardly extending hooks <NUM> that extend into apertures <NUM> formed at an outer edge of the top surface <NUM> of the housing <NUM>. The side wall <NUM> also includes a latch <NUM> having two outwardly extending projections <NUM> that engages a groove <NUM> disposed within the gap <NUM>, wherein the groove <NUM> has a width W1 that is greater than a width W2 of a middle section <NUM> of the latch <NUM>, but less than an overall width W3 of the latch <NUM>. In this manner, the projections <NUM> prevent removal of the insert <NUM>.

The insert <NUM> is attached to the housing <NUM> by inserting the middle section <NUM> of the latch <NUM> into the groove <NUM> and, thereafter, snapping the hooks <NUM> into the apertures <NUM>. The insert <NUM> may be removed in an opposite manner. In particular, a user may pull upwardly on the insert <NUM> such that the hooks <NUM> are removed from the apertures <NUM> and thereafter, move the insert <NUM> downwardly such that the latch <NUM> is removed from the groove <NUM>. The dispenser <NUM> may be provided with one or more inserts <NUM> and/or inserts <NUM> may be sold separately. In this manner, users may use no insert <NUM> or may attach any number of different inserts <NUM>, depending on home décor, the day of the week, the user's emotions, or for any other reason.

Referring to <FIG>, <FIG>, and <FIG>, an outer side <NUM> of the top wall <NUM> of the insert <NUM> includes one or more flexible designs or indicia <NUM> that indicate to a user an intensity level for the dispenser <NUM>. In particular, in one embodiment, each of the indicia <NUM> includes one or more concentric circles. An intensity level is indicated by the number of circles, for example, fewer circles designates a lower intensity and more circles designates a higher intensity.

As seen in <FIG>, an inner side <NUM> of the top wall <NUM> includes one or more features <NUM> that project from the inner side <NUM> of the top wall <NUM> to enclose one or more LEDs <NUM> within the housing <NUM>. When a particular intensity level is selected by a user, the LED <NUM> associated with the indicia <NUM> for that level is illuminated.

In a further embodiment, the top wall <NUM> adjacent the indicia <NUM> is thinned so that light projected from the LEDs <NUM> may be visible through the thinned areas. In such an embodiment, the features <NUM> may or may not be present.

Referring to <FIG>, a plug assembly <NUM> is disposed between the top and bottom portions <NUM>, <NUM> of the housing <NUM> at a rear portion <NUM> of the housing <NUM>. The plug assembly <NUM> includes two electrical prongs <NUM> adapted for insertion into a conventional outlet. While the plug assembly <NUM> is shown as being a conventional plug assembly for the United States, a plug assembly adapted for use in any other country may be utilized. In addition, the plug assembly <NUM> may include any features known in the art, for example, the plug assembly <NUM> may be partially or fully rotatable.

A button <NUM> extends outwardly from the first side surface <NUM>, as seen in <FIG>. The button <NUM> is adapted to actuate a switch <NUM> (as seen in <FIG>) within the housing <NUM> and connected to a circuit board <NUM> (see <FIG>) to set an intensity level of the dispenser <NUM>. In particular, the button <NUM> may be pressed once for low, twice for medium, three times for high, four times for off, five times for low, and so on. As seen in <FIG>, a slide switch <NUM> extends outwardly from the second side surface <NUM> of the housing <NUM> to control a mode of the dispenser <NUM>. One or more arms <NUM> extend from a rear surface <NUM> of the sliding member <NUM> for communication with a rocker switch <NUM> within the housing <NUM> and connected to the circuit board <NUM>. The operation of the switch <NUM> and the rocker switch <NUM> will be discussed in greater detail hereinafter.

A first embodiment of a heater assembly <NUM> for use within the dispenser <NUM> is best seen in <FIG>. The heater assembly <NUM> includes a generally rectangular heating block <NUM> having a central cylindrical channel <NUM> and cavities <NUM> disposed on opposite sides of the channel <NUM>. Resistors <NUM> have a power rating of about <NUM> watts each, although resistors <NUM> with different power ratings may be used. The resistors <NUM> are disposed within the cavities <NUM> and the resistors <NUM> are potted in a ceramic or other conductive material to retain the resistors <NUM> within the cavities <NUM> and conduct heat throughout the heating block <NUM>.

Referring to <FIG>, a first resistor lead <NUM> includes a first section <NUM> that extends outwardly from a first side <NUM> of each resistor <NUM> and a second section <NUM> that extends generally transverse to the first section <NUM>. Each of the second sections <NUM> extends toward the other resistor <NUM>. The second sections <NUM> of the resistor leads <NUM> are overlapped and spliced together at splices <NUM>. A second resistor lead <NUM> extends from a second side <NUM> of each resistor <NUM> and is electrically connected to the circuit board <NUM>, which will be discussed in greater detail hereinafter.

The heater assembly <NUM> is disposed atop a support <NUM> that is connected to or integral with the housing <NUM> of the dispenser <NUM>. The support <NUM> has a generally cylindrical profile, but may have any other profile that provides support to the heater assembly <NUM>. A generally cylindrical channel <NUM> extends through the support <NUM> for insertion of a wick of a refill <NUM>, as will be discussed in detail below. The support <NUM> and/or heater assembly <NUM> may also include one or more features that attach the heater assembly <NUM> to the support <NUM> or otherwise prevent the heater assembly <NUM> from movement within the housing <NUM>. In one embodiment, as seen in <FIG> and <FIG>, the heater assembly <NUM> includes an outwardly extending platform <NUM> having a U-shaped groove <NUM> in an edge thereof, wherein a cylindrical projection <NUM> extending upwardly from the support <NUM> sits within the groove <NUM> to prevent side-to-side movement of the platform <NUM>.

The circuit board <NUM> is best seen in <FIG> and <FIG>. As noted above, the switch <NUM> and the rocker switch <NUM> are electrically connected to the circuit board <NUM>. When the rocker switch <NUM> is in a first position, a first mode is actuated in which a cycle includes operating the dispenser <NUM> for <NUM> hours and turning the dispenser <NUM> off for <NUM> hours. Similarly, when the rocker switch <NUM> is disposed in a second position, a second mode is actuated in which a cycle includes operating the dispenser <NUM> for <NUM> hours and turning the dispenser <NUM> off for <NUM> hours. Once a cycle of <NUM> hours on and <NUM> hours off or <NUM> hours on and <NUM> hours off is completed, the dispenser <NUM> automatically continues with a further cycle. This cycling continues until power to the dispenser <NUM> is interrupted. While two modes are disclosed, any number of modes may be utilized.

The button <NUM>, as noted above, is pressed by a user to actuate the switch <NUM> and change the intensity at which the volatile material in the refill <NUM> is emitted. In particular, upon a first depression of the button <NUM>, the dispenser <NUM> is set at a first, high intensity level. Similarly, when the switch <NUM> is actuated a second time, the dispenser <NUM> is set at a second, medium intensity level and upon a third actuation, the dispenser <NUM> is set at a third, low intensity level. As one skilled in the art would understand, the number of actuations corresponding to the various intensity levels may be modified without departing from the spirit of the present invention.

The first intensity level is a high level. Upon initiation of each of the first, second, and third intensity levels, the resistors <NUM> are operated at <NUM>% of their power rating for a first period of time preferably between about <NUM> minutes and about <NUM> minutes, more preferably between about <NUM> minutes and about <NUM> minutes, and most preferably about <NUM> minutes to quickly increase the heat within the resistors <NUM>. At the high/first intensity level, after the first period of time, the resistors <NUM> are operated at <NUM>% of their power rating for the remainder of the on cycle. At the medium/second intensity level, after the first <NUM> minutes, the resistors <NUM> are operated at <NUM>% of their power rating for a second period of time that is preferably between about <NUM> hours and about <NUM> hours, more preferably between about <NUM> hours and about <NUM> hours, and most preferably about <NUM> hours and, thereafter, are operated at <NUM>% of their power rating for the remainder of the on cycle. At the low/third intensity level, after the first period of time, the resistors <NUM> are operated at <NUM>% of their power rating for a third period of time that is preferably between about <NUM> minutes and about <NUM> minutes, more preferably between about <NUM> minutes and about <NUM> minutes, and most preferably about <NUM> hour and, thereafter, are operated at <NUM>% of their power rating for the remainder of the on cycle. These algorithms are repeated for every on cycle.

As noted above, the resistors <NUM> are electrically connected to the circuit board <NUM> by the second resistor leads <NUM>. The circuit board <NUM> is programmed to operate the resistors <NUM> in different manners per the switch <NUM> and the rocker switch <NUM>, as described in detail above.

As further seen in <FIG> and <FIG>, the LEDs <NUM> are electrically connected to and extend upwardly from the circuit board <NUM>. The LEDs <NUM> reside within the features <NUM> or at least adjacent the indicia <NUM> such that the LEDs <NUM> illuminate a respective indicia <NUM> to indicate which intensity level is being operated.

As noted above, the cavity <NUM> is formed by the housing for insertion of a refill <NUM> therein. A small-sized refill <NUM> is depicted in <FIG> and generally includes a container <NUM> with a volatile material therein, wherein the container is adapted to be retained within the housing <NUM>. The container <NUM> includes a body <NUM> having a base portion <NUM>, opposing front and rear walls <NUM>, <NUM> extending upwardly from the base portion <NUM>, and opposing side walls <NUM>, <NUM> connecting the front and rear walls <NUM>, <NUM> and extending upwardly from the base portion <NUM>. The front and rear walls <NUM>, <NUM> are generally planar and each of the side walls <NUM>, <NUM> includes first and second generally planar wall sections <NUM>, <NUM> connected by a curved section <NUM>.

Still referring to <FIG>, the front, rear, and side walls <NUM>, <NUM>, <NUM>, <NUM> at a shoulder portion <NUM> that leads into a neck <NUM>. The neck <NUM> is generally cylindrical, has a threading <NUM> on an outer surface of the neck <NUM> for attachment of a cap <NUM> and/or attachment to a dispenser, and forms an opening <NUM>. A wick holder <NUM> is disposed within the neck <NUM> for holding a wick <NUM>.

As seen in <FIG>, the wick holder <NUM> includes a first generally cylindrical wall <NUM> connected to a second generally cylindrical wall <NUM> by an angled wall <NUM>. An annular wall <NUM> extends outwardly from and is generally orthogonal to the first cylindrical wall <NUM> to form a ledge or abutment. Referring to <FIG>, a first plurality of angled fins <NUM> extend along an inner surface <NUM> of the curved wall <NUM> to give the inner surface <NUM> of the curved wall <NUM> a frustroconical shape. As seen in <FIG>, a second plurality of angled fins <NUM> extend along an outer surface <NUM> of the wick holder <NUM> from a central portion of the curved wall <NUM> to a central portion of the second cylindrical wall <NUM>. The second plurality of angled fins <NUM> forms have a profile that is generally frustroconical in shape.

Referring to <FIG>, one or more projections <NUM> extend outwardly from an outer surface <NUM> of the first cylindrical wall <NUM> of the wick holder <NUM>. The projections <NUM> are formed by two angled walls <NUM> and a planar wall <NUM> connecting the angled walls <NUM>. Upon insertion of the wick holder <NUM> into the neck <NUM> of the refill <NUM>, the projections <NUM> form an interference fit with the neck <NUM> to provide resistance to extraction of the wick holder <NUM>. In addition, the first plurality of angled fins <NUM> engage the material of the wick <NUM> to retain the wick <NUM> within the wick holder <NUM>.

A medium-sized refill <NUM> is depicted in <FIG> and is identical to the small-sized refill <NUM> of <FIG>, except that the medium-sized refill <NUM> is taller. A large-sized refill <NUM> is depicted in <FIG> and is similar to the refills of <FIG> and <FIG>, except that the front and rear walls <NUM>, <NUM> also include first and second generally planar wall sections <NUM>, <NUM> connected by a curved section <NUM>, wherein the curved section <NUM> is connected to and continuous with the curved section <NUM> of the side walls <NUM>, <NUM>.

The volatile material disposed in the container <NUM> of any of the refills <NUM> herein may be any type of volatile material adapted to be dispensed into an environment. For example, the container <NUM> may include a cleaner, an insecticide, an insect repellant, an insect attractant, a disinfectant, a mold or mildew inhibitor, a fragrance, a disinfectant, an air purifier, an aromatherapy scent, an antiseptic, an odor eliminator, a positive fragrancing volatile material, an air-freshener, a deodorizer, or the like, and combinations thereof. Additives may be included in the volatile material, such as, for example, fragrances and/or preservatives.

As seen in <FIG>, the dispenser <NUM> includes opposing resilient latches <NUM> extending downwardly from the support <NUM>. As further seen in <FIG>, the latches <NUM> are capable of holding the small-sized, medium-sized, and large-sized refills <NUM> of <FIG> in two different manners. First, each refill <NUM> may be inserted such that the threading <NUM> is in contact with the latches <NUM> and the refill <NUM> can thereafter be turned to full insert the refill <NUM>. Secondly, each refill <NUM> may be inserted upwardly, pushing the latches <NUM> outwardly, wherein the latches <NUM> grasp and retain the refill <NUM> by an annular ledge <NUM> disposed below the threading <NUM>.

A second embodiment of a volatile material dispenser <NUM> is depicted in <FIG>. The volatile material dispenser <NUM> generally includes a housing <NUM> comprised of top and bottom portions <NUM>, <NUM> that are joined to form the housing <NUM>. The housing <NUM> could optionally be made of any number of pieces. As best seen in <FIG>, the housing <NUM> generally includes an oval-shaped wall <NUM> with a front surface <NUM>, a rear surface <NUM>, and first and second opposing curved side surfaces <NUM>, <NUM>. A bottom of the wall <NUM> is not enclosed, thereby forming a cavity <NUM> for insertion of any of the refills <NUM> disclosed herein, for example those shown in <FIG>. The housing <NUM> further includes an inset top surface <NUM> connecting the front, rear, and side surfaces <NUM>, <NUM>, <NUM>, <NUM>, wherein an emission aperture <NUM> is formed within a central portion of the top surface <NUM>.

The first embodiment of a heater assembly <NUM> disclosed in conjunction with the first embodiment of <FIG> is disposed within the housing <NUM>, as seen in <FIG>. Like components will therefore be assigned like reference numerals. In particular, the heater assembly <NUM> includes a generally rectangular heating block <NUM> having a central cylindrical channel <NUM> and cavities <NUM> disposed on opposite sides of the channel <NUM>. Resistors <NUM> are disposed within the cavities <NUM> and the resistors <NUM> are potted in a ceramic or other conductive material to retain the resistors <NUM> within the cavities <NUM> and conduct heat throughout the heating block <NUM>. The resistors <NUM> have power rating of about <NUM> watts each, although resistors <NUM> with different power ratings may be used.

Referring again to <FIG>, a first resistor lead <NUM> includes a first section <NUM> that extends outwardly from a first side <NUM> of each resistor <NUM> and a second section <NUM> that extends generally transverse to the first section <NUM>. Each of the second sections <NUM> extends toward the other resistor <NUM>. The second sections <NUM> of the resistor leads <NUM> are overlapped and spliced together at splices <NUM>. A second resistor lead <NUM> extends from a second end <NUM> of each resistor <NUM> and is electrically connected to the plug assembly <NUM>, such that power is supplied to the resistors <NUM> when the dispenser <NUM> is plugged into an outlet.

The heater assembly <NUM> is disposed atop a support <NUM> that is connected to or integral with the housing <NUM> of the dispenser <NUM>. The support <NUM> has a generally cylindrical profile, but may have any other profile that provides support to the heater assembly <NUM>. A generally cylindrical channel <NUM> (see <FIG>) extends through the support <NUM> for insertion of a wick of a refill <NUM>, as will be discussed in detail below. The support <NUM> and/or heater assembly <NUM> may also include one or more features that attach the heater assembly <NUM> to the support <NUM> or otherwise prevent the heater assembly <NUM> from movement within the housing <NUM>. In one embodiment, as seen in <FIG>, the heater assembly <NUM> includes an outwardly extending platform <NUM> having a U-shaped groove <NUM> in an edge thereof, wherein a cylindrical projection <NUM> extending upwardly from the support <NUM> sits within the groove <NUM> to prevent side-to-side movement of the platform <NUM>.

Each of the refills <NUM> is inserted into and retained within the dispenser <NUM> by screwing the threading <NUM> on an outer surface of the neck <NUM> into a threaded portion within the dispenser <NUM>.

The dispenser <NUM> of <FIG> is depicted in <FIG> and <FIG> with a second embodiment of a heater assembly <NUM>. As best seen in <FIG>, the heater assembly <NUM> includes a cylindrical ring <NUM> having a cylindrical channel <NUM> therethrough, wherein the channel <NUM> is aligned with the cylindrical channel <NUM> of the support <NUM> such that a wick can extend through the cylindrical channel <NUM> and into the cylindrical channel <NUM> for heating, as discussed below. The cylindrical ring <NUM> may be made of aluminum or any other conductive material. A positive temperature coefficient (PTC) element <NUM> is disposed adjacent and is connected to the cylindrical ring <NUM> by a connecting portion <NUM> made of a conductive material. As seen in <FIG>, the PTC element <NUM> is arranged on its side such that a side <NUM> of the PTC element <NUM> having the largest surface area is connected to the cylindrical ring <NUM>. The PTC element <NUM> may be electrically connected to the plug assembly <NUM> in any manner known in the art.

Referring to <FIG>, the heater assembly <NUM> may further include an insulated housing <NUM> disposed over the cylindrical ring <NUM> and the PTC element <NUM>. The housing <NUM> encloses the cylindrical ring <NUM> and the PTC element <NUM> to retain heat within the heater assembly <NUM>. The housing <NUM> may be attached to the support <NUM> in the same manner as described above with respect to the heater assembly <NUM>.

During operation, the PTC element <NUM>, which would generally operate as a point heater with heat emanating from a single point, operates to heat the cylindrical ring <NUM> due to the conductive nature of the connecting portion <NUM> and the cylindrical ring <NUM>. The arrangement of the PTC element <NUM>, and the cylindrical ring <NUM> therefore creates a cylindrical ring of heat that uniformly heats a wick disposed within the channel <NUM> from all sides.

Upon plugging the dispenser <NUM> of <FIG> into a conventional electrical outlet, the PTC element <NUM> would be actuated continuously at a constant intensity level until the dispenser <NUM> is removed from the outlet. Optionally, the dispenser <NUM> may be provided with one or more switches, for example one or more of the switches disclosed with respect to the embodiment of <FIG> or any other switch, that may allow adjustment within the dispenser <NUM> or on/off actuation of the dispenser <NUM>.

A further embodiment of a heater assembly <NUM> that may be utilized within any of the volatile material dispensers disclosed herein is depicted in <FIG>. In particular, the heater assembly <NUM> includes a heating block <NUM> having a central cylindrical channel <NUM> and cavities <NUM> disposed on opposite sides of the channel <NUM>. Resistors <NUM> are disposed within the cavities <NUM> and the resistors <NUM> are potted in a ceramic or other conductive material to retain the resistors <NUM> within the cavities <NUM> and conduct heat throughout the heating block <NUM>.

Resistor leads <NUM> extend outwardly from a first side <NUM> of each resistor <NUM> and are electrically connected to a circuit board <NUM>. One or more LEDs <NUM> are connected to the circuit board <NUM> for providing an indicator to a user (e.g., that the dispenser is on, that a particular intensity level is selected, etc.). One or more resistors <NUM> extend from the circuit board <NUM> and are electrically connected in series with one or more LEDs <NUM> to act as dropping resistors to limit the current through the LEDs <NUM>. When a refill <NUM> is inserted into the heating block <NUM>, the wick extends through the cylindrical channel <NUM>. The proximity of the one or more resistors <NUM> to the cylindrical channel <NUM> allows heat produced by the dropping resistor(s) <NUM> to heat the wick disposed within the channel <NUM>, providing a boost in heat. In one embodiment, a first LED <NUM> is provided to indicate that the heater assembly is operating and a second LED <NUM> is in series with a dropping resistor <NUM> to provide a boost heating function, wherein illumination of the second LED <NUM> indicates that the boost heating function is in operation.

One or more isolating structures <NUM>, for example walls, may be disposed between the dropping resistor(s) <NUM> and the resistors <NUM> to isolate and provide proper thermal isolation for the dropping resistor(s) <NUM>. This thermal isolation prevents the resistors <NUM> from detecting the additional heat provided by the dropping resistor(s) <NUM> and decreasing their heat output to maintain the temperature of the system. In this manner, the dropping resistor(s) <NUM> truly provides a boost of heat.

While one dropping resistor <NUM> is depicted, any number of dropping resistors may be utilized. Also, the dropping resistors <NUM> may be oriented in a horizontal manner, as depicted in <FIG>, or oriented in a vertical manner. Also, while the use of a dropping resistor <NUM> is disclosed in combination with one or more resistors <NUM>, one or more dropping resistors <NUM> may alternatively be used with one or more PTC elements, as seen in <FIG>.

The additional boost of heat provided by the dropping resistor(s) <NUM> is done so without additional circuitry. In particular, in previous PTC-type heaters employing a change in heater temperature, the intensity or heat applied has been varied by turning the heater on and off or changing the amplitude or frequency of an electrical wave (through pulse width modulation). These previous methods involve the expense of adding a circuit board.

Still another embodiment of a heater assembly <NUM> is shown in <FIG>. The heater assembly <NUM> includes many features similar to the embodiment of <FIG> and includes a heating block <NUM> having a central cylindrical channel <NUM> and cavities 536a, 536b disposed on opposite sides of the channel <NUM>. A resistor <NUM> is potted in ceramic or other conductive material to retain the resistor <NUM> within the cavity 536a and conduct heat throughout the heating block <NUM>. The resistor <NUM> may be a ceramic cylinder with a resistive metal oxide coating that is deposited by sputter coating on the hollow ceramic cylinder. A spiral pattern may formed in the resistive metal oxide coating to create a desired resistance value for the resistor.

Still referring to <FIG>, a PTC element <NUM> having a generally cylindrical shape is disposed within the cavity 536b and may be oriented horizontally (see <FIG>) or vertically (see <FIG>). A conductive material may be disposed within the cavity 536b for transferring heat to the heating block <NUM>. Optionally, the PTC element <NUM> may be otherwise connected to a wall <NUM> forming the cavity 536b by a conductive material. In a manner similar to the embodiment of <FIG>, resistor leads <NUM> connect the resistor <NUM> and the PTC element <NUM> to a circuit board <NUM> for powering the resistor <NUM> and the PTC element <NUM>.

A further embodiment of a heater assembly <NUM> is shown in <FIG> and is similar to the heater assembly <NUM> of <FIG>. In this embodiment, two resistors <NUM> are disposed in two cavities 536a. Optionally, two or more resistors <NUM> may be used and/or may be disposed in the same cavity 536a. As noted above, the PTC element <NUM> is also disposed vertically within the cavity 536b. In particular, the PTC element <NUM> is pill-shaped, includes first and second opposing flat surfaces, and a cylindrical wall. By vertical, it is meant that the PTC element <NUM> is oriented with one of the first and second opposing flat surfaces facing a channel adapted for insertion of the wick <NUM>.

The heater assemblies disclosed herein may include any number of additional features known in the art. For example, if multiple resistors are utilized, the resistors may have different heating capacities.

Although a specific dispenser <NUM> and container <NUM> are described with particularity, it is contemplated the heater arrangements of the present invention may be utilized in conjunction with any type of electrical dispenser employing a heater and any type of refill and/or container. For example, dispensers useful for the present invention include, but are not limited to, the dispensers described in <CIT>, <CIT>, <CIT>, Zobele <CIT>, and <CIT>. Further, containers useful for the present invention include, but are not limited to, the containers described in <CIT>, and the containers described in <CIT>, both of which are owned by the same assignee as the present invention. The principles of the present invention should not be limited by a shape or size of a dispenser and/or refill.

Any of the embodiments described herein may be modified to include any of the structures or methodologies disclosed in connection with other embodiments.

Further, although directional terminology, such as front, back, top, bottom, upper, lower, etc. may be used throughout the present specification, it should be understood that such terms are not limiting and are only utilized herein to convey the orientation of different elements with respect to one another.

The present disclosure provides various heater assemblies for a volatile material dispenser and various bottle configurations for insertion into one or more volatile material dispensers. The present disclosure also provides a method for operating a volatile material dispenser, wherein the method provides for a quick ramp-up in heat at the beginning of an operating cycle, different intensity levels, and/or different modes of operation.

Claim 1:
A refill (<NUM>) having a volatile material contained therein, the refill comprising:
a container (<NUM>) having a body (<NUM>) and a cylindrical neck (<NUM>) forming an opening (<NUM>);
a volatile material disposed within the body (<NUM>) of the container (<NUM>);
a wick (<NUM>) in contact with the volatile material and extending out of the container through the opening (<NUM>); and
a wick holder (<NUM>) for retaining the wick (<NUM>) within the cylindrical neck (<NUM>) of the container (<NUM>), the wick holder (<NUM>) comprising:
an outer surface (<NUM>) in contact with the cylindrical neck (<NUM>); and
an inner surface (<NUM>) have a first plurality of fins (<NUM>) extending outwardly from the inner surface (<NUM>) for centering and retaining the wick (<NUM>) within the wick holder (<NUM>);
wherein the wick holder (<NUM>) further comprises a first cylindrical wall (<NUM>) connected to a second cylindrical wall (<NUM>) by an angled wall (<NUM>) and the first plurality of fins (<NUM>) extend along the inner surface (<NUM>) of the angled wall (<NUM>) to give the inner surface (<NUM>) a frustoconical shape.